SOUTH AFRICAN
www.foodreview.co.za
Journal for food and beverage manufacturers
MARCH 2018 Vol. 45 • No. 3
Concept to Launch Offering value-added product development services
Safe proof your plant against listeria
Food processing technology’s
latest innovations
Fortified ingredients: first defence against malnutrition
ALL GOOD THINGS COME FROM NATURE
Nature’s gift to us – GLASS! Glass is non-porous and impermeable, so it never affects the flavour of food or beverages and prevents any after taste. Products packaged in glass bottles and jars always keep their natural flavour and aroma. Glass is also 100% recyclable and can be recycled endlessly without loss of quality or purity - giving us continual benefits without harming our environment. Consider nature! After enjoying the contents please recycle your glass. To find out where to recycle visit www.tgrc.co.za for your nearest glass bank.
@TGRC
www.facebook.com/TheGlassRecyclingCo
CONTENTS MARCH 2018 | Vol. 45 • No. 3
The right tech to
avoid a food contamination crisis 13
07 NEWS The link between ultra-processed food and obesity
Rockwell’s ethical stance
PAGE
Are you ready for the glutenfree revolution?
10 NEW ON THE SHELF Latest products to hit the shelves
12 EVENT Specialised celebrates 50 years of memorable exhibitions
37 Beverage Review BeverageREV IE SOUTH AFR ICAN
13 INDUSTRY TALK
Quality
How to avoid the food contamination crisis
“BOH Plantations in Malaysia recently installed a high quality Matcon IBC system”
16 SAFETY, HYGIENE & QUALITY ASSURANCE Top tips to keep your plant listeria free
Safety boots can make a difference
Personnel hygiene - the first line of defence
March
In the belly of the listeria beast
26 FOOD PROCESSING TECHNOLOGY Effective hot-fill, cook-seal pasteurisation
Sensor equipment can minimise risk
Induction technology seals in safety
Tna launches new starch mogul
32 FUNCTIONAL INGREDIENTS Manage malnutrition with food fortification
Ensure your digestive wellbeing
Jury’s out on the new EU framework
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March 2018 | Volume
www.foodre view.co.za
“The best way to make a good decision when choosing label printing technology is to know what technologies are available and what their strengths and weaknesses are”
March 2018 | Food Review
3
EDITOR’S COMMENT
EDITORIAL
NEVER COMPROMISE
on food safety
Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmediapub.co.za Assistant Editor: Aarifah Nosarka +27 (0)11 877 6209 aarifah.nosarka@newmediapub.co.za
Layout & Design: Kirsty Thomas +27 (0)11 877 6168 kirsty.thomas@newmediapub.co.za Contributors: Anton Hanekom, Doug Hunter, Linda Jackson, Sarah Louise, Michael Lütjann, Gernut van Laak
P
rocessed food manufacturers Enterprise and Rainbow Chicken Limited have been issued with safety recall notices following the listeriosis outbreak in South Africa. The Enterprise food production facility in Polokwane, Limpopo has been identified as the source of the current listeriosis situation. In what has been described as the world’s biggest listeriosis outbreak thus far, the total number of laboratory-confirmed listeriosis cases has risen to 948 since January 2017, often in the poorer sections of our society. Of the 948 cases, a total of 659 patients have been traced. Tragically, 180 people have died, meaning this outbreak has a 27 per cent fatality rate. While it is good news the source has been found, it also brings the issue of food safety and hygiene into sharp focus. The listeria contamination crisis and how to offset its impact and resulting reputational crisis for the brands involved, make up a large part of our safety, hygiene and quality assurance feature. Turn to page 16 now for all the information you need on how to deal with this emergency. Access to safe and healthy food products is a fundamental human right and remains a priority for those who work with food and beverages. It is estimated that approximately one third of the world’s population is malnourished. Calorie rich, but nutrient poor diets result in a phenomenon called hidden hunger. We explore this concept on page 32 where the latest information on fortified and functional ingredients is under discussion. Both these topics are close to the heart of Food Review’s team. We make sure we bring you relevant information. If you have any data, research and development trends or case studies, please send them to me for inclusion in the magazine and on our online and social media platforms.
ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmediapub.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmediapub.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmediapub.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmediapub.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmediapub.co.za
Happy reading,
Production Controller: Rae Morrison
ADVERTISERS’ INDEX MARCH 2018 ABB South Africa....................... 23....www.new.abb.com/foodbeverage Atlas Copco................................. 26....www.atlascopco.co.za Brewtech Engineering...............31....www.brewtech.co.za Bruker........................................... 20....www.bruker.com/optics Cabletech Marketing................ 45....www.cabletech.co.za Deli Spices................................... 33....www.delispices.co.za Deluxe Chemicals.......................17....www.deluxe.co.za DFS Process Solutions.............. 27....www.dfs.za.com DSM Nutritional Products.... OBC....www.dsm.com Eptech.............................................7....www.eptech.co.za Extrupet........................................47....www.phoenixpet.co.za Glanbia Nutritionals.................. 36....www.glanbianutritionals. com/tenacious Heat and Control............21, 25, 30....www.heatandcontrol.com Imperial Logistics.........................9....www.imperial.co.za
Inoxpa........................................... 34....www.inoxpa.comMesse München Drinktec.......................7....www.fdt-africa.com Neptun boot.................................19....www.neptunboot.co.za Novus Holdings.............................5....www.novus.holdings Plastics|SA................................... 49....www.plasticsinfo.co.za Protea Chemicals....................... 29....www.proteachemicals.co.za Savannah Fine Chemicals....... 35....www.beneo.com SK Chemtrade......................... OFC....www.skchemtrade.co.za Smartload.................................... 43....www.smartload.co Specialised Exhibitions...............8....www.foodandhospitality.co.za Tal...................................................18....www.tal.co.za The Glass Recycling Co.........IFC....www. theglassrecyclingcompany.com Vega Controls.............................. 28....www.vega.com Verder Pumps............................. 40....www.verder.co.za
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 on behalf of Media24 by New Media Publishing (PTY) Ltd. MANAGING DIRECTOR Aileen Lamb CHIEF EXECUTIVE OFFICER Bridget McCarney EXECUTIVE DIRECTOR John Psillos NON EXECUTIVE DIRECTOR Irna van Zyl
EDITORIAL ADVISORY BOARD Two doctorates in chemistry; leader in the field of palm oil; SAAFoST president 1993-2001 and honorary life member; past president, Society of Cosmetic Chemists SA.
Dr Aubrey Parsons With a PhD in biochemistry, an MBA and a Institute of Brewing and Distilling diploma Heidi also serves on the Innovation Hubs BioPark and UNISA’s Life Science advisory board.
SA Food Review
@SA_FoodReview
Managing director of Symrise South Africa; chairman of SAAFFI.
Gail Angela Macleod
Head of communications, Tetra Pak Sub-saharan Africa.
Penny Ntuli
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
4
Food Review | March 2018
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Rudy McLean
Dr Heidi Grimmer Founder, creative director and entrepreneur of Strategic Communications Company (Stratcom).
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Food Review | March 2018
London, UK www.foodtechnology. conferenceseries.com
NEWS
Ultra-processed food under attack A REPORT ENTITLED Household availability of ultra-processed foods and obesity in 19 European countries, found that more than half the food bought by UK consumers was ultra-processed. The term refers to food made in a factory with industrially processed ingredients and additives. Head of the research team Professor Carlos Monteiro from the University of São Paulo claims there is a link between these types of food, obesity and poor health. The Institute of Food Science & Technology refuted these claims, saying processing was a normal part of food preparation - often necessary for safety and palatability. The Food and Drink Federation urged people to stop demonising processed food, as they provide all sectors of society access to safe, affordable products. It also claims processed food have become healthier in the past 10 years, due to reformulations by manufacturers. An FDF spokesman NEW & USED FOOD MACHINERY – IN STOCK explains, ‘In • A&K Corn Cutters & Huskers • Eillert 2-stage vegetable washers the last decade • FAM Dice, Slice & Strip Cutters • Key 4” Hydro Food Pumps food and drink • FAM TS-1D Transverse Slicers • Key Vibratory Shakers • FAM PMD Poultry & Meat Dicers • Kronen GS10 Slicers manufacturers • FAM 7944 French Fry Cutters • Kronen KUJ Dicers have reduced • FAM 7407 Bean Cross Cutters • Kronen Gewa 3800 Washers the sugar, salt, • Feuma Apple Peelers • Mado Meat Mincers • Femia Bean Snippers • Ramon Bowl Cutters fat and calories • Herbort Bean Top & Tailers • Many Other Machines Available in their product CALL US NOW FOR A QUOTATION ranges. There is now a greater variety of healthier Food Processing Systems & Technology, Paarl products available Tel: 021 - 868 -1594 | Fax: 021 - 868 - 1599 to shoppers than Visit us on http://www.eptech.co.za or mailto:info@eptech.co.za ever before.’
