SOUTH AFRICAN
www.foodreview.co.za
Journal for food and beverage manufacturers JUNE 2019 Vol. 46 • No. 06
Taking the air out
of dairy
Risk management strategies that matter
Pushing the boundaries in convenience food
IFFA 2019 headlines hygiene and food safety
YOUR STRATEGIC ALLY IN FIGHTING LISTERIA Highly effec�ve and natural ingredient solu�ons include: Op�.Form® Powder Ace S61 - an easy-to-use, cost-effec�ve blend of sodium lactate, sodium acetate and sodium diacetate for use in cured and uncured ready-to-eat meats. Op�.Form® PPA Plus - a highly concentrated blend of potassium lactate and food grade potassium acetate which can be used in cured and uncured cooked meat products, as well as in fresh meat products, to inhibit Listeria growth throughout shelf life and the manufacturer’s supply chain. Verdad® Powder N4 - a vinegar-based solu�on that is extremely effec�ve in helping to control the growth of Listeria monocytogenes in ready-to-eat meat and poultry products, which are par�cularly suscep�ble to pathogens. BRENNTAG SOUTH AFRICA (PTY) LTD 11 Mansell Road Killarney Gardens, Cape Town. 7441
Verdad® Powder N6 - also based on vinegar, a rich source of ace�c acid and a wellknown inhibitor of microbes and pathogens.
BRENNTAG BOKSBURG Cnr 15th Ave & Cason Road, Boksburg North, Johannesburg. 1459
Verdad® Avanta® Y100 - a proprietary blend of vinegar and citrus flour, which provides Listeria control while improving cook yield, controlling purge and enhancing the texture of processed meats.
BRENNTAG POMONA 58b Maple Street, Pomona, Kempton Park. 1619 Phone: +27 (0)10 020 91 00 Phone: +27 (0)21 020 18 00 Email: info@brenntag.co.za
www.brenntag.com/food-nutrition
The Corbion Listeria Control Model (CLCM) helps calculate an�microbial dosage levels required to effec�vely retard the growth of Listeria monocytogenes in a food system.
CONTENTS JUNE 2019 | Vol. 46 • No. 06
PAGE
40
PAGE
12 “Globally, the dairy industry is troubled with difficulties in accurate flow measurement during processing and offloading. Endress + Hauser’s new technology, the Promass Q can assist in managing these challenges”
07
EVENT
Anuga celebrates 100 years of F&B trends
08
NEWS
Alternative proteins challenge the
dairy industry
The best beers in Africa announced
Big pharma drives salt awareness
Nutritional benefits in infant formula
Borentz joins Tastestrik
11
INDUSTRY TALK
DSM accelerates R&D with new centre
The future of technology
30
FATS & OILS
Akospread guarantees excellent stability
The perfect alternative to palm oil
32
SUGAR TAX UPDATE
What's new with sugar tax
33
WINE
Curb contaminants for hassle-free wine production
Innovate with neutralised grape juice
36
IFFA 2019 REVIEW
Hygienic design and food safety dominate at IFFA
Pushing boundaries in portioning and grading
Multivac’s high-quality vacuum skin packs
Reliable foreign body contamination
14
RISK MANAGEMENT
Energy efficient rotatory pumps
Get to know food grade lubricants
How automation can minimise production cost
How to deal with pests
NSF registration a must for non-food compound products
44
FLEXIBLE PACKAGING
Comprehensive water analysis ensures safe consumption
Convenience appeal drives innovation
Improve safety and reduce inspection time
46
INSPECTION & DETECTION
Metal detection technology gets gold star
22
CONVENIENCE FOOD PROCESSING
Avoid expensive recalls
The perfect slicer for tricky ingredients
Unlock fibre for greater digestive tolerance
End-to-end tracking to safeguard products
Locally manufactured goods are a priority
June 2019 | Food Review
3
EDITOR’S COMMENT
EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: Andipha Nkoloti +27 (0)11 877 6168 andipha.nkoloti@newmedia.co.za Contributors: Linda Eales, Dominique Floch, Geoff Furniss, Khathu Musingadi, Louis Munnick and Marilyn Nel
F&B trumps SA’s manufacturing growth
S
tatistics South Africa’s latest report indicates the food and beverage sector makes up the largest component of South Africa's manufacturing industry at 25 per cent. This is closely followed by petroleum and chemical products, with basic iron and steel in third place. The sector showing the highest year on year growth in the food and beverages category is dairy products with volumes of 9.96 per cent higher than January 2018. Beverages also show strong growth with volumes increasing by 5.58 per cent. Meat, fish and fruits disappoint with volumes down by -0.86 per cent in January 2019 when compared to the same time as last year. Total manufacturing volumes of all goods produced in South Africa show a very slim increase in the volume of goods produced at 0.1 per cent compared to January 2018. This is not a good sign for South Africa's growth as manufacturing is the fourth biggest industry in its economy. Manufacturing contributes 14 per cent to the gross domestic product. The food and beverages division is the most important player in the industry, contributing 25 per cent to total manufacturing activity. While it is predicted we will see a spike in imported manufactured goods in coming months, Food Review strives to continue to bring you all the latest information, research and trends that will keep you at your manufacturing best. Exciting news for the industry is the investment by DSM in its Innovation and
Application Centre in Isando, Johannesburg. The new facility will assist customers to develop on-trend, nutritional products that consumers will love. Read all about it on page 11. We also look at the value of NSF registration on non-food compound products. Turn to page 18 where Louis Munnick details the importance of this registration to ensure optimal equipment operation and reduced contamination risk. The sharp increase in the average selling price of sugary drinks is primarily due to the impact of the sugar tax. The insights in this article will go far in explaining consumer behaviour and how beverage producers can harness these changes to their advantage (page 32). Food Review was invited to attend IFFA 2019, held in Frankfurt, Germany in May. Turn to page 36 for all the latest in meat processing equipment, technologies, ingredients and systems that can revolutionise the meat industry as we know it. We are also in the process of tallying the Food Review/Symrise New Product Competition entries so watch this space for the full scoop on entries received. Happy reading,
ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za Sales Executive: Daleen Filbey +27 (0) 83 409 3119 daleen.filbey@newmedia.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmedia.co.za Production Controller: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media, a division of Media24 (Pty) Ltd MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis BRAND STRATEGY DIRECTOR: Andrew Nunneley CHIEF FINANCIAL OFFICER: Venette Malone HEAD OF HR: Camillah West
EDITORIAL ADVISORY BOARD Two doctorates in chemistry; leader in the field of palm oil; SAAFoST president 1993-2001 and honorary life member; past president, Society of Cosmetic Chemists SA.
Dr Aubrey Parsons With a PhD in biochemistry, an MBA and a Institute of Brewing and Distilling diploma Heidi also serves on the Innovation Hubs BioPark and UNISA’s Life Science advisory board.
Dr Heidi Grimmer CEO of Stratcom Branding, founding member of the glba (Global Local Branding Alliance)
Gail Angela Macleod
4
Food Review | June 2019
CEO: MEDIA24: Ishmet Davidson
Managing director of Symrise South Africa; chairman of SAAFFI.
Rudy McLean She is a qualified food technologist with an honours in Bachelor of Commerce in Business Management and a PMD at the Gordon Institute of Business Science.
Kerusha Pillay
HEAD OFFICE New Media House, 19 Bree Street, Cape Town 8001 PO Box 440, Green Point, Cape Town 8051 Tel: +27 (0)21 417 1111, Fax: +27 (0)21 417 1112 www.newmedia.co.za
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.
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Cereal & Malt Extract (Pty) Ltd.
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Cereal and Malt Extract, (Pty) Ltd. is a South African owned and operated company supplying a range of quality malted extracts and ingredients to the beverage and cereal industries, micro brewing, baking, confectionery, savoury and snack foods for the past 60 years. We are leaders in malt extract production in Africa, and proud millers of ancient grains and manufacturers of malt extract syrup, malt extract powder, barley and malt flour, rice flour, oat flour and oat meal. Distribution: Deliver products in southern Africa in modern, hygienic packaging.
6 Bunsen Street, Industria, 2093, South Africa Tel: (011) 474 2424 Email: enquiries@cerealandmalt.com For product specifications, please visit
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Speciality & Fine Food Fair
12 - 15 World Food Fair
Singapore www.singaporefoodshows.com
EVENT
Anuga 2019 keeps its pulse firmly on food trends
T
he show boasts an impressive 10 trade shows under one roof concept. Each individual trade show is unique and offers a targeted selection of specialised trend themes. The new Boulevard of Inspiration is the first point of contact for visitors, who are interested in innovation, new products, market and consumer trends, imminent development scenarios and future themes of the food and beverage industry. Current products and industry trends will be presented in the Anuga Trend Zone and the Anuga Taste Innovation Show. The former is the key lecture stage where a team of experts from Innova Market Insights and Euromonitor will present the latest and illuminating analyses on future developments. A strong focus is placed on the future of food. Surveys indicate that the global In brief... population will shortly reach 10 • Ten trade billion. The key question is then: shows in one how can all these people be fed? • 284 000m2 of The world of food is faced with the largest transformation ever exhibition space experienced and many companies • 7 405 exhibitors are occupying themselves with • 165 000 alternative solutions. trade visitors. Anuga Horizon 2050 exclusively addresses the future of food. Trade visitors can inform themselves about the visions and new solutions for the next 50 years and engage in an active exchange with industry pioneers, experts and start-ups. The aim is to inform visitors about new technologies, solutions, trends and innovations using best practice examples. New technologies changing the food industry and disruptive innovations that guarantee sustainable transparency and safety within the food chain will be under discussion. These and further questions following five thematic blocks will be answered during panel discussions, start-up pitches and keynote addresses. The focus will fall on: • Sustainable Environment – Better Food for a Better World • Startup-Day – New Solutions, New Products • Alternative Proteins – New Sources to Feed 10 Billion • New Nutrition – The Evolution of Food • The Internet of Food. •
AMAZING
COLOGNE, 05. – 09.10.2019
Since its inception in Stuttgart, Germany in 1919, Anuga has offered a platform for significant developments in the international food and beverage industry. This, not-to-be-missed meeting point for the global market, celebrates its 100th anniversary this year.
Meet old and new friends. Priceless networking since 1919.
Secure admission tickets at www.anuga.com/tickets
Southern African – German Chamber of Commerce and Industry P.O. Box 87078, Houghton 2041 47, Oxford Road, Forest Town, 2193 Johannesburg, South Africa Tel. +27 (0)11 486 2775 dvanjaarsveldt@germanchamber.co.za
Anuga – www.anuga.com
June 2019 | Food Review Anuga_2019_Anzeige_SA_Food_Review_88x262mm_ZA.indd 1
7
28.05.19 10:04
NEWS
Alternative proteins challenge dairy dominance
T
he value of the sports nutrition market is set to grow by around eight per cent per year to reach over US$17 billion globally in 2021. This is according to a Innova Market Insights forecast. The mainstreaming of the market has led to a surge in interest in plantbased alternatives that challenges the traditional dominance of whey and other dairy proteins. More than 40 per cent growth has been reported in new sports nutrition launches with a plantbased claim. Vegan-friendly positioning was used for six per cent of global food and beverage launches, which rises to 14 per cent for sports nutrition. RTD sports drinks have an even higher level of prevalence for these positioning at 18 per cent.
Some of the fastest-growing plant-based proteins include soy protein isolate, pea protein and rice protein. Moving beyond the protein arena there is an increased use of other plant-based ingredients in sports nutrition new product development. Specialist vegan sports nutrition ranges are starting to appear, while more mainstream companies and brands are greening up their portfolios to attract those wanting to add more plant-based options to their diets. As demand for sports nutrition products continues to soar globally, the market has become mainstream. The concept of active nutrition is developing widely as interest spreads beyond the traditional core base of bodybuilders, endurance athletes and highlevel sportsmen. The focus is now shifting towards everyday health and fitness as a lifestyle choice.•
Boomers drive sugar replacement
A
s sugar becomes central to the obesity debate, its reduction is becoming a major dietary target for many consumers. This is manifesting itself most in the Baby Boomer demographic (born 1946-1964). Innova Market Insights research shows that one in two US Boomers have been reducing their sugar intake or buying more reduced sugar products, while two in five are cutting back on their consumption of sweet snacks. This trend is supported by research into the typical shopping basket. ‘Boomers are below-average purchasers of certain sweet products such as chocolate, desserts and ice cream and snack bars,’ says Lu Ann Williams, director of Innovation of Innova Market Insights. ‘In contrast, they are
8
Food Review | June 2019
markedly more important in the yoghurt, sweet baked goods and breakfast cereals categories, so these could offer opportunities for sugar reduction.’ The US yoghurt category is seeing high levels of low/ no sugar development, with 20 per cent of all launches in 2018 carrying such claims, up from just four per cent in 2013. Breakfast cereals and sweet baked goods have not followed suit, with just two per cent penetration for reduced sugar products in 2018. •
Yoghurts are seeing a special drive for sugar reduction
Best beers in Africa announced
A
midst hot competition for the best beers on the African continent, eight Anheuser-Busch InBev (AB InBev) Africa brews were awarded trophies at the inaugural African Beer Cup. Gold awards went to Botswana’s St Louis Lager in the Standard American Beer category, Swaziland’s Sibebe Lager in the International Lager category, South Africa’s Castle Milk Stout in the Dark British Beer category and Nigeria’s Hero Premium Lager in the Alternative Fermentables Beer category. ‘It was exciting to be awarded all three spots in the hotly contested International Lager category, with Tanzania’s Kilimanjaro Premium Lager and South Africa’s Carling Black Label claiming silver and bronze,’ said Tshepo Tloubatla, beer culture manager, SAB and AB InBev Africa.
AB InBev’s Cape Town-based craft brewery Newlands Spring Brewing Co was awarded a bronze for Jacob’s Pale Ale in the British Bitter category as well as for the Passionate Blonde in the Belgian Ale category. The African Beer Cup, an annual competition, which seeks to crown the continent’s best beers, was open to licenced, commercial breweries large and small if the beers entered were brewed in Africa. Entries were judged by a panel of judges who had completed the international Beer Judge Certification Programme. The competition was founded by local beer industry movers and shakers Lucy Corne, editor of On Tap Magazine and founder of Brewmistress.co.za, and Shaun Duthie, brewer and former president of the Southyeasters Homebrewers Club, out of a love for beer and a desire to nurture a stronger beer culture across the African continent. •
South Africans still clueless about salt
T
o test SA’s salt-smarts, a prevention-minded pharma company conducted an online poll among men and women across the country. A quarter of South Africans conceded to being salt addicts, with 31 per cent adding salt to their food ‘all the time’ and 37 per cent ‘some of the time’. Most still don’t have a handle on how much salt is used in popular food such as cereal, yoghurt and chips. Nicole Jennings, spokesperson for Pharma Dynamics notes, ‘Our survey, which polled 245 men and women across the country, found that while more than 90 per cent understood the link between hypertension and excessive salt consumption, very few actually knew just how much salt is contained in food consumed on an almost daily basis.’ More than 64 per cent of respondents didn’t know that there is about 1.5g of salt in a slice of pizza; 45 per cent were off the mark with how much salt was in a small tub of plain yoghurt; 60 per
cent was clueless about the amount of salt in an average take-away beef hamburger, which is in the region of 3.5g; 60 per cent guessed wrong about the quantity of salt in a bowl of cornflakes with milk and 68 per cent didn’t know how much salt was in a handful of peanuts. While efforts have been made since 2016 by government to reduce salt levels in food, with a second set of even lower levels of salt being introduced this year, the public should be made more aware of foods that are high in salt as many don’t pay attention to food labels,' says Jennings. Based on recent research published in the SA Medical Journal (September 2018), one in five children at the age of five is hypertensive and 60 per cent of children with elevated blood pressure maintain that status into adulthood. By decreasing salt consumption by even just 0.85g per day, deaths related to heart disease could be decreased by 7 400 and would result in 4 300 fewer non-fatal strokes per year. •
NEWS
From breast milk to formula
R
esearch shows that there is good Arla Foods Ingredients has developed awareness of milk fat globule Lacprodan MFGM-10, the first MFGM ingredient membrane (MFGM), an important launched for the global infant formula market. nutritional component of breast milk, among Rich in bioactive components and offering mothers and mothers-to-be. high phospholipid content, it is supported MFGM is found naturally in breast milk and by a long history of use and is backed by the is comprised of phospholipids, glycolipids, most comprehensive and compelling clinical proteins and glycoproteins. Recently, MFGM documentation available. Several doubleingredients made from whey have been blind, randomised clinical trials have shown introduced into the infant nutrition category. it to be well-tolerated and safe. This means that, where breast feeding is not Lacprodan MFGM-10 is produced through MFGM is found naturally in possible, infants can still benefit from the key gentle processing methods that preserve its breast milk components of MFGM in their diet, helping to nutritional content, avoiding excessive heat close the gap further between breast milk treatments and using only mild membrane and formula. filtration. Manel Romeu Bellés, industry Although MFGM ingredients for formula are marketing manager at Arla Foods Ingredients still relatively new, a survey of 5 500 pregnant says, ‘Breast feeding delivers optimal infant women and mothers across seven countries, nutrition. Where this isn’t possible, the aim is commissioned by Arla Foods Ingredients, to produce a formula that comes as close as found that as many as 20 per cent were already possible to mother’s milk. aware of it. Awareness was highest in China, Lacprodan MFGM-10 helps formula with 28 per cent of respondents having heard manufacturers towards this goal with of MFGM. a nutritious ingredient that is clinically Furthermore, 43 per cent of Chinese mothers documented for efficacy and registers high who were aware of MFGM say they would prefer levels of awareness among mothers and to buy an infant formula that contains it. mothers-to-be.’ fdt-Visitor Promo Half Page Advert-177x130mm trim-May • 2019-REPRO.pdf 1 2019/05/07 3:29 PM
Connecting Global Competence
food & drink technology
C
M
Y
Africa 2019
July 9 – 11 2019 • Johannesburg Gallagher Convention Centre, Midrand
CM
MY
CY
CMY
Get to food & drink technology Africa – Southern Africa’s premier beverage and food event
Register Now At www.fdt-africa.com
Discover the latest trends and solutions across the full food & drink value chain at food & drink technology Africa trade show. Network with up to 6,000 industry visitors and discover:
K
• • • •
The spectrum of technologies behind food and beverage production, quality control and packaging Industry trends and updates in the knowledge-sharing forum Business opportunities in B2B matchmaking for key decision-makers, manufacturers, new business owners and agro-business stakeholders New solutions across water, sewage, refuse and recycling, and laboratory technology, analysis, biotechnology and diagnostics at the co-located IFAT and analytica Lab Africa events
Bringing together partners for the Southern African market in the analytics, food & beverage and environmental technology, we are proudly co-located with:
June 2019 | Food Review
9
NEWS
Barentz announces joint venture with TasteStrik
T
he global ingredients distributor announced its agreement with TasteStrik, a successful Dutch developer, producer and supplier of high-quality flavourings and ingredients for the bakery, cereal, chocolate, confectionery, dairy and specialty foods industry. This joint venture will give Barentz a higher diversity of sources to deliver solutions for taste concepts, while offering TasteStrik the knowledge and expertise of Barentz’ global network. Robert Strik, managing director of TasteStrik looks forward to joining Barentz. ‘This is a promising joint venture, where both parties will immediately benefit from each other’s strengths. The customer-centred and entrepreneurial spirit of Barentz are of decisive importance. We are a family business with an extraordinary passion for taste. We see the same attitude at Barentz, along with the shared will to always strive for better solutions.’ For Barentz’ CEO Hidde van der Wal, TasteStrik’s taste expertise is an excellent addition to the Barentz family of food and nutrition solutions. ‘This is where we bundle all expertise and skills we have throughout our organisation to devise and implement innovative and suitable solutions. TasteStrik’s sophisticated application lab in the Netherlands will be a valuable addition to our global network of 15 labs with 50 food engineers.’ •
Show awarded prestigious ISO Sustainability Certificate
A
record 24 211 visitors attended this year’s Vitafoods Europe, an increase of 15 per cent from 2018. Floor size grew by 10 per cent to meet demand, showcasing new ingredients and finished products; packaging and contract manufacturing. As a reflection of the success of the event, more than three quarters of this year’s exhibitors have rebooked for 2020. In the lead to the event, organisers encouraged the industry to come together to explore what was required to shape a more sustainable future through a series of networking events, roundtables and seminars. Ensuring that sustainable practices were in place throughout every aspect of the event – from planning to delivery – was a priority. It included working with suppliers that share this commitment, powering the event with renewable energy and introducing new stand build regulations
Certification on
Midrand: 7 August 2019 Midrand Convention Centre Cape Town: 13August 2019 Ruslamere Hotel and Conference Centre
10
Food Review | June 2019
to drive exhibitors to move away from using disposable materials. Vitafoods Europe has become the first legacy Informa event to achieve the ISO 20121 Event Sustainability Management System certificate, a standard designed to help organisations in the events industry have confidence in the sustainability credentials of their eventrelated activities, products and services. Ben Wielgus, head of sustainability at Informa says, ‘Sustainability has moved from being a differentiator to an essential. Vitafoods Europe is the ideal setting for varied stakeholders to have the conversation about how to create a more sustainable future. Having our efforts recognised in this way is a true reflection of our commitment to the issue and how far we have come in ensuring both our own actions, and those of our exhibitors and visitors, have as little environmental impact as possible.’ •
FSSC 22000 HACCP SANAS 10330 HACCP Codex ISO 22000 ISO 9001 ISO 14001
Third Annual Conference
ISO 45001 ISO 22301 ISO 27001 ISO 20000 ISO 50001 GFSI Basic GFSI Intermediate
Contact: Elsie.Stricker@cpg.global TOTAL COMPLIANCE CONFERENCE Elizra@eltsolutions.co.za 076 145 9149 FSSC V5.1 ISO 22000 076 443 0235 ISO 9001 Total Compliance for Retail ISO 14001 ISO 45001 HACCP SANS 10330
Training What Auditors Look For And More
I N D U S T RY TA L K
Innovation and application centre supports a brighter future DSM recently opened its new Innovation and Application Centre in Isando, South Africa – the first of its kind for the company on the African continent. The Innovation and Application Centre in Isando
The centre can provide regional support to customers
W
ith its state-of-the-art facilities, the centre will accelerate R&D and innovation for customers in the region looking to develop nutritious food and beverage products and bottom pyramid food solutions that combat malnutrition. The new centre will meet the company's goal of providing regional support to its customers and will enable co-innovation opportunities for partners worldwide. During the opening ceremony, food and beverage customers and customers supplying staple foods heard DSM spokespeople and guest nutrition experts present on topics including common problems in food applications and affordable nutritional solutions to fight hidden hunger. Customers were also given the opportunity to tour the Innovation and Application Centre’s advanced facilities and create nutritional concepts from scratch. Opening the ceremony, Andre Rhoen, vice president, human nutrition and health EMEA, DSM commented, ‘We are passionately committed to achieving a brighter future for everyone through continuous innovation. We aim to be a positive contributor to the changing world and we recognise that it is only through collaborative work that we can create pioneering, tailored solutions that enable brighter living. To work together as effectively as possible, we believe it is important to be near our customers so that we can fully support them and their specific needs.’
Guest speaker at the opening ceremony, Bibi Giyose, senior nutrition and food systems officer and special advisor to the NEPAD CEO, explained why overcoming the global malnutrition challenge is central to giving individuals the opportunity to reach their full potential and help communities prosper.
“Through its state-of-the-art technologies and consumerdriven innovation, DSM’s Innovation and Application Center will help customers to develop on-trend, nutritional products that consumers will love” Further to Bibi’s presentation, Professor Lyal White – senior director of the Johannesburg Business School (JBS) emphasised the importance of feeding growing global populations, particularly in Africa where the population is expected to rise significantly. To meet these demands and succeed in providing nutritional solutions for the world’s most vulnerable populations, innovation is critical. As well as benefiting from DSM’s long-standing experience and evolving capabilities in the bottom of the pyramid food solutions, customers utilising the Innovation and Application Centre will
be supported by a network of nutrition, science, technology, innovation and business experts. This will help food, beverage and dietary supplement manufacturers to develop effective, safe and affordable products, including food fortification solutions, that have been proven to fill nutritional gaps and support the health of populations worldwide. The Innovation and Application Centre will also benefit food and beverage customers looking to meet evolving consumer needs. As consumers worldwide become increasingly health aware, they are demanding food and beverage products that offer functional benefits beyond nutrition. Through its state-of-the-art technologies and consumer-driven innovation, DSM’s Innovation and Application Centre will help customers to develop on-trend, nutritional products that consumers will love, giving them a competitive advantage in the market. Putting this in practice during the opening ceremony, food and beverage customers could develop their own sports drink concepts to cater to the major sports nutrition trend, which they were invited to take away and use for future development. If you would like to book a session with DSM’s experts in their Innovation and Application Centre in Isando, contact Marketing.DNPE@dsm.com. •
DSM – www.dsm.com
June 2019 | Food Review
11
C O M PA N Y F O C U S
How to ensure accurate
liquid flow measurement Globally, the dairy industry is troubled with challenges in accurate flow measure during processing and offloading. Food Review spoke to Anban Pillai of Endress + Hauser about its new technology, the Promass Q.
T
he most common cause of inaccuracies in flow measurement is the degree of entrained gas. This negatively affects fundamental measuring principles. Coriolis mass flowmeters are usually only used for single-phase liquids, namely liquid or gases. Production facilities have been dealing with this challenge by implementing so-called correction factors in control systems to compensate for discrepancies. While flowmeters are accurately calibrated, the complete loop integrity is compromised when these factors are introduced. Endress + Hauser (E+H) was approached by a local dairy processor to support this facility with fair and equitable measurement. The dairy is renowned for producing a wide range of cheese and dairy products. It is highly regarded for producing products with unrivalled quality and flavours and products have won several local and international awards. The state-of-the-art manufacturing facility is located strategically near local dairy farms on the Garden Route in South Africa. This ensures milk is supplied to the facility with minimal delays. ‘It also feeds into the culture of innovation to meet changing requirements of today’s discerning consumer,’ Anban Pillai, industry manager, food and beverage at E+H enthuses.
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Food Review | June 2019
The dairy processor realised that success is still reliant on operational efficiency and process optimisation. The key priority of the customer is the reduction of milk losses, which will benefit its efficiency drive. ‘As a socially responsible company, our customer doesn’t pass additional costs to consumers but looks internally to reduce costs. It is with this spirit of innovation and efficiency that our company was approached for a solution to reduce milk losses in the processing area. ‘Existing flowmeters were proving to be inaccurate, which resulted in major losses. This is an application area that has become notorious in the industry due to the varying degree of entrained gas that can be found. Mild protein and fat structures tend to easily entrap air. This can cause errors during batch offloading,’ Pillai explains.
ENDRESS+HAUSER AT A GLANCE The company is a noted supplier of products, solutions and services for industrial process measurement and automation. It offers comprehensive process solutions for flow, level, pressure, analysis, temperature, recording and digital communications across a wide range of industries. The optimising process product profile offers a strong focus on economic efficiency, safety and environmental protection.