Rockwell’s ethical stance THE COMPANY HAS been recognised by Ethisphere Institute as one of the 2018 World’s Most Ethical Companies. It is the tenth year Rockwell made the list of 135 global companies that influence and drive positive change and improve ethical leadership and corporate behaviour. ‘Integrity and honesty is part of our corporate DNA. I am proud that Ethisphere recognises the work our employees do to live our company’s values every day,’ says Blake Moret, chairman and CEO, Rockwell Automation. ‘Global corporations that operate with a common rule of law are now society’s strongest force to improve the human condition. This year we saw companies finding their voice,’ concludes Ethisphere’s CEO, Timothy Erblich.
March 2018 | Food Review
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NEWS
Energy Partners grows footprint THE COMPANY ANNOUNCED its acquisition of KwaZulu-Natal’s Clint Refrigeration. The transaction will substantially grow its reach in the region. Energy Partners Refrigeration CEO Dawie Kriel explains that the acquisition of Clint Refrigeration brings together a complimentary set of skills. This will allow Energy Partners Refrigeration to enhance service levels to clients in the industrial refrigeration and commercial industry. Energy Partners Refrigeration is a division of Energy Partners and part of the PSG group of companies. It supplies highperforming refrigeration technology and services to the commercial, industrial and hospitality industries. Energy Partners is the best in class sustainable energy company in Africa, delivering simple, innovate and costeffective solutions. The acquisition was finalised and took effect on 1 February 2018. Under new ownership, Clint Refrigeration will be rebranded as Energy Partners Multistage KZN.
Bakery is top of the
gluten-free shopping list DUPONT NUTRITION & Health has announced the results of a consumer survey that reveals clients want betterquality products with extra nutritional benefits. While an estimated one per cent of the population is gluten-intolerant through celiac disease, Mintel reports the percentage of consumers who buy gluten-free products is considerably higher. DuPont has launched a new gluten-free solution finder based on its latest application trials. Research findings indicate healthy living is a main driver of gluten-free sales in these markets. It also shows gaps in the current range of glutenfree bakery products on store shelves. ‘Consumers are looking for gluten-free bakery products that match regular products in terms of taste, texture and appearance. From a health perspective, they are interested in claims such as reduced sugar, high fibre and other ingredients that give a better nutritional profile,’ says Lena Hamann, strategic marketing manager, bakery EMEA. The findings provide valuable insights for
ongoing gluten-free trials in the DuPont bakery application centre. Exploring key production parameters and ingredient combinations, the trials focus on ways to improve processing efficiency and sensory properties, including taste, texture, appearance and fresh-keeping quality. This knowledge is behind the customised gluten-free solutions developed by DuPont for individual customer needs. It is also the foundation of the DuPont gluten-free solution finder, a tool that helps bakers identify the right ingredient combinations to meet their market needs. The solution finder includes new DuPont Danisco ingredient blends. PowerFresh GF is aimed at glutenfree bread and sweet goods that stay soft and moist throughout shelf life. The ingredient locks flexibility into glutenfree tortillas, so they fold easily without tearing even after four weeks in ambient storage. For more insights from the DuPont gluten-free consumer survey and from the DuPont bakery application team, visit www.bakeryperformance.com.
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Food Review | March 2018
2018/03/05 1:39 PM
ADVERTORIAL
Advanced transportation management system
offers competitive advantage
Improved efficiency, cost controls and visibility. These are just some of the benefits that Imperial Logistics clients can look forward to, following the group’s implementation of a standardised transportation management system. The new system will be rolled out across all road transport operations in Africa and Europe. This is the view of Michael Lütjann, chief information officer at Imperial Logistics.
L
ÜTJANN REVEALS THE supply chain and logistics leader has opted for the CarLo Transport Management System from Soloplan. ‘The switch in individual business divisions has been completed in Johannesburg, Stellenbosch and Durban. The first German and Polish business locations in the general cargo and liquid sections of the road business unit are due to follow during the first and second quarters of this year,’ he says. Imperial Logistics’ new software solution covers all aspects of transportation management. This includes planning and controlling, tracking and telematics, quoting, order management, invoicing and accounting for all modes of transport. Expanding on the system’s benefits for clients, Lütjann says they will enjoy more visibility through portals. ‘They will also have better access to information through real-time tracking. Client service will be enhanced by extended reporting and augmented analytics capabilities that encompass orders, shipments, vehicles and drivers. ‘By enabling Imperial Logistics to minimise manual work and seamlessly integrate with clients’ operations, the new system will boost efficiency and service delivery to drive clients’ competitiveness. The financial benefits include optimal management of cost and revenue, transaction auditability from start to finish and a clear view of profit and loss,’ Lütjann expands. He notes that Imperial Logistics opted for a forward-looking solution in the shape of CarLo. The system can handle enormous volumes of data in a short time. As an example of the importance of this capability, Lütjann cites a major client in the automobile industry. ‘Imperial Logistics has to handle between 10 and 15 000 orders within tight time frames on this client’s behalf daily. In this kind of situation, you need extremely powerful software,’ he stresses. ‘Another benefit of CarLo is the availability of status
NEW SYSTEMS DRIVE CHANGE interfaces, which are essential when working in the automobile sector.’ Doug Vela, CIO of Imperial Logistics South Africa, reports that the group achieved increases in productivity within weeks of implementing the new system in Africa. He notes that subcontractors can be smoothly connected to CarLo through interfaces with many other transport management systems. Drivers connect via an app to the InTouch telematics system, which is embedded in CarLo, and can then transmit status reports. There are plans to link up about 900 drivers. CarLo’s advanced web-based communications platform ensures data is synchronised in real time, and is designed to reduce logistics costs and eliminate transmission errors. Imperial Logistics will complete the roll out of the new system during 2019. It will be employed at all the group’s business locations around the globe, by some 2 000 users. •
CARLO WILL REPLACE several transport management systems (TMS) at Imperial Logistics. The aim is to implement a standard, comparable, highly automated process for planning, invoicing, monitoring, electronic documentation and archiving. The company plans to involve subcontractors via a web portal and an app – and makes use of a reporting function for clients. The new TMS will be integrated into the existing IT systems landscape including ERP, DMS or telematics. This will be done via various interfaces with other programmes. They include different processes from operations like fleet management, price quotations (price information), planning the use of personnel and key performance indicators (KPIs). Imperial Logistics – www.imperial.co.za
March 2018 | Food Review
9
NEW ON THE SHELF
Peter Rabbit makes Easter special Cadbury Dairy Milk is egg-cited to announce the launch of a special limitededition Peter Rabbit Milk Chocolate Egg. The product is filled with delicious Astros. This mouthwatering egg is sure to delight consumers this Easter.
Kindred spirits join forces Pioneers of craft brewing and distilling, Innis & Gunn and Tullamore D.E.W. Irish Whiskey, have collaborated to create Kindred Spirits, a limited edition Scottish stout. Aged using triple distilled Irish whiskey barrels, Kindred Spirits is a flavourful and mature take on a popular stout.
New Xcite Energy Cider A new guarana energy cider has just been launched by Chill Beverages International. The beverage is made with 100 per cent locally grown and pressed golden delicious apples and guarana fruit extract for a crisp, refreshing taste and a sassy burst of energy. Available in two juicy flavours, Apple & Guarana and Berry & Guarana.
Versatile green mix hits the shelves McCain’s Green Medley Mix is a perfect combination of four nutrientpacked veggies: broccoli, spinach, green beans and peas. Healthy food doesn’t have to taste bland or boring when you dress up these delicious greens.
Earthly twist to new vintage Score Zero packs a sugar free explosion Produced in Stellenbosch by Chill Beverages International, new Score Zero offers a fresh spin on its ultra-premium Score Black. The product features the same great taste minus the sugar. Both variants are fuelled with a triple shot of guarana for an explosive caffeine boost and a healthy dose of B vitamins. Both Score Black and Score Zero are free of taurine.
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Food Review | March 2018
Constantia Glen, known for exceptional Bordeaux-style wines, has released the 2017 vintage of its flagship white. Constantia Glen TWO 2017 i s a meticulous blend of 68 per cent Sauvignon Blanc and 32 per cent Sémillon. This vintage marks the first time the winemaking team has experimented with a new element by adding a five per cent dash of Sémillon matured in locally crafted clay amphora.
Entries now open for the 2018 New Product Competition
Contact Natalie Da Silva: natalie.dasilva@newmediapub.co.za | +27 (0)11 877 6281
EVENT
Specialised celebrates a memorable years
50
Industry partners and stakeholders came together to celebrate the 50th birthday of exhibition organiser, Specialised Exhibitions Montgomery in grand style.