“The new trial Promass Q was installed and runs in conjunction with existing meters so that accuracy improvements are comparable” The installation of air eliminators in the process can help to an extent, but cannot totally remove entrained gas. This is primarily because the gas bubbles are undersized or due to insufficient holding times. ‘Our local E+H sales engineer, George Dyman, visited the site and recommended using the latest Promass Q from E+H, which was specifically designed to
Accurate flow measurement of milk unloading from tanker trucks into processing plants
C O M PA N Y F O C U S
ENDRESS+HAUSER INVESTS IN SENSOR TECHNOLOGY In May 2019 Sensor Technology IST AG officially opened its expanded plant in EbnatKappel, Switzerland. The facility was built at a cost of nearly 15 million Euros and offers double the floor space of the previous plant. Growing demand for innovative sensors and corresponding strong growth made expansion necessary. ‘We’re confident that we’ve created the space we need to produce even more innovations,’ said Matthias Altendorf, CEO of the Endress+Hauser Group. The 13 500m² plant includes roughly 3 700m2 of production space, where 1 500m2 has been set aside for clean rooms. The office facilities and cafeteria were expanded as well. The expansion was necessitated by increasing demands on production and growing space requirements. Innovative Sensor Technology IST AG manufactures physical, chemical and biological sensors. It specialises in the development and manufacturing of thin- and thick-film platinum and nickel RTD temperature sensors, thermal mass flow sensors, capacitive humidity sensors, conductivity sensors and biosensors. The company has been part of the Endress+Hauser Group since 2005.
A wide variety of liquid food products can be measured using Promass Q technology
The official opening of the expanded Innovative Sensor Technology IST AG facilities
measure entrained gas. The unique multifrequency technology employed by the Promass Q allows for the measurement of entrained gas and can be compensated for in the flow measurement. This delivers superior accuracy in milk applications,’ Pillai points out. The dairy’s site engineering manager indicated the issue of entrained gas has been causing significant quality and financial issues for the organisation.
CHALLENGES WHEN DELIVERING AND RECEIVING MILK Milk proteins and fat structures tend to entrap air, causing errors in bath unloading. In the milk industry, air can be introduced into the process in different ways: • Agitation in and during the travelling tanker process • Pump unloading when gravity drainage isn’t possible • Insufficient settling time in tanks • Improperly or undersized air eliminators.
He requested that E+H provide a formal confirmation stating that should the Promass Q not measure accurately in this application, the flowmeter would be returned without cost to the customer. ‘Our flow product manager Frans van den Berg, with the support from the Flowtech offices in Switzerland, committed and offered the customer a written guarantee confirming our confidence in the product's performance in this application,' Pillai highlights. The new trial Promass Q was installed and runs in conjunction with existing meters so that the accuracy improvements are comparable. The trial was completed successfully and delivered on the set assessment criteria. It also exceeded the customer's expectations. The success of the trial has led to the customer purchasing additional flow meters for use in another high loss application area, namely during milk reception and offloading. •
Endress + Hauser – www.endress.com
June 2019 | Food Review
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R I S K M A N AG E M E N T
What you should know about food grade lubricants A manufacturer’s worst nightmare is a robot or machine with an oil contamination problem or a leak from a gearbox. In most cases, such a situation can be rectified quickly and production can get up and running almost immediately, writes Linda Eales
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ood grade lubricants can easily encounter ingestible products and are specifically formulated to meet the stringent requirements of the global food industry. They are tasteless and odourless and designed to be resistant to plastics and other packaging containers. These greases must dissolve sugars and withstand degradation from food products, chemicals, water and steam. Above all, food grade lubricants must increase machine efficiency, dissipate heat and decrease wear, friction, corrosion and oxidation.
Food lubricants play a critical role in the optimal running of a food processing plant
FACTS ABOUT FOOD GRADE LUBRICANTS A study commissioned by the Food Marketing Institute and Grocery Manufacturers Association, Capturing Recall Costs, puts the average cost of a food recall at US$10 million or roughly R146 million. The figure is modest as it only takes into consideration direct costs such as notifying authorities, public and the removal and disposal of damaged products. Not included are indirect costs like lost revenue and the damage a recall can do to a company's brand reputation. When it comes to food process management, the introduction of automation and robotics has clear benefits. For the consumer who buys ingestible products, the risk of contamination must be negligible. Cleanliness and hygiene are of utmost importance. Lubricants can encounter food, beverages or drugs at any moment. They can contaminate an entire inventory with the potential to create unknown health and safety risks. Just three drops of oil can contaminate 1 000 l of product, which can result in an average of six hours of downtime. For manufacturers, picking, packing and palletising (PPP) robots are ideal for handling repetitive work and heavy lifting often required with a picking and palletising line. In addition to doing the dirty, dull, delicate and dangerous jobs often associated with packaging, these robots can also reduce costs associated with new product packaging and shrinking product life cycles. The global food industry represents nearly US$8 trillion of the world's GDP, according to Plunket Research. Picking and packing robotic applications are defined as the picking of products and packing them into a case or tray.
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Food Review | June 2019
“When it comes to food process management, the introduction of automation and robotics has clear benefits” In most packaging robotic operations, the product is delivered from a primary packaging operation on a continuously moving conveyor. Packaging robots make packaging applications faster, precise and more costefficient. They are extremely flexible. With correct tooling, a robot can complete any type of packaging from meat and poultry to pharmaceutical tablet packaging. The pressure is on for makers of food and beverages, fast moving consumer goods and pharmaceuticals to increase productivity and lower total ownership costs while maintaining uncompromised quality and safety. The shift towards smaller lots of greater variety of products and their packaging is also making automation more complex and less predictable. ABB is helping customers in fast-moving industries such as food, pharmaceuticals and consumer goods improve their ability to accommodate change efficiently while avoiding costly downtime. This is at the heart of the ‘factory of the future.' ABB's range of automation solutions helps these types of
manufacturers increase their flexibility and efficiently adapt to today's dynamic markets and shorter cycles. ABB has introduced the newest member of its growing family of food grade lubricant robots, IRB 1200. This food grade lubricant (NSF H1) option includes Clean Room ISO Class 3 and IP 67 protection rating, which ensures uncompromising safety and hygiene for food and beverage applications. The Clean Room ISO 3 design eliminates the potential for contamination of the food handling area. The new variant joins ABB’s IRB 360 and IRB 120 robots to create a portfolio of small robots uniquely designed for the food sector. They are supported by advanced ABB Ability Connected Services and a broad array of grippers and accessories; machine safety equipment and ABB’s complete motion control offering including drives, motors and PLC controllers •
ABOUT THE AUTHOR LINDA EALES is ABB’s Southern
African regional industry manager for food and beverage.
ABB – new.abb.com
—
A plant that creates certainty. Talk to us. Is achieving production consistency a constant battle? Are countless variables creating a multitude of challenges? Our comprehensive portfolio and consultative approach runs from power to palletizing. So whether you need to automate a process or integrate production across your value chain, we have the answer. Discover the infinite possibilities at new.abb.com/africa/food-and-beverage
R I S K M A N AG E M E N T
Manage pest risk in the processing environment
Food processors are under scrutiny to enforce strict food safety laws. This is chiefly done by ensuring materials and products supplied are safe during formulation and in final production.
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ood processors have a responsibility to the relevant authorities to prove their procedures, processes and facilities comply with legislation. Rentokil sponsors research on the impact of pests on businesses to get detailed insights into the most pressing issues for businesses and the true economic effects of pests. Research has shown the main reason for non-compliance with food safety standards is the lack of attention to basic hygiene in the operating environment. This includes: • basic sanitation • cleaning and hygiene • pest control • personnel hygiene.
PESTS IN FOOD PROCESSING Pest control is an essential part of good manufacturing practice in food processing. Pests can carry a wide range of diseases causing bacteria, viruses, protozoa and helminths that can cause harm to consumers and staff of businesses
processing and handling food. They can also cause physical contamination of ingredients and processed products from droppings, shed fur and feathers, body parts, nesting material and damaged packaging. Not taking adequate measures to prevent and control pests can lead to substantial financial costs to the business from stock and product loss, product recall, loss of reputation and legal action that could ultimately cause a business to close. Pests can be brought into the food processing facility through the supply chain in ingredients or through packaging. The facility itself can also attract pests through food odours and lighting. Buildings provide shelter, warmth, food, water and safety from predators - ideal conditions for proliferation unless appropriate action is taken. Control of pests in food processing requires the implementation of an integrated pest management programme. This has three basic steps, namely inspection, identification and treatment. This is a complex process that requires
specialist expertise to achieve accredited food standards and comply with legislation.
TOP PEST CONCERNS FOR FOOD PROCESSORS The range of pests found in food processing plants will vary according to climate, geography and food ingredients processed. The most common are stored product insects (SPIs), rodents, cockroaches, and flies. • Stored product insects: Also known as SPIs, this is a generic term that covers beetles, weevils, moths and mites (arachnids) infesting food in storage anywhere along the food chain. • Rodents: Rats and mice are attracted by food supplies and do not venture far from their shelter or nesting sites. In a large facility, they will nest close to accessible food stores. When given an abundant food supply, rats and mice are capable of a rapid increase in population. This is due to the number of litters they produce and their short time to maturity. • Cockroaches: They cause problems for food processors for a number of reasons: their small size gives them the ability to hide in small places; their varied diet; rapid reproduction and the diseases they
Metal & X-Ray Detectable Products & Stationary
Johannesburg, South Africa Email : jeremy@jelatech.co.za Phone: +27 (0)11 465 1528 Cell : +27 (0)82 412 0076 Web : www.jelatech.co.za
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Food Review | June 2019
Protect your reputation and avoid a costly product recall!
Rentokil technician at work
R I S K M A N AG E M E N T
Technician illuminating the environmental tracking gel
can carry (Salmonella, Staphylococcus, Listeria, E. coli, and also fungi, viruses and parasitic worms). They feed on decaying matter, mould, faecal matter in sewers, from rodents and birds, and animal carcasses, which can then be transmitted into the food production environment on their bodies or from excreta. They shelter in places which are hard to reach using normal cleaning and sanitation methods. Rentokil uses chemical-free control methods suitable for sensitive business environments and Insect Monitor Units to detect signs of activity.
• Flies: Fly species are attracted to the odours present around food processing plants, including fruit flies, drain flies and filth flies. To control flies, it is important to identify which species are present as each has different attractants and breeding habits. In warm conditions with suitable substrate in which to breed, flies have a short lifecycle and can multiply rapidly. Filth flies are known to be able to carry over 100 pathogens
Insect Monita units can detect insect activity
that can cause disease in humans, including Salmonella, cholera, Shigella, Campylobacter, E. coli, Cryptosporidium, parasitic worms and fungi. •
Rentokil – www.rentokil.co.za
Infestations of Stored Product Insects
can cost businesses huge amounts in both downtime and stock loss
Get in touch with us!
0800 736 86545 or www.rentokil.co.za
June 2019 | Food Review
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R I S K M A N AG E M E N T
The value of NSF registration on non-food compound products Maintenance teams in the food industry often don’t understand the value of using NSF Registration of non-food compound products. This could ensure that plant and equipment operates optimally and simultaneously reduces contamination risk. by Louis Munnick
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SF International’s non-food compounds registration programme is an independent, third-party review that evaluates proprietary substances and non-food compounds intended for use in food processing environments.
“NSF registers thousands of products such as lubricants, water treatments chemicals, cleaners and coatings in over 90 categories, based on the intended end use of the product” This programme is a continuation of the U.S. Department of Agriculture (USDA) compound approval and listing programme. It is based on meeting applicable regulatory requirements including the U.S. Food and Drug Administration’s 21 CFR (Code of Federal Regulations) or other applicable regulations. NSF registers thousands of products such as lubricants, water treatments chemicals, cleaners and coatings in over 90 categories, based on the intended end use of the product.
NON-FOOD COMPOUND REGISTRATION PROCESS REQUIREMENTS • Formulation review – NSF provides an independent review of ingredients against the requirements of 21 CFR and/ or other acceptable regulations for a specific end use. Value add – An independent third party review of the formulation provides the industry with confidence the product was logically classified and allocated into areas in the plant where the product can be used. • Label Review – NSF verify that the label has no misleading claims and includes appropriate end use instructions. Value add – Ensures accurate information description is on the labels. This removes confusion and ensures users can rely
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Food Review | June 2019
on the information and use the correct product on an application. • Traceability – Registered products must bear the NSF registration mark and include the applicable category code. Value Add – Traceability is usually a given for products manufactured in an ISO environment. Certain manufacturers are not ISO compliant and this component of registration forces them to provide traceability details. Generally aerosols stamp the appropriate manufacture batch and date at the bottom of the can. The registration mark and number provides the industry with traceable information to validate and verify information independently. • NSF's White Book Listing – Products registered can be found at www.nsfwhitebook.org Value Add – This is a huge benefit to the food industry as it provides quality assurance, health and safety, HACCP and maintenance teams to independently check and verify that companies and products are listed on the NSF White Book. The food industry does not have to rely on the suppliers marketing information and can check details of the supplier. The ability to check information with a credible party such as the NSF, provides substantial benefits from a risk management point of view to ensure all products used on the plant have been properly registered, are used in specific areas of the plant and have the necessary supporting information on file.
SAFETY THROUGH THE LINE Using non-food compound registration components manufactured by an ISO 9001:2015 certified company provides the necessary assurance that products are consistently manufactured to the highest international quality standards. If the manufacturer matches the quality of their products with the same high
quality standard of the information such as supporting documents, you then have a strong base to reduce contamination risks, improve competency and meet all stringent audit requirements.