A
fter five decades of serving the exhibition industry, it was a fitting celebration for a company that has stood the test of time with strong leadership, high values and unwavering ethics. The company has built a reputation for consistently delivering shows of excellence across a broad spectrum of industries. ‘We’ve built a proud heritage over the past 50 years,’ enthuses Gary Corin, managing director of Specialised Exhibitions Montgomery. ‘Our experience and strong reputation brings confidence to our stakeholders. It is through their continued support that we have reached this important milestone. We thank our industry partners, exhibitors, suppliers and media partners for their immense contributions.’ It is an exciting time in South Africa’s history. The rand has strengthened, the bond market is at its best level in almost two years and the equity market rose nearly four per cent on the day newly elected President Cyril Ramaphosa delivered his maiden state of the nation address. Ramaphosa believes the country has entered a period of change. While change can produce uncertainty, it also offers great opportunities for renewal, revitalisation and progress. This will require collaboration and support. ‘The tide is turning and we look forward to renewed business confidence and growth,’ Corin says. ‘The very nature of exhibitions is to stimulate trade. We have been providing this platform across many different industry sectors through our portfolio of exhibitions. It is reassuring to reflect on opportunities for renewal, revitalisation, progress and collaboration. We have recognised the importance of collaboration over many years and remain committed to our industry partners.’ Specialised Exhibitions Montgomery is wholly owned by the Montgomery Group, one of the most widely respected exhibition companies in the world. It offers projects in Europe, the Middle East, Africa and Asia.
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Food Review | March 2018
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S andy Angus, chairman of Montgomery and Angus Montgomery
2
I ndustry celebrates 50 years with Specialised Exhibitions Montgomery
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S andy Angus and his wife Jane
4
H aving some fun
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G ary Corin, managing director of Specialised Exhibitions Montgomery addressing guests
Special guests at the 50 th celebration were Sandy Angus, chairman of Montgomery and Angus Montgomery, and Damion Angus, group managing director. ‘You are only able to build a business like this over 50 years if it has a solid foundation,’ reflects Angus. ‘The ethos of the business is all-important: high values and ethics are strongly embedded in all we do. This drives our vision and purpose. Success involves staying close to the industries you serve and a willingness to put money back into these industries. There is no room for compromising on quality. We invest in long-term partnerships with our industry stakeholders.’
Damion Angus concurs, ‘Without teamwork, partnerships and cooperation, a business is less likely to succeed. Our business has been built on collaboration. It is vitally important that we work together with industry as a whole, servicing their needs. We spend time building strong relationships, even with our fiercest competitors. Specialised Exhibitions Montgomery is a proudly local business. We use local skills, suppliers, products and services. We invest in the local economy and assist with local job creation. This boosts business, whilst creating opportunities for growth for our exhibitors.’ •
I N D U S T RY TA L K
The right tech to avoid a food contamination crisis necessary. This becomes very expensive. Conducting this process manually is simply not an option anymore.
KICKING UP QUALITY The industry’s overall standard of food quality management must improve. This is a task for advanced technology. Food authorities play an important part in ensuring certain standards are maintained. This doesn’t mean F&B companies can’t and shouldn’t conduct their own inspections. ERP can assist with this. It allows you to schedule process inspection points, through which you can take samples and have them sent to the lab. When you receive raw materials from a supplier, you typically receive some form of certification for them. To ensure a higher standard test your own samples.
When staring down the threat of a food contamination crisis, the right technology can help save lives and your reputation, writes Doug Hunter.
I
t’s every food and beverage (F&B) company’s worst nightmare. Consumers are getting sick and the Health Department is knocking on your door. The brand reputation you’ve worked so hard to build is in tatters. Food contamination is a constant threat when you deal with perishable products. Given recent events in South Africa, it’s a scenario most companies won’t find too difficult to imagine. While headlines may soon move on from the latest food contamination crisis, it will mark a period of change for the industry. The absolute minimum in food quality management will no longer be good enough. Companies of all sizes will turn to tech to maintain the requisite standards.