Examples of a few NSF classified products and what supporting documentation you can expect to provide you with the confidence you need: 1. Food Grade H1 lubricants – incidental contact – supporting documents 1.1. Product data specification 1.2. Safety data specification – 16 points including safety details, transport, storage, sub-tariff codes etc. 1.3. NSF Letter of registration – registration number, date, description and definition of the classification 1.4. Allergen certificates that cover the facility, plant and products 1.5. Food certificate 1.6. RoHS letter 2. NSF Classified H2 lubricants – no contact with food 2.1. Product data specification 2.2. Safety data specification – 16 points as above 2.3. NSF letter of registration as above. •
CRC Industries - www.crcindustries.co.za *(Source - NSF Non-Food compounds: Mark of Assurance)
NSF H1 lubricants , H2, 3H, C1, K1, K2, R1, P1 and more...
CRC Industries RSA (Pty) Ltd tel: +27 87 135 5888
CRC South African Team Contact details:
Louis Munnick +27 (0) 82 968 4789 - louis.munnick@crcind.com Rick Ellis +27 (0) 78 097 8028 - rick.ellis@crcind.com Johnny Johnson +27 (0) 79 922 9494 - johnny.johnson@crcind.com
www.circindustries.co.za
R I S K M A N AG E M E N T NOSA Testing’s ISO 17025 states specific minimum requirements for potable water
Comprehensive water and wastewater analysis Access to safe drinking water is a basic human right and vital to human health. The South African National Standard (SANS) 241 Drinking Water Specification states the minimum requirements for potable water to be considered safe for human consumption.
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his includes effluent water generated in multiple operations, in myriad industries, including mining, food and industrial processes. In other words, any water used, treated and then tested following any of these applications must be clean enough for a person to potentially consume it without falling ill. These requirements include the
microbiological, chemical and physical properties of the water. NOSA Testing's ISO 17025 accredited laboratory service has increased its scope of accreditation to render the following water analysis capabilities. Expertise includes, but is not limited to: • heavy metals via ICP-MS and ICP-OES • microbiological (pathogens and bacteria)
“… water used, treated and then tested following any of these applications must be clean enough for a person to potentially consume it”
• • • • • • • • •
total organic compounds (TOCs) chemical oxygen demand (COD) testing for trihalomethanes (THM) groundwater analysis borehole water analysis treated water analysis mining discharge water analysis wastewater analysis SANS 241 chemistry, microbiology, somatic coliphages and protozoan parasites. If your company utilises water in its process or provides water solutions, and you require further technical information water analysis capabilities, NOSA can assist. •
NOSA – www.nosa.co.za
Aspirata - 12 H - Food Review June 2019.pdf 1 2019/06/10 12:48:32
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NOSA Tes�ng now provides comprehensive water and waste water analysis
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NOSA Tes�ng’s ISO 17025 accredited laboratory service has increased its scope of accredita�on to render the following water analysis capabili�es. Exper�se include, but are not limited to:
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MY
• • • • • • •
CY
CMY
K
heavy metals via ICP-MS and ICP-OES microbiological (pathogens and bacteria) total organic compounds (TOCs) chemical oxygen demand (COD) tes�ng for trihalomethanes (THM) groundwater analysis borehole water analysis
• • • •
treated water analysis mining discharge water analysis waste water analysis SANS 241 chemistry, microbiology, soma�c coliphages and protozoan parasites.
Whether your company u�lises water in its process, or provides water solu�ons, and you require further technical informa�on on our water analysis capabili�es, please contact: Keshav Beachen NOSA Tes�ng Na�onal Sales Manager keshav.beachen@nosa.co.za +27 (0) 71 442 9418
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Food Review | June 2019
Collin Naidu NOSA Tes�ng Laboratory Manager collin.naidu@nosa.co.za +27 (0) 71 370 8680
R I S K M A N AG E M E N T
Indicator reduces downtime and improves safety A newly launched tamper-proof vibration-warning indicator paste can improve safety and reduce inspection time in manufacturing environments.
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pplications for Dykem Cross-Check Torque Seal ranges from haul trucks to head gaskets in vehicles, gearboxes and conveyor belts. ‘When a piece of equipment vibrates there’s a chance that the torque of nuts and bolts may loosen. It is essential to be on the lookout for this when servicing equipment or carrying out routine maintenance to prioritise safety and reduce downtime,’ BI product manager, Richard Lundgren explains. With this technology, the artisan draws a line of paste from the bolt head and along the threads of the screw, once perfect torque has been achieved. At the next inspection, the artisan checks to see if the brightly-coloured mark is still in alignment. If not, action can be taken on that specific bolt. This speeds up the process significantly and reduces the possibility of missing loose bolts.
With its excellent adhesion to all types of materials, including steel, the indicator paste comes in a range of eight colours for high visibility. It is also fluorescent under UV lighting. ‘The safety aspect of this product cannot be overstated, especially when you consider the potential danger of a bolt coming off a kilometre-long conveyor belt in a factory where people are working. Preventing potential dangers like this by using a vibration-warning indicator paste means safety checks can be carried out more regularly, as they now take just a few minutes,’ Lundgren enthuses. The indicator paste is supplied in a tube and comprises a gel-like substance. This is dry to the touch in one to two hours and fully cured in 24 hours. ‘It has a two-year shelf-life so clients can be sure of the quality of their stock,’ Lundgren points out. The product
The Dykem Cross-Check Torque Seal range
is GHS compliant and meets the Globally Harmonised System for classification and labelling of chemicals. This acts as a guideline for ensuring the safe production, transport, handling, use and disposal of hazardous materials. It’s a product that should be in every workshop, maintenance facility or warehouse,’ he concludes. •
Bearings International- www.bearings.co.za
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Belts & Pulleys
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June 2019 | Food Review
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Tricky texture ingredients like Swiss cheese are consistently and optimally diced
CONVENIENCE FOOD PROCESSING
Supreme dicing of all processing ingredients Difficult to cut products like cheese and soft, high-fat meat are exactly what designers had in mind when they created the premier Affinity Integra Dicer.
C Put Urschel to the Test As a valuable service to you our customers, Heat and Control AND Urschel offer sample test cutting. This may assist with R&D, help explore different machines to decide on a capital purchase, or discover additional cutting capabilities for your existing Urschel machinery. Urschel machinery produces precise cuts at high capacities within your designated parameters – meeting your production goals, improving your end-products to reduce waste, and maximising your profits. Schedule a visit with the Heat and Control South Africa team to test cut your product, or simply send samples so we can test for you.
Set-up a free test cut of your product with Heat and Control South Africa!
www.heatandcontrol.com | info@heatandcontrol.com Cape Town +27 21 948 5934 The Global Leader in Food Cu ng Technology ÂŽ Comitrol, Urschel, Urschel logo symbol, and The Global Leader in Food Cutting Technology are registered trademarks of Urschel Laboratories, Inc. U.S.A.
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utting and dicing products stored at cold temperatures or with high tack can be troublesome for other models. This unit is specifically tailored for difficult-to-cut applications. Having conquered challenging product textures and conditions, the clean-cut action achieves precise, targeted cut sizes - well within customer parameters. The result is a product that is consistently and reliably cut and diced to the desired output. These capabilities are key to long-term success in the food industry. System upgrades can be achieved effortlessly. The Affinity Integra incorporates design elements from the longstanding Urschel Model RA series, the Affinity and the Sprint with the ability to simply replace existing inline Model RA series machines. The unit also offers greater design efficiencies and will enhance the user’s production capabilities with a dicer that accepts a larger infeed product size combined with a larger impeller case. That potentially means a 20 per cent increase in yield. When compared to the standard RA-A, it equates to potential increase yield of 50 per cent. The Integra accepts infeed products up to approximately 114mm and the food zone is separate from the mechanical zone. This ensures faultless sanitation and cleanability. The machine also features a slice adjustment knob, allowing dial-in and lockin of a specific slice size to ensure precise tolerances hold true throughout production runs. The dicer can produce slices up to 12.7mm. The range can furthermore dice, granulate, crumb, strip and shred with a combination of circular and crosscut knife spindle set-ups. Hinged panels provide full access to allow fast cleaning and maintenance procedures. The Integra is designed for continuous operation with uninterrupted production in mind. Urschel food cutting technology is exclusively distributed by Heat and Control in South Africa. ‘Our team of experts can add value to your slicing and dicing operations. With insight to your operations and desired results, our team will tailor a cutting and slicing machine to ensure top results for energy efficiency and speed, as well as maximum saleable yield,’ concludes Heat and Control’s Jeff Rossouw. •
Urschel’s Affinity Integra Dicer is equipped for difficult-to-cut applications
Heat and Control – www.heatandcontrol.com
Innovation In Action
Complete turnkey solutions for Prepared Food Systems
Heat and Control offers the latest value add technology to cook, coat, brand and sear a wide range of meat, seafood and poultry products. Our fryers, ovens, branders, searers and breading/batter applications can produce, prepare and cook the highest quality chicken, beef, pork, and fish products, using the most efficient processing and packing technology.
With manufacturing facilities and sales offices worldwide, Heat and Control supports manufacturers with experience, expertise and resources to develop the most value driven and efficient solutions for any food production challenge. Put our innovation to action in your plant today!
Preparation | Cooking | Coating + Conveying | Inspection | Weighing + Packaging | Controls + Information
www.heatandcontrol.com | info@heatandcontrol.com | Cape Town +27 21 948 5934
CONVENIENCE FOOD PROCESSING
Adapt products without compromising on taste Health authorities and regulators are calling on food and beverage companies to lower sugar and calories to stem the tide of obesity and associated diseases. Consumer demand adds a further business incentive for brands to act on health. By Dominique Floch
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eople are taking control of their wellbeing and look to food as one of the tools to do this. Research suggests that food is a more popular choice than supplements. More than half (61 per cent) of consumers say healthfulness has an impact on buying food and beverages 1. Dietary fibres offer a good example of a nutrient as consumers become aware of the health benefits of consuming more fibre. This awareness goes beyond the well-understood laxation effect of dietary fibres to awareness of fibre’s weight management benefits and support for healthy blood glucose levels. Tate & Lyle believes the demand for these better-foryou products will continue to grow. Health is an essential area of focus in some companies’ innovation strategies. Many major brands have made big The Tate & Lyle team during the recent roadshow commitments to deliver healthier products – not just healthier new variants, but How do you make products will less adaptations to their hero brands and a sugar and calories, but that features added wider portfolio to help them deliver on nutrition? The reformulation toolbox has ambitious commitments. Working with never been broader, with ingredients and an ingredient partner like Tate & Lyle, solutions for every technical challenge, food and drink brands are adjusting their category and consumer preference. High recipes to improve the nutrition quality intensity sweeteners, which match the without compromising the taste or eating sweetness of sucrose (table experience. Food is a source sugar) and are used in much of enjoyment and consumers smaller quantities, are choose food and beverages now used to deliver that taste good. A many of these reduced majority (81 per cent) of sugar products. consumers polled in a Product launches in South Sucralose continues recent survey said that Africa with no added sugar to be a formulator’s taste has the greatest or a reduced sugar claim favourite when it impact on food and are on a long-term comes to a sugar-like beverage purchases. upward trajectory. sweetness profile with In South Africa, excellent stability. For consumers are seeking brands developing clean naturally sweetened and reduced label products and simple, sugar food and beverages. Product recognisable ingredients from nature, launches in South Africa with no added stevia is a popular choice. The range sugar or a reduced sugar claim are on a of stevia ingredients has expanded long-term upward trajectory. Added fibre significantly over the past decade. The is a big trend too locally, as there was a plant-based trend is not limited for 22 per cent jump in new products with a sweeteners; all plant-derived options are high or added fibre claim launched in 2018 2 viewed positively. compared to the previous year .
DID YOU KNOW?
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Food Review | June 2019
Globally, soluble fibres are being used to great effect in sugar-reduced products, replacing the bulk and body of sugar. Combined with a low or no calorie sweetener, the product delivers a great eating experience. For consumers, it’s a ‘win-win’, delivering less sugar and calories, with added health benefits. Ingredient manufacturers such as Tate & Lyle understand it is no longer about supplying single ingredients, but working with the manufacturer to build a holistic solution fit for the brand and the consumer. • 1 International Food Information Council Foundation, 2018 Food & Health Survey, 2018 2 Mintel
ABOUT THE AUTHOR DOMINIQUE FLOCH is
the technical and sales director Europe, Middle East and Africa for Tate & Lyle PLC. Tate & Lyle – www.tateandlyle.com
CONVENIENCE FOOD PROCESSING
Traceability is a profit opportunity End-to-end tracking in the food supply chain can do more than safeguard against potential disasters, particularly at the processing stage, writes Geoff Furniss
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t is widely understood that traceability is important for food safety. Traceability can also help food producers and processors improve profitability. At this stage in the supply chain, sorting machines (important for ensuring traceability, food quality and food safety) can assist in reducing food waste, analysing yield and optimising operating efficiencies. Sorting technologies can help food producers and processors win business by ensuring their products attain the quality standards appealing to retailers. The core need for traceability is trust. Just think of food-related news headlines in recent years: Melamine in dairy products; salmonella in peanut butter; wood pulp bulking-out parmesan cheese; horsemeat passing as beef; E.Coli bacteria in romaine lettuce and listeria bacteria found inside an apple processing plant. Whether these scandals are caused through fraud or by accident, higher levels of traceability in the food supply chain would prevent many from happening. If food scandals do occur, traceability can make it easier to track down the sources of contamination or adulteration. Take the case of E. Coli in romaine lettuce. The cause was quickly found to be water in a canal in Arizona, but it was impossible
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Food Review | June 2019
to trace back all affected products as the bagged salads contained ingredients from multiple ranches and their records of origin were not thorough enough. Detailed and standardised record-keeping is essential.
“Whether these scandals are caused through fraud or by accident, higher levels of traceability in the food supply chain would prevent many from happening.” Consumers want this complete story, and they want to access it through digital channels such as websites and smartphone apps. This matters as consumers make food purchasing decisions based on detailed product information available to them. Brands and products perceived as trustworthy can win customer loyalty and command price premiums. That perception gains strength when retailers share information about food origins, ingredients and processing. In 2018 Walmart China launched a traceability project, which gives shoppers detailed information about the
provenance of fresh packaged vegetables, accessed through a QR code scanned by a smartphone. This is just the start of a big trend – anticipated by market researchers several years ago. According to the 2016 Label Insight Transparency ROI Study, which surveyed 2 000 consumers, 73 per cent of all respondents (and 86 per cent of mothers aged 18 to 34) are prepared to pay more for food which has information transparency. More than half of all consumers – 56 per cent - are more likely to trust a brand that offers additional information about how their food is produced, handled and sourced. Retailers know this, of course. This means that food producers and processors who want business from retail chains must find ways to gather and standardise data. Multinational grocery chain Walmart is another good example. The brand’s Food Traceability Initiative launched in September 2018. It requires suppliers in the US to trace fresh, leafy produce from farm to table in real time. Initially, suppliers must provide one-stepback traceability, but by October 2019 there must be end-to-end traceability, which goes all the way back to the farm. It won’t be long before this level of detail is required by other retailers. This may sound daunting, but food producers and processors can achieve accountability easily enough through technology. As a specialist manufacturer of sensor-based sorting machines for the food industry, Tomra Food and its sister companies Compac and BBC Technologies, are advancing the digital transformation of the fresh produce supply chain. BBC Technology’s innovative FreshTracker software (http://freshtracker.com) enables traceability of the origins and characteristics of individual products, such as blueberries - from harvesting, processing and packaging to point-of-sale. This means users can integrate the postharvest supply chain and original point-
CONVENIENCE FOOD PROCESSING
Regulators, retailers and consumers demand traceability
of-harvest information. FreshTracker also provides real-time information on attributes of the yield and can compare and analyse yields to enhance production efficiency. Reporting provides additional visibility for packers who are running another grower’s fruit. With all product characteristics prepared by a third-party system and classified by lot and time, the grower can clearly see the result of harvest activities. Complementing this technology, Compac’s pack tracking software traceability system records and stores information about produce as it moves through the packhouse. Barcode scanners track incoming bins, identifying them by variety, orchard block location, grower, bin weight, fullness, and DID picker details. Bins are then scanned YOU KNOW? into the sorting line at bin-tip and Compac’s pack tracking their information is recorded. Then software traceability Compac’s sizer software tracks system records and stores produce as it moves through the information about produce sorting machine, identifying the as it moves through location of each individual piece of the packhouse. produce and which bag, box or carton it has been placed. Another new development is the cloud-based data platform Tomra Insight. By turning sorting machines into connected devices that generate process data, Insight unlocks valuable new opportunities for sorting equipment users. Insight obtains data needed for traceability while transforming sorting from an operational process into a strategic management tool for fact-based decision-making at every step of the value production chain. The workload associated with traceability is more than just a necessity to meet retailers’ requirements and safeguard against food scandals. This is an opportunity for food processors and pack houses to improve production efficiencies and incrementally increase profits. Sorting equipment can play an important role in achieving these gains. •
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ABOUT THE AUTHOR GEOFF FURNISS is the head of BBC Technologies.
www.heatandcontrol.com | info@heatandcontrol.com Cape Town +27 21 948 5934
BBC Technologies - http://bbctechnologies.com
SAFoodReview_Jun19_88.5w x 262h_CEIA.indd 1
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5/8/2019 1:25:31 PM June 2019 | Food Review
CONVENIENCE FOOD PROCESSING
Buy local to support a growing industry
At the Jobs Summit held in Midrand, Johannesburg, president Cyril Ramaphosa urged South Africans to prioritise the purchase of locally manufactured goods in a bid to create and save jobs.
Ready-to-eat fruit salads are a hit with consumers looking for a convenient and healthy snacking option
Toothed packaging punches
Cube, strip and slice blades
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or the economy to grow and jobs to be created, a substantial increase in domestic demand is essential. The most direct way for South Africans to create jobs is to buy South African products. The biggest challenge faced by local business is a reluctance on the part of consumers to buy locally produced goods. This is primarily due to the assumption they are inferior to imported goods. Food Review spoke to Mikko Brunner of Renlaw Engineering to get his take on the local movement, its benefits and limitations. 'In general, South Africans are very hesitant to trust the quality of local goods and automatically assume that imported is better,’ Brunner explains. ‘What many buyers don’t realise is that even spares from original equipment manufacturers in Germany are often produced cheaply in other countries. Ironically, we find it easier to sell to foreign markets than to local users. 'Although we source all our speciality steels from Germany and our key personnel have years of experience and European training and qualifications, it has taken us a long time to get to our current position where local customers trust the quality of our work,' Brunner adds. With South Africa’s weak economy, buyers are under pressure to source firstrate products at modest prices. Buying
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Food Review | June 2019
local means excluding a section of the supply chain with its associated fees and transportation costs. It also means cutting down on your carbon footprint. 'There are many fantastic suppliers in South Africa,’ Brunner enthuses. 'We're always open to testing locallymanufactured products. We’ve have had some pleasant surprises with local products actually outperforming their imported equivalents. We try to source locally as much as possible, although certain materials such as our steels are not produced in South Africa and must be imported from Europe.’ Renlaw manufactures industrial machine knives, primarily for the food processing and packaging industries. The company has invested heavily in the latest technology, ensuring the production of blading of equivalent or superior quality to imported tooling. 'We manufacture for most local OEMs and have had fantastic feedback from local and international customers,’ Brunner continues. 'We can customise our tooling to each customer's specific needs. 'Importers usually sell standard blades that offer the same cutting geometries for all materials, whether foil, paper or plastics. We engineer the edges to suit the precise application. We have worked with many customers on product improvements and with just slight modifications to an
FAST FACT Renlaw has built four CNC machines in-house with more currently in production. This gives the company a competitive edge, allowing it to produce quality cutting tools while keeping prices in check. existing tool, designs have often seen noticeable improvements in tooling performance, with tool-life extended many times over. On top of this, we offer proprietary steels that improve each blade’s sharp-life compared to tools made from inferior steels,' he adds. Another difficulty encountered by local tool manufacturers is the threat by local agents that a machine’s service agreement or guarantee might be invalidated if generic parts are used instead of imported, original-brand spares. 'This anti-competitive behaviour is more of a coercion tactic than a legal argument,' he contends. 'Your car’s guarantee isn't nullified simply because you use a different brand of oil or windscreen wipers. Similarly, your machine guarantee is not void if you use generic consumables.' •
Renlaw – www.renlaw.co.za
Renlaw CUTTING-EDGE TECHNOLOGY
Africa’s leading supplier of industrial cutting tools
CAPE TOWN BRANCH:
JOHANNESBURG BRANCH:
+27 (0)21 701 7917
+27 (0)79 155 7358
sales@renlaw.com
sales2@renlaw.com
www.renlaw.com
FAT S & O I L S
Deliver quality and stability in chocolate and nut spreads AAK has developed Akospread, a range of fats for chocolate and nut-based spread applications that guarantee excellent stability, spreadability, visual appeal, texture and flavour.
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hen used in chocolate and nut spreads, the product delivers excellent stability throughout the shelf life of the product – even in high nut content recipes, which are prone to oil separation. A selection of Akospread solutions are available, tailored for different applications: • Spreads with a high percentage of nuts • Products sold in warmer climates, where stability is a greater issue • Applications that are high in liquid oil • Spreads made with blends of non-hydrogenated, non-trans and low-saturated fats for clean label appeal • Spreads based on shea oil for palm oil-free labels. The global chocolate and nut-based spreads market is projected to record a CAGR of 3.2 per cent between 2018 and 2023 when it will be worth US$11 billion. This growth is being driven by consumers enjoying sweet spreads in new ways. Office workers and Millennials increasingly view a sweet spread on bread as a quick and healthy breakfast solution. Dipping biscuits or baked goods into spreads or eating spreads straight from the jar with a spoon is also becoming more popular. Marco Oomen, AAK’s global business director for chocolate and confectionery fats says, ‘The sweet spreads category is benefiting from growing awareness of the favourable health effects associated with consumption of nuts. Spreads high in protein and unsaturated fats satisfy consumer perceptions of a healthier snack. ‘Akospread will enable companies to overcome the formulation and manufacturing challenges associated with sweet spreads to deliver high-quality products that align with this market trend,’ he concludes. •
Akospread – www.aak.com
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Food Review | June 2019
FAT S & O I L S
The perfect alternative to palm oil Refined hazelnut oil is a fatty oil obtained from hazelnuts (Corylus avellane) by pressure followed by a refining process. The product is typically used in applications such as dressings, sauces, seasonings and nutritional supplements.
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lvea is a manufacturer specialising in the supply of vegetable oils used in the food, beverage and nutritional industry. The company utilises its fullyequipped facility to grind seeds, which are then cold pressed to extract oils and the end product. The company produces a wide range of refined olive oil, virgin macadamia nut oil, cold pressed pumpkin seed oil and organic virgin argan oil, amongst others. Its wide range of vegetable oils and speciality ingredients are sourced from conventional, organic, sustainable or fairtrade supply chains. These are produced for the cosmetics, pharmaceutical and food industries. To maintain high standards regarding the quality, traceability and
consistency of its raw materials, Olvea has set up global and sustainable supply chains. These include facilities in Morocco for Argan oil and Burkina Faso for shea butter and sesame oil. To strengthen its commitment to sustainable development, the company recently inaugurated Olvea Green Technologies, one of the first eco-refineries in Europe. The facility can now offer its customers bio-sourced and eco-refined vegetable oils with complete traceability. Products are supplied locally by Savannah Fine Chemicals. •
Savannah Fine Chemicals – www.savannah.co.za
ABOUT OLVEA VEGETABLE OIL: • More than 160 people are involved in the production of vegetable and fish oils • Annual sales of more than 100 million Euro • Production and storage facilities in Morocco, Burkina Faso and Mauritania • Trade offices in the US, Netherlands and Ghana • More than 40 000 tonnes of oils per annum • 70 per cent export share • Certified organic by Ecocert in line with NOP standards and European Organic Regulation No 889/2008 Regulation • Certified trade fair according to ESR standard.
June 2019 | Food Review
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S U GA R TA X U P DAT E
Sugar tax leaves a bitter taste for the beverage sector The sharp increase in the average selling price of sugary drinks is primarily due to the impact of the national health promotion levy, commonly referred to as sugar tax. Volumes in some beverage categories in South Africa declined in 2018. By Marilyn Nel and Khathu Musingadi
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ther segments, like sparkling soft drinks, recorded significant volume declines in the second and third quarters of the year, but slight increases in the last quarter due to seasonal purchases. As important as they are, figures like these only tell half the story: the negative impact of sugar tax at the till. What about the broader effect of the tax on the beverages sector from a consumer perspective? Is it actually changing purchase behaviour as it was intended? Is it discouraging the excessive consumption of high sugar drinks among South Africans where rising obesity levels remain a concern? The short answer is yes. These 2018 statistics combined with a negative 2019 outlook due to further sugar tax increases and continually shrinking disposable income point to a definite change. Volumes are expected to stay low this year. It has been noted that consumers are shifting completely to other types of beverages, like flavoured water, which is more affordable. The long-term answer is a little more complicated. Along with these powerful market conditions that wield massive influence over where consumers spend their money, is the factor of entrenched consumer behaviour. If sugary drinks are seen by consumers as a reward at the end of the day, or as an essential lunchtime treat or assigned any other positive association by consumers, they are unlikely to allow a price increase to dull that shine. Sin taxes bear witness to this hypothesis. Instead, they will adjust their lifestyle to suit market conditions. This could mean dropping other non-essential items from their shopping baskets to ensure they can continue to buy their favourite sugary drinks at a higher price. The other option is to buy a similar sugary drink but for a cheaper price. BMi Research’s surveys last year revealed that some middle to lower LSM consumers had shifted from buying premium brands to more affordable competitor products as selling prices soared. Major market events like heightened taxes put brand loyalty under pressure. If either, or both, scenarios were in play, shouldn’t this translate into flat figures or at least, marginal growth? The volumes of consumer market insights BMi Research has gathered over the past 10 years has shown
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Food Review | June 2019
“The only way to positively grow a sector under the current conditions is to ask consumers what they want, and then make sure you deliver on this” us that South African consumers are conservative and slow to adapt to change. They’re also innovative, and we expect to see product usage change in the future as consumers find new ways to adjust to price increases. Smaller bottles, for example, were previously regarded as convenient, but following the introduction of sugar tax, two litre bottles were seen as offering better value. Smaller pack sizes took an instant hit, with volumes declining. It is likely consumers are using two litre packs differently postsugar tax, possibly by decanting the contents into smaller bottles to replicate that convenience factor while still capitalising on the more attractive, value-adding price point. It is not only consumers who have been forced to innovate as a result of the levy. Manufacturers prepared for the market impact by developing low sugar and no sugar variants that launched the year before the tax was introduced. Production and sales of these variants shot up dramatically after 1 April 2018. It’s too early to gauge how successful these variants will be in the future. Most
producers indicated their customers did not like the new formulations as they didn’t taste the same as the original ‘sugared’ product. Customers were also sceptical about artificial sweeteners, following the bad press many sugar replacements had received in previous years. Such market insights are vital, as they help manufacturers navigate what will continue to be a tough storm, with sugar taxes rising year on year with inflation increases. Aside from simply allowing the sector to assess the evolving impact of the sugar tax on consumers, in-depth market research like this arms manufacturers with a much more powerful weapon – a true understanding of what their customers really want at this time. Product, packaging and even promotional innovation means little if they all miss their mark. The only way to positively grow a sector under the current conditions is to ask consumers what they want, and then make sure you deliver on this. •
ABOUT THE AUTHOR MARILYN NEL is a research
manager and Khathu Musingadi is a research analyst at BMi Research.