FOLLOW THE BATCH Producers and processors are asking more questions about ERP functionality and the standard of a system’s batch management and lot traceability. As soon as a potential
“While headlines may soon move on from the latest food contamination crisis, it will mark a period of change for the industry”
health risk is detected, you must revert to your batch numbers quickly. If a problem is detected at a restaurant, you should be able to go back and identify the batch that contained contaminated products. Once identified, you will see where else that batch has been distributed and the dates it was sent. It is critical to be sure it was the finished product that was contaminated and not one of the ingredients. You must know which ingredients were used in a batch. Many of these ingredients will have their own batch numbers so you can drill down even further, identifying which batches of product were made using the affected ingredient. It is essentially a process of going up the supply chain to investigate the raw materials used, and down the supply chain to recall any products affected. Efficiency is the only real way to minimise health risk. If risk of contaminated product on a retailer’s shelves comes at the cost of lives lost, you must deal with it quickly and efficiently. If you can’t trace exactly which products were affected, you will end up recalling a much greater volume of product than
THIRD TIME’S A CHARM
Once raw ingredients are combined, you can conduct further quality tests. Tests associated with a specific product and supplier should all be linked on the ERP. This can assist in proving that certain tests were conducted, and passed on certain days. Before shipping products, you can double check whether all previous checks were met to satisfaction. The more quickly and efficiently you do this, the better your ability to reduce health risks and save money. Having anticipated the growing need for rigorous checks and balances, Syspro has been working on enhancing the quality management module of its ERP system. The product has better functionality, making it simpler for companies to conduct thorough quality stream processes. At the end of the day, you need to ensure you are asking the right questions of your ERP system. Not all of these systems have batch traceability – a major concern considering you may one day need it to help save lives and your reputation. •
Syspro – www.syspro.co.za
DOUG HUNTER is head of
professional services for Syspro.
March 2018 | Food Review
13
C O M PA N Y F O C U S
Derek Kitchen with Colleen and Mark Ferrao
From concept to launch SK Chemtrade Services offers value-added product development services. Its team of food scientists and association with companies such as International Flavors & Fragrances (IFF), Lycored, Vitablend and Nexira means the company can take a product from concept to launch. By Maryke Foulds
A
fter 40 years in the business, SK Chemtrade Services (SK) is equipped with knowledge and innovative speciality food ingredients including flavours, colours, vitamin premixes, botanical extracts and other functional ingredients. ‘We can create the perfect tailormade compound or blend for customers in the beverage, confectionery, dairy, savoury and baked goods industries. 2018 has seen the implementation of our small-scale pilot bottling line to assist entrepreneurs entering the market,’ enthuses managing director, Mark Ferrao.
DEVELOPMENT AND COMPOUNDING A product’s journey begins with a brief from customers who are encouraged to share as much information about the concept as possible. This should include the product, benchmarks and key points of differentiation. Information on unique selling points and ingredients should be included i.e. if kosher or halaal; comprised of natural flavours and colours, sugar-free ingredients or fortified with vitamins and minerals. ‘Our innovation team starts from scratch, working tirelessly to develop a formulation. Application samples are prepared in our state of the art Innovation Centre, where after the customer will be invited for an evaluation in our tasting bar. Once the application sample has been approved, commercial and marketing support begins. Either we offer the customer single ingredients in a formulation or real, tangible value by compounding (blending or premixes). All compounds are available in
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Food Review | March 2018
powder and liquid format. Comprehensively natural where possible is a keyword for us,’ Ferrao notes. All-in-one compounds contain a complete basket of key ingredients in the formulation. This removes the hassle of sourcing requirements. The company is adapting to the changing face of food products that feature less sugar and salt. It has numerous innovative formulas available to our clientéle. Natural sweeteners and modulators, which can be included as enhancers or sugar reducing technologies all contribute to a cleaner label. A quick walk through the factory highlights capabilities. The facility is broken down into four main sections: 1. The liquid section offers precision through automatic dosing and weighing systems. High sheer mixers, dedicated tanks and a homogenisation plant can keep up with global trends made available to the local market. The production facility can be temperature controlled down to freezing conditions. This enables the successful handling of sensitive products e.g. enzymes. 2. In the powders section, all blenders are fitted with dedicated vibrating sieves. Quality and food safety is paramount. Bespoke premixes that require broad dispersion of key active ingredients are dealt with easily. Custom-built machines are constantly put to the test in the rigorous quality department. 3. Homogenisation from concept to production is a seamless process. SK can produce complex beverage emulsions or low cost dairy solutions. 4. The bottling plant can handle CO 2 injected or still beverages, filled into either PET or glass. Products are capped with crown, ROPP and screw caps. This is the ideal solution for start-ups or small line additions. The system offers minimum order production runs in as little as one pallet in some cases. SK has undergone Food Safety Management System 3rd