BMi Research - www.bmi.co.za
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WINE 1: Ecowize’s cleaning solutions meet stringent food safety standards 2: Ensure product quality and integrity with proper barrel cleaning procedures
Cleaning and sanitation in the wine industry
Cleanliness, hygiene, consideration for the environment and on-site technology all contribute to the taste and image of a winery and its products. Food Review spoke to PF Coetzee of Ecowize on how to curb contaminants that can leave wines in violation of health and food safety laws.
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ontaminants are present from harvesting the grapes and persist right through to the bottling process. During this processing chain, it is vital to entrench effective hygiene and sterilisation practices. Informed cleaning practices, the right cleaning chemicals and appropriate brushware are suited to some parts of production. Others require special attention; an understanding of the wine-making process and specialised cleaning chemicals and materials to combat specific sanitation conditions. There are several ways that wine producers can approach the challenge of contamination. Selecting the most viable option generally depends on the capabilities and scale of the winery. Maintaining regular and thorough cleaning and sanitation practices appropriate to the production of wine is one. Wineries can also outsource these
routine efforts to ISO 22000 accredited cleaning and sanitation companies like Ecowize. The company offers existing training and hygiene maintenance for wine preparation, in addition to providing sustainable pest control solutions. Ecowize disinfectants have achieved a fivelog reduction when applied as directed by the appropriate cleaning and sanitation protocols. The brushware range offers an array of products suited to all cleaning needs. With 11 colours to choose from, and additional custom made products - such as shadow boards, Ecowize makes enhancing food safety programmes with the correct equipment much simpler. •
Ecowize – www.ecowize.co.za
June 2019 | Food Review
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WINE
Neutralised grape juice makes innovation possible Welch’s Global Ingredients Group has collaborated with experts from Cornell University in the US and the New York Wine & Grape Foundation. The aim was to develop a proprietary technology that neutralises the aroma and flavour of Welch’s signature Concord grape juice.
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eutralised juice can be used as a base wine or blender and provides a new option for winemakers wishing to reduce costs without sacrificing quality across a wide variety of wine styles. Welch’s showcased the benefits of the technology at the Eastern Winery Exposition, which took place in Syracuse, the US in March this year. Visitors had the opportunity to sample Welch’s neutralised Concord grape juice and discuss the potential of the innovation for global winemakers. With more than 151 million litres of bulk storage, Welch’s can offer Concord and Niagara grape juices year-round to the wine industry. The company has facilities in Washington, Michigan,
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Food Review | June 2019
Pennsylvania and New York, which gives regional winemakers the opportunity to save on storage and freight while taking advantage of Welch’s operational efficiencies. Welch’s grape juices for wine are all made from grapes grown on family-owned farms across the US. Zach Longhini, global business development manager at Welch’s Global Ingredients Group explains, ‘Our new technology for producing neutralised Concord grape juice takes our participation in the winemaking industry to a new level. Pooling our expertise with Cornell University and the New York Wine & Grape Foundation was very rewarding and delivered significant benefits during the development process. Eastern Winery Expo will be
the perfect event for demonstrating the benefits of this new technology.’ Sam Filler, executive director of the New York Wine & Grape Foundation comments, ‘We were excited to partner with Welch's and Cornell University to develop Concord products specifically intended for wine production uses. This new Concord product will address demand from wineries for high quality and affordable blending wine. Most importantly, it provides the National Grape Cooperative grape growers another viable market to sell their grapes.’ •
Welch’s Global Ingredients Group www.welchsgig.com
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Packages & Skids
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GEA Southern & Eastern Africa 48 Reedbuck Crescent, Corporate Park South, Midrand 1682, RSA Tel. + 27(0)11 392 7114, Fax. +27(0)11 392 7000 info-sea@gea.com
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engineering for a better world
Hygiene, design and food safety headline at IFFA 2019 International companies presented their latest technologies and revealed the most important trends and developments in the meat processing industry during IFFA 2019. The event was held in Frankfurt, Germany in May.
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he meat-processing industry remains heavily dependent on manual handling and people continue to be the greatest hygiene risk throughout the value-creation chain. An important step towards greater food safety is to replace the manual activity with automated processes. An example is the fully automated portioning and insertion of fillets, steaks and cold cuts into packaging through dispensing units and industrial robots. Reducing human input into the process is another approach. What technical measures can be taken to avoid contamination of meat and sausage products from microbial germs? Consistent and hygienic design of appliances, apparatus, machines and plants are critical in maintaining hygiene during processing. The basis for this is laid down in statutory regulation, such as machinery guidelines and food hygiene regulations and recommendations set out by the European Hygienic Engineering & Design Group. These prescriptions are essentially constructive measures. It is about avoiding dead spaces, undercuts, depressions and crevices. This is where the remains of products are most likely to collect and provides an ideal breeding ground for microbial infestation. Hygienic design is about making machinery and plants easier to clean in a way that minimises resource use. It also involves ensuring that cleaning materials and disinfectants can drain off unhindered. Foreign bodies in food are often the cause of recalls. To what extent can these be prevented with the technologies available today?
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Food Review | June 2019
Contamination with foreign bodies in meat and sausage products can occur anywhere along the production chain. It can be as simple as a broken knife in the cutting room or an overlooked screw or sealing gasket during unplanned maintenance or repair work. Other sources of contamination are material failure and bits of the machinery breaking due to wear and tear. Foreign bodies can be picked up by means of an inspection system with metal detectors or X-ray equipment. Metal detectors are an efficient and cost-effective way of picking out ferrous and non-ferrous metals, and plastics or plastic film containing metallic powder in food and packaging. More frequently than metallic foreign bodies, items like stones, glass, bone or plastics appear in products. X-ray technology offers a broad spectrum of tests to combat this problem. Used in combination with weight checks, it is possible to monitor several criteria at the same time in packaged and unpackaged foodstuffs. Aberrations regarding completeness, weight and adequate quantity or correct shape can also be identified. In practice, both monitoring systems are linked to a rejection system to remove contaminated or deficient products from further processing automatically. Constant documentation of data that results from checks and measurements constitutes a major step in the direction of traceability. This is a valuable aid in identifying the source of faults in the production process and putting in place appropriate remedial action. The need to establish regularly documented assessments of any weak points, together with risk analyses
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1: The IFFA Forum 2: The Sealpac stand 3: International competitions for young butchers 4: International quality competition for sausages 5: Protection chain glove when handling meat
specifically with regards to dangers posed by food fraud. These must be implemented along the entire value-creation chain from raw material to end products, in conjunction with appropriate HACCP concepts. This requires very close cooperation, based on a relationship of trust, with official bodies, testing and certificating bodies, and research institutions. •
Stainless Steel Products for Hygienic Applications
Heat Resistant • Corrosion Resistant • Grease Free
KFG2
CJ5/CG5
ASG
KQG2
Stainless Steel Cylinder Series CJ5/CG5 Features
• Uses grease for food processing machines (Approved by NSF-H1) • Special scraper (standard) prevents water from entering the cylinder • Two types of seal material NBR or FKM can be selected to accommodate the application • Can be disassembled (Series CG5-S ø20 to 40)
Series CJ5
Standard stroke
Bore size [mm] 10
15, 30, 45, 60, 75, 100, 125, 150
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15, 30, 45, 60, 75, 100, 125, 150, 175, 200
400
Series CG5
Standard strokeLong stroke
Bore size [mm] 20
25, 50, 75, 100, 125, 150, 200
Max. man. stroke
201 to 350
25
301 to 400
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301 to 450
40 50, 63
25, 50, 75, 100, 125, 150, 200 250, 300
1500
301 to 800 301 to 1200
80
301 to 1400
100
301 to 1500
Stainless Steel Speed Controller Series ASG Features
• Metal parts: Stainless steel 316, Seal parts: Special FKM • Ambient and fluid temperature: −5 to 60˚C
Applicable tubing I.D. [mm] 4, 6, 8, 10, 12
Connection thread M5, 1/8, 1/4, 3/8, 1/2
Stainless Steel 316 One-touch Fittings Series KQG2 Features
• Compact and lightweight • Fluid temperature: −5 to 150˚C • Material: Metal parts stainless steel 316, Seal parts special FKM • Grease-free/Can be used with steam
Applicable tubing O.D. ∗: Can be used with steam.
Metric
ø3.2, ø4, ø6, ø8, ø10, ø12, ø16
Inch
ø1/8", ø5/32", ø1/4", ø5/16" ø3/8", ø1/2"
Connection thread M5 R, Rc 1/8, 1/4, 3/8, 1/2 UNF10-32 NPT1/8, 1/4, 3/8, 1/2
Stainless Steel 316 Insert Fittings Series KFG2 Features
• Compact and lightweight • Fluid temperature: −65 to 260˚C (Swivel elbow: −5 to 150˚C) • Material: Stainless steel 316. Rubber material is not used. (Except swivel elbow) • Grease-free/Can be used with steam.
Applicable tubing O.D. ∗: Can be used with steam.
Connection thread
Metric
ø4, ø6, ø8, ø10, ø12, ø16
R, Rc 1/8, 1/4, 3/8, 1/2
Inch
ø1/8", ø5/32", ø1/4", ø5/16" ø3/8", ø1/2"
NPT1/8, 1/4, 3/8, 1/2
SMC helping you reduce contamination
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Pushing boundaries of portioning and grading systems Marelec Food Technologies and Marlen International presented their innovative processing solutions to the industry at IFFA 2019.
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arelec Food Technologies has been in operation since 1983. Its core activity is focused on the design and production of highly technical portioning and grading systems for food processing companies in the fish, poultry and meat industries. The Portio Intelligent Portion Cutter cuts fresh meat, poultry or fish into fixed weight portions. Machines are designed and developed by a team of enthusiastic engineers. Each is a specialist in the field of mechanical design, electromechanics and electronics. Software is written in-house for the machine’s operating systems and production management software called Matrix. The range of intelligent portion cutters has gone through many developments. It started with a single camera machine (Portio 1) for flat meat products. The technology then moved to three camera machines (Portio 3) for rounded meat products. Dual lane machines were developed for higher capacities on a small footprint. A different range, the Angle-Portio, allows the operator to select multiple cutting angles, from 0°, 30° and 45°. Portio B is the latest development for bone-in portioning. This Intelligent Portion Cutter was developed to cut bone-in meat to fixed target weight such as pork chops. Due to their irregular shape, scanning over 360° is a must. Three cameras, with 120° spacing scans around the meat to determine its exact shape and volume. Knowing the shape in combination with density allows intelligent software to instantly calculate where to cut a portion for target weight. To prevent the product from moving during cutting, several product holders act simultaneously. The product is kept in place on a belt with specially designed spikes. A gripper with pneumatically controlled fingers holds the loins in place during cutting, in combination with holders located at the top
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Food Review | June 2019
“Recipe-driven software ensures accurate control of product-specific conditions to maintain water temperature within a degree of the set temperature through the entire cook and chill process”
The Marelec stand at IFFA
and at the side. The specially designed knife has two sections: the sharp knife section ensures that the quality of the meat is kept intact and the serrated section cuts the bone
easily. Field results are extremely promising and will continue for a few more months to gather enough data and experience to assist future users of this new technology.
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MARLEN HAS SOUS VIDE IN THE BAG Recognised as a global manufacturer of highly engineered food processing equipment and systems, Marlen International designs and builds innovative solutions for the food processing industry. The company’s premium products have long set the standard for quality and performance in vacuum stuffing and pumping, portioning, size reduction, thermal processing and food handling. Marlen works hard to assure value to its customers through consistency, accuracy and product integrity. The company’s engineering, design and technical personnel consult, collaborate and partner with processors to create custom solutions for clients. The manufacturer works closely with food industry leaders to develop New technology continuous industrial from Marlen sous vide processes to cook, chill and/or pasteurise products in a bag. As sous vide applications continue to grow, an efficient industrial sized linear water cooker is a viable solution. Known as the Aquaflow, it is designed and engineered by Unitherm to process products such as meat
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and vegetables. These items are gently carried through the water bath on a flighted conveyor. The system requires no racks, baskets or batch loading. Its ability to hold a large volume of water, coupled with product movement and recirculation eliminates double handling. Recipe-driven software ensures accurate control of product-specific conditions to maintain water temperature within a degree of the set temperature through the entire cook and chill process. This reduces product spoilage and purge. Residence time spans from 60 seconds to over six hours. With sufficient holding capacity, processors don’t have to worry about product overcrowding. Whether you’re blanching vegetables, cooking meat, chilling bagged soups or pasteurising hot dogs, the Unitherm Aquaflow Water Cook and Chill System offers processors a continuous solution for sous vide perfection. All products are represented by DFS Process Solutions in South Africa. •
DFS Process Solutions – www.dfs.za.com
CM
MY
CY
CMY
K
Leaders in Processing Equipment
TEL +27 (0)87 238 1873 | EMAIL sales@dfs.za.com | www.dfs.za.com
The future of technology MultiFresh was a core focus for Multivac at IFFA. This packaging concept allows for highquality vacuum skin packs. The technology was showcased on a thermoforming packaging machine and several traysealers.
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ultiFresh packaging machines meet market requirements in terms of pack size, output and level of automation. Units are designed for packing a wide range of meat and sausage products with different product protrusion heights. These films combine functional benefits with outstanding visual properties. MultiFresh technology was showcased on the R 105 MF thermoforming packaging machine, T 300 H and T 800 traysealers. The R 105 MF thermoforming packaging machine is a compact and economic model for producing vacuum skin packs in small and medium-sized batches. The machine is easy and reliable to operate and will enable smaller manufacturers to make the entry into vacuum skin packaging. It also offers a high level of flexibility in terms of pack shapes. Units are equipped with integrated upper web chain guidance. This ensures the
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upper web is guided precisely during the packaging procedure. The R 105 MF was shown with an innovative packaging concept for producing recyclable MultiFresh skin packs made of paper fibre-based material - marketed under the PaperBoard brand. Packs can be designed in such a way that the end user can separate the cardboard backing from the plastic barrier layer and then put it into paper recycling.
X-LINE PORTFOLIO EXPANDS WITH NEW TRAYSEALER Following the introduction of the RX 4.0 thermoforming packaging machine, the new TX 710 traysealer features a robust machine and intelligent control system.
“The R 105 MF was shown with an innovative packaging concept for producing recyclable MultiFresh skin packs made of paper fibrebased material” The new TX 710 traysealer is versatile and compact and has the same features as the RX 4.0. It is suitable for packing a wide variety of products. The spectrum of products that can run ranges from fruit and vegetables through to meat, sausage, fish, poultry, dairy products and ready meals of all types. The high output of the TX 710 is a result of the perfect interaction between the
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intelligent machine control and mechanical construction that is robust and space-saving. The output with air packs is up to 25 cycles per minute. With modified atmosphere packs it is up to 18 cycles/min and with MultiFreshTM packs up to 10 cycles/min. The machine's comprehensive sensor system is crucial for the rapid and precise process sequences with MAP and MultiFresh applications. As part of the traysealer's intelligent machine control, one of the functions of its Multi Sensor Control is to determine the switching times of the various control circuits and compensate for these where required by triggering early starts of the subsequent processes. Another component of the intelligent machine control is the Flow Manager function. This monitors the powerful servo drives to overlay consecutive movements with great precision and process reliability. This ensures the maximum cycle output and the highest possible level of operating stability are always achieved. The modular construction of the TX 710 allows frequent format changes to be carried out in less than five minutes. If the associated racking and preheating systems are used, the die can be preheated to the required production temperature. This allows the TX 710 to be available for the next production batch immediately after the format change. Since all the relevant functions are depicted in the die of the TX 710, the operator can change between various pack shapes or different applications with minimal effort. •
Multivac - www.multivac.com
1: MultiFresh with Label 2: The modular construction of the TX 710 3: MultiFresh technology for thermoforming packaging and tray packing
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Food Review | June 2019
Reliable foreign body detection Suitable for use in dry and wet areas, the Intuity metal detection coil from Bizerba reliably detects any metallic contaminants in products or bulk goods.
U
sing the multi-simultaneous frequency technology, the metal detection device uses at least two frequencies to check packed or unpacked goods for steel, stainless steel, iron or nonferrous residues. Intuity improves product quality and minimises the risk of recall campaigns, thereby increasing product safety and consumer confidence. To ensure contaminant-free goods, the metal detection system generates an electromagnetic field near the coil. Each product passing the detector leaves a specific pattern, and any deviations from this pattern indicate contamination. Affected products can be ejected via a pre-installed conveyor belt. Improved product compensation and increased sensitivity enable more precise detection results in combination with steel, stainless steel and non-ferrous metals. The metal detection coil especially excels with meat
Extensible electronics
products and similar goods that exhibit a strong product effect (intrinsic conductivity).
INNOVATIVE CONTROL Intuity is controlled using the innovative Intuity Control user interface. It enables the pre-selection of products and associated settings to predict the object size to be detected. Intuity includes a multi-product memory and provides HACCP, IFS and BRC compliant quality control including audit check, a password-protected system log and a menu-driven validation system. Providing a seven-inch touch display as a standard feature, Intuity also features high mechanical stability and interference immunity and is largely insensitive to vibrations, impacts and temperature changes. The metal-detection coil can be flexibly integrated into conveyor systems like Varicon+, checkweighers and price labelling systems. As an additional option, it can also be combined with a separating system or a
Performance 200 packs/ minute
Plug-In Label
The Intuity metal detection coil
materials slide. Straightforward cleaning is facilitated by the hygienic design not having any dirt-collecting edges. For efficient wet cleaning of the tunnel, Intuity meets the requirements of IP66/69 for the detection tunnel and IP65 for the entire device. •
Bizerba – www.bizerba.co.za
Quality – Check Inside
The intelligent labeling line called GLM-levo, has been designed for the automatic weighing and labeling of pre-packed goods and is available in several different versions. Thanks to the modular systema and a perfomance of up to 200 packs/minute, it has been built to cope with todays and future requirements the food industry may make.
Tel: 011 745 1940 Johannesburg 021 404 1800 Cape Town Email: sales-za@bizerba.com www.bizerba.co.za
June 2019 | Food Review
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Rotary vane pump is ready for Industry 4.0 Busch showcased its new R 5 PLUS, a pioneering vacuum pump for food packaging. The unit can run with pressure control or at a constant speed, making it exceptionally energy efficient.
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cting either as the sole vacuum pump in a packaging machine or as a vacuum module in a central vacuum supply, the R 5 PLUS makes sure a specified pumping speed is maintained. It can accurately sustain the required vacuum level, regardless of how the packaging volume changes. Thanks to its variable speed drive, the vacuum pump covers a pumping speed range from 440 to 760m3 per hour and reaches an ultimate pressure of 0.1 millibars. All operating data is recorded and saved on a permanent basis. This data can be accessed directly on the built-in display or transferred via a Modbus TCP/IP client/ server protocol. A remote control of the vacuum pump via a computer is possible. Busch's new vacuum pump is therefore ready for Industry 4.0. The R 5 PLUS can be operated in two modes. Following an intuitive menu structure on the display, users can choose between the constant speed mode or pressure control mode. The most suitable operating mode depends on the type of packaging. If you are packaging smaller units at high cycle times with just a few seconds between evacuation cycles, it makes sense to leave the vacuum pump running. Adjusting the speed directly on the display allows it to be adapted to current demand without having a negative impact on packaging quality or cycle times. This means that the pumping speed can be kept at a constant level somewhere between 440 and 760m3 per hour. When working with longer packaging cycles or when the vacuum pump is operated in a central vacuum supply, speed control is the more suitable option. In this case, the vacuum pump
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Food Review | June 2019
maintains the preselected vacuum level, regardless of how the pumping speed changes. Once the required vacuum level is in place, the R 5 PLUS continues to run at a minimum speed of 35 hertz, enabling it to respond to a sudden need for increased pumping speed by increasing the rotational speed. In the event of extended breaks, the vacuum pump can also switch on and off automatically thanks to Ecomode. The R 5 PLUS vacuum pump is based on Busch's proven rotary vane vacuum technology. Thanks to its stable pumping speed curve, this vacuum pump can still reach 70 per cent of its pumping speed at atmospheric pressure, even at a vacuum level of just five millibars. One of the fundamental benefits of rotary vane vacuum pumps is that power consumption drops as pressure starts to fall. The rotary vane vacuum pump consumes the most power between the moment it is restarted and when it reaches a level of around 300 millibars. Within the working range between 10 millibars and the ultimate pressure of 0.1 millibars, the vacuum pump consumes a mere 40 to 60 per cent of the specified rated power. This feature alone makes the R 5 PLUS the most powerful and effective vacuum pump in its performance class. The R 5 PLUS can save even more energy
The R 5 PLUS rotary vane vacuum pump is energy efficient while its connectivity features make it Industry 4.0 ready
thanks to two freely selectable operating modes and demand-driven power adjustment. A standard built-in PLC records and stores all operating data on a permanent basis. This enables not only complete, uninterrupted data recording, but also warning and alarm functions. Using the selfexplanatory menu structure on the display, operators can decide when these warnings and alarms are displayed and/or trigger an action. All data recorded by the PLC can be transferred to other PLCs, computers or SMS control units in either analogue or digital form, meaning that the R 5 PLUS rotary vane vacuum pump has full connectivity. •
Busch – www.busch.co.za
GEA’s MaxiFormer produces formed products with excellent shape retention and weight accuracy
Fully automated production lines can minimise cost GEA’s production line for chicken nuggets integrates several machines. These units are responsible for recipe-controlled meat grinding, mixing, forming, coating, cooking, frying and freezing in one seamless, fully automatic process.
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he coupling of meat treatment machines with additional process steps adds several advantages to the overall production process. A major advantage of a centralised system is that the product recipe is only read once. Parameters are then sent to individual machines that communicate with each other. This automatically triggers the preproduction phase, with materials provided just-in-time from silos. Nugget quality is improved since components are supplied at a constant temperature, mixture and consistency. The fine-tuned system ensures low tolerances so the degree of deviation is very low. After production, reports are available to check the process conditions of each batch.
HIGH PRODUCTION CAPACITY WITH LOW LABOUR COSTS The chicken nugget line includes the GEA MaxiFormer. This unit provides very high production capacity, consistency and lower operating costs. The step-filling
system minimises the pressure used to fill each cavity carefully and progressively. This, combined with its rigid drum design, reduces waste, improves filling accuracy, creates a higher quality formed product with excellent shape retention and minimises downtime for cleaning. Its knock-out system uses dry air at high pressure applied only to relevant cavities, instead of the entire drum.
LINE ADVANTAGES Danpo commissioned GEA in 2018 to build a fully automatic line for chicken nuggets. Meat is delivered to the line in 500kg batches, ground and then mixed with water and a range of ingredients and chilled to minus two degrees Celsius in the GEA ProMix with the use of nitrogen. GEA's patented step-fill system pumps the meat into the GEA MaxiFormer to create the desired shape in a stable filling process. Nuggets are then moved by conveyor through a pre-duster, cooked to a core temperature of 73°C, breaded or battered as required then flash fried at
190°C and frozen. The entire process takes just six minutes. The company runs 60-hour production shifts, with only a quick forming drum replacement and some light rinsing of the conveyors approximately every 10 hours.
INDIVIDUAL AUTOMATION OF PROCESSES At the centre of each automated process is the ability to start multiple machines at once. Key features are semi-automatic batch control and machine collision interlock. The interconnection of the belt loader, filler and former eliminates the need to use and store trolleys given everything remains inflow. This first level of automation is available from single equipment to the full line set up. When customers must comply with traceability regulations, the system can be used to record all material movements throughout the process while interacting with the customer’s systems. Barcode scanners are used to record all manual material additions and label printers are used to identify all materials discharged to bins/containers. The system allows users to find out where materials were used and to trace the process conditions for end products. •
Automated food processing lines meet customer demands with different operating modules
GEA – www.gea.com
June 2019 | Food Review
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FL E X I B L E PAC K AG I N G
Convenience closure and fitment innovations drive growth
Demand for pouches is expected to grow 3.7 per cent per year to US$10.6 billion by 2023. Pouch design continues to evolve and now is expanding to include convenience-focused closure and fitment innovations that were once only available on rigid packaging.
F
eatures offering convenience, such as resealability, spouts, and stick packs will see the fastest growth. Features primarily for functionality or aesthetics will see a more moderate rate of uptake. Examples include: • flip-top caps to dispense condiments in pouches • fitments to attach a spray trigger on cleaning chemicals in pouches. In general, pouches and particularly standup types will continue to provide cost savings compared to rigid containers; amenability to high-quality graphics and the perception of a more contemporary packaging format. The snack market is the largest outlet for pouches, as they have capitalised on the healthy eating and snacking trend. Pouches provide effective means to package singleportion quantities of product, whether the small amount is desired for nutritional or convenience reasons. Demand for all types of converted flexible packaging is forecast to increase 2.9 per cent annually to US$22.8 billion in 2023. The ongoing conversion from rigid to flexible formats and consumer interest in products packaged for single servings or uses will continue to drive gains.
IDENTIFYING GROWTH OPPORTUNITIES Growth in flexible packaging is also due to conversion that improves sustainability. The first wave was rigid to flexible, which reduced total lifecycle environmental impact. The next wave is the move to mono-material and other recyclable film structures, whether from
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Food Review | June 2019
non-recyclable multi-material construction or leapfrog conversions from alternative materials. Other growth avenues include: •Convenience: Single serve and on-the-go packaging. Examples include packs of apple slices and carrot sticks, pureed baby food etc. Brands are introducing products like retort oatmeal in a SUP with a fitment. •Ecommerce: The major drivers is frustration free packaging that enhance the consumer experience. Innovations include using shrink wrap over a primary packaging box instead of a second box. Products traditionally packaged in clam shells and a secondary shipping box transitioning to an easy-open, abuseresistant, and tamper-evident pouch or another primary package format. The sustainability benefits of lighter weight flexible packaging will also come into play. Converting to flexible packaging can reduce material costs, shipping costs and ease logistical challenges. These take cost out of the supply chain for the retailer and the shipper and may in turn lower the retail price for the consumer. Products which needed to be merchandised for the retail environment don’t have the same requirement when sold online. This allows for different package formats and branding. Ultimately, the result will likely be convergence, where one package format and structure can be used for brick and mortar and ecommerce sales. These packages will incorporate the performance and aesthetic requirement of both sales channels, and offer an overall cost advantage over multiple stockkeeping units (SKUs) for identical products. •
Recyclable tray packages for apples launched
S
leeves are made out of 100 per cent recyclable cardboard packaging material. With the new technology, apples stay visible and are secured in place so they can’t be taken out of their packaging. The design of the sleeve comes with a handle, so packages are easy to carry. Sleeves can be used with trays that hold four or six apples. Introduced in 2018, the sleever can process up to 80 apple trays per minute and has a very short changeover time of less than five minutes; features a hygienic design and is easy to operate. The Sleever is a compact plug-and-play machine, which can be added to packaging lines. The equipment is also energy efficient and has an ROI of less than a year. The new Jasa Sleever for apples is supplied locally through Goldpack. •
The JASA Sleever PERSONALISES AND SLEEVES APPLES USING CARDBOARD TRAYS
JASA SLEEVER FOR APPLES Process up to 50 trays per minute with a single belt model or 100 trays per minute with a two belt model
PERSONALISES TRAYS AND CUPS USING PRE-FOLDED AND GLUED SLEEVES
The JASA SLEEVER can decorate many types and sizes of trays and cups, square, rectangular, oval or round. Sleeves up to 50 trays per minute with a single belt model or 100 trays per minute with a two belt model.
• 100% CARDBOARD • 100% SUITABLE FOR RECYCLING
CAPE TOWN Tel: 021-534 0215 DURBAN Tel: 031-569 4199 JOHANNESBURG Tel: 011-312 4976 sales@goldpack.co.za www.goldpack.co.za TAS3372
INSPECTION & DETECTION
Metal detection technology hits gold Food manufacturers supplying packaged products to retailers can now use the latest metal detection technology from Thermo Fisher Scientific. The equipment meets gold standard requirements set by Marks & Spencer, a leading UK retailer and one of the toughest food safety codes of practice for foreign object detection.
C
odes of practice typically specify which type of foreign object detection system should be used. They also stress how the system should function to ensure rejected products are removed from production and how the systems should “fail” safely under all conditions. The codes also dictate how results should be audited, which records must be kept and the desired sensitivity for various metal detector aperture sizes.
“Thermo Scientific APEX Metal Detectors and Thermo Scientific NextGuard X-ray inspection systems have been updated with new software and hardware features designed to ensure compliance” The Thermo Scientific Sentinel Multiscan Metal Detector is an innovative metal detector that rapidly scans up to five frequencies at a time. The system now features updated software and hardware
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Food Review | June 2019
FAST FACT:
1
Metal detection technology can assist food manufacturers to meet retailers’ rigorous codes of practice for foreign object detection.
to meet stringent standards. Sentinel is a high-performance contaminant detection solution ideally suited to applications with high product effect, such as meat, dairy, bakery, confectionery and fresh fruit and vegetables. ‘Inspecting with the Sentinel enables food manufacturers to demonstrate to retailers that their foreign object detection technology will help to avoid brand-damaging and costly recalls,’ said Bob Ries, lead product manager, metal detection and X-ray inspection, Thermo Fisher Scientific. ‘As the trend towards adopting codes of practice grows, we are supporting the highest level of market need for compliant foreign object detection solutions across our portfolio of inspection and detection technologies.’ Ries notes that Thermo Scientific APEX Metal Detectors and Thermo Scientific NextGuard X-ray inspection systems have also been updated with new software and hardware features designed to ensure compliance with the retailer codes. This provides more options for food manufacturers based
1: Thermo Scientific Sentinel Multiscan Metal Detector meets stringent standards set by Marks & Spencer and other leading retailers 2: The Thermo Scientific Apex range of metal detectors
2
on their manufacturing specifications and application. •
Thermo Fisher – www.thermofisher.com
BASIC CONVEYOR SYSTEM FEATURES M&S requires the following system features to meet its basic requirements. All these items are standard on Thermo Scientific M&S compliant systems. • All system sensors must be failsafe. If they fail they are in the closed position and trigger an alarm • Automatic rejection system (including belt stop) • Pack registration photo-eye on the infeed • Lockable reject bin • Full enclosure between the inspection point and the reject bin to prohibit the
removal of a contaminated product • Reject confirmation sensing (reject activation for retracting belt systems) • Bin full notification • Bin open/unlocked time alarm • Low air pressure switch with air dump valve • Key switch to start the line • Lamp stack with: - Red lamp where on/steady indicates alarms and blinking indicates bin open - White lamp indicating the need for QA Check (audit software feature) - Alarm horn.
Your product’s best defense! Catch issues before they cross the line with Thermo Scientific product inspection solutions TM
We share your goal: keeping consumers safe and protecting your brand reputation. A custom solution is within reach — and so are the savings. Ensure consistent product quality and safety with the answers you need, simply packaged.
Take a closer look at thermofisher.com/productinspection
X-Ray Inspection
Metal Detection
Checkweighing
© 2016 Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher Scientific and its subsidiaries unless otherwise specified.
INSPECTION & DETECTION
A new world of flexible and smart label inspection
The ability to catch a defective product before shipping to retail customers can offer significant savings in time and money. It can also prevent expensive product recalls, wasted production and expensive legal costs. package markings, especially in the food and pharma sector.
ALL PRESENT AND CORRECT
Labels benefit from accurate vision inspection systems
Q
uality inspection of packaging is critical for perishable products. An unreadable barcode or an incorrect expiry date could result in perfectly good products being recalled and discarded. As production lines become more automated, so must inspection and quality control. These systems can improve a line’s effectiveness, by performing tasks quickly and accurately. The real benefits only materialise when smart automation is implemented. When applied to vision inspection systems, defects can be spotted and dealt with swiftly with minimal impact to the line. A smart vision inspection system can make a production line efficient and less wasteful. All production lines face challenges regarding inspection and quality control. Governments want to protect their citizens and are enforcing tighter restrictions on
Omron systems cover all parts of the production line, including quality inspection. Whether a complete system solution or a partial upgrade to an existing system, each component is geared towards ensuring the highest quality control. Omron’s very compact visual inspection units monitor production in real time and respond instantly to any defect. Data sent from the vision system is processed locally and sent via the cloud for powerful analysis that allows the system to take appropriate actions. The system is totally interlinked, with the improved connection between machines in a manufacturing line delivering accurate quality control and higher efficiency. If any error is detected, the system can often compensate automatically, allowing production to continue unaffected. Omron's smart automation solutions are very fast and possess lots of processing power, yet they are easy to use. This combination of speed, intelligence and user-friendliness deliver effective inspection and transparent quality control.
FOLLOW THE RULES For an inspection system to make smart decisions, it needs to collect data from a sensor, such as a vision camera. Vision cameras can be set up to monitor
different aspects of the product; check for imperfections or labels for misprints or missing information. Powerful processing then analyses this data to monitor the process, comparing actual results with expected results. If any problems are found, the system follows programmed rules on how to respond to changes. It may even be able to deal with the matter automatically. An operator will always be informed for correct process management or additional action that might be required.
FUTURE FLEXIBILITY A further advantage of an effective inspection and process management system is flexibility. Combining vision, motion, control, safety and robotics in a single management system, such as Omron’s Sysmac Studio, production lines can accommodate short production runs and adapt to market demands. Line set-ups can be changed quickly for new production runs and the recognition pattern for quality inspection can be updated easily in the software. This ensures different variants or even different products are produced and packaged correctly. The system is also future-proofed as it can easily adapt to accommodate changes to regulations. All that is required is to roll out a new firmware update for the existing solution. •
Omron - www.industrial.omron.co.za
Superior image sensing speed and precision FH Series
• High-precision object detection • Ultra-high-speed searching • Flexible functionalities to provide high compatibility with manufacturing machines
Would you like to know more? +27 (0)11 579 2600 info.sa@eu.omron.com industrial.omron.co.za fh_series_177x65_ad_enza_01.indd 1
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Food Review | June 2019
11-06-18 09:42
Suduko
Coffee time
Solution
ADVERTISERS’ INDEX JUNE 2019 ABB South Africa................................15......www.new.abb.com Aspirata.................................................20......www.nosa.co.za Atlas Copco..........................................34......www.atlascopco.co.za Bearings International........................21......www.bearings.co.za Bizerba Southern Africa ....................41......www.bizerba.co.za Brenntag South Africa..................... IFC......www.brenntag.com Cereal & Malt.........................................5......www.cerealandmalt.com CRC Industries.....................................19......www.circindustries.co.za DFS Process Solutions........................39......www.dfs.za.com Ecowize Group ....................................33......www.ecowize.co.za Endress + Hauser ...........................OFC......www.za.endress.com Eptech Products..................................50......www.eptech.co.za GEA Africa...........................................35......www.gea.com Goldpack ..............................................45......www.goldpack.co.za Hahn & Hahn Inc........................... OBC......www.hahn.co.za
Heat & Control SA .................22 ,23, 27......www.heatandcontrol.com ISW Shrink............................................44......www.iswshrink.co.za Jelatech.................................................16......www.jelatech.co.za Koelnmesse GmbH...............................7......www.anuga.com Leco Africa ..........................................30......www.lecoafrica.co.za LTL Consultants..................................10......www.cpg.global Messe München South Africa ...........9......www.fdt-africa.com Omron Electronics .............................48......www.industrial.omron.co.za Renlaw...................................................29......www.renlaw.com Rentokil Initial......................................17......www.rentokil.co.za Savannah Fine Chemicals.................31......www.savannah.co.za SMC Pneumatics South Africa ........37......www.smcza.co.za Tate & Lyle............................................25......www.tateandlyle.com Thermo Fisher Scientific....................47......www.thermofisher.com
June 2019 | Food Review
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Sales executive +27 (0)82 976 6541
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Leading through Innovation PHT is the leading provider of state-of-the-art technology for hygiene and food safety. Our unique systems offer efficient, effective and sustainable solutions for your hygienic challenges. We develop both individual and integrated hygiene solutions for your company. We are always there for you and we support you through our actions, professionally and reliably. Hygiene and food safety is our passion. We care about our customers, our suppliers and our people – we measure our success by the way we touch their lives. Because we care, we design innovative and holistic solutions. Tel: +27 861 777 993 | info.za@pht.group | www.pht.group
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METROHM SOUTH AFRICA Metrohm SA is a subsidiary of Metrohm AG, a leading Swiss company. We are a regional support centre for all sub-Saharan countries, including Mauritius and Madagascar. We are proud suppliers of Swiss-made analytical solutions that greatly enhance the output, efficiency and reliability of your labs and processes. Our products are widely used in the environmental, pharmaceutical, food, mining, electroplating, petrochemical and water treatment industries as well as tertiary institutions for teaching and research.
Offering the following across all regions in SA: • Food Safety Implementation (BRC, FSSC 22000, GFSI, GLOBALG.A.P.) • Customised food safety training • Pre-certification audits • Coaching and mentoring of Food Safety Manager • Food Safety Systems Maintenance & Support • Tempo paperless FSMS software solutions
Tel: +27 (0)11 656 1918/ +27 (0)21 852 0213/ +27 (0)31 265 0067 www.metrohm.co.za
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MATRIX SOFTWARE
A FoodBev SETA accredited training provider offering training in the: •B akery NQF 2 + 3 qualifications •M eat and Fresh Meat processing qualifications •P ackaging qualification •F ood and Beverage Handling qualification
Matrix Software, specialist leading ERP software providers for the Meat and Food industry, offers various solutions to assist the factory floor function in production plants.
In addition to the above qualifications we offer numerous skills programmes that addresses the needs of the Food industry. Training is offered across all regions in SA and Africa. shirley@iots.co.za www.iots.co.za
FORMPAK For over 40 years Formpak has supplied specialised processing, packaging and printing machinery to the pharmaceutical, cosmetic, plastic, glass, chemical, food and dairy industries.
Our diverse range of software offerings features a unique module listing of more than 700 modules (program nodes). Our software solutions are tailored for the Feedlot/Abattoir/ Debone / Production Retail industries. Matrix Software is deployed in 8 countries throughout Africa, Australia, New Zealand and Seychelles. www.matrixsoftware.co.za
FIRMENICH We create Fragrances and Flavours for the world’s most desirable brands. Our aim is to delight billions of consumers around the world everyday. Innovative Craftsmanship in
Tel: +27 (0) 11 828 8870/1/2 Fax: +27 (0) 11 828 8880 email: haase@formpak.com or service@formpak.com www.formpak.com
Fragrances and Flavours since 1895.
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QUANTUM COLOURS SA
• Supplier to the hospitality trade and food factories • Service excellence, • Quality, portion controlled products (chilled/frozen /dried) • Innovation & Flexibility • Meat & chicken products tailored for special applications in the food industry • Dried meat products – real meat real flavour! Tel: +27 (0)11 032 8600 email: sales@dinnermates.co.ca Tel: +27 (0)15 516 1515/4 email: factory@dinnermates.co.za/www.dinnermates.co.za
Your No. 1 industry leader for the most comprehensive ranges of both synthetic and natural colours – used in food, pharmaceutical, cosmetic and industrial applications. Our technical team is available to shade and colour match to specific requirements and / or Pantone references and to give legislative support on colours.
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www.quantumcolours.com
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Janusz F. Luterek for: Hahn & Hahn Inc, Intellectual Property Practitioners, Reg. No. 98/22644/21 Directors: V C Williams, J F Luterek, PCR Venter, C Michael, C Berndt, V Lawrance, Y Ra Physical Address: 222 Richard Street, Hatfield, Pretoria, South Africa • Postal Address: PO Box 13575, Hatfield, 0028, RSA Docex: 219, Pretoria • Tel: (27) (12) 342 1774 • Fax: (27) (12) 342 3027 • 430 7637 • Email: hahn@hahn.co.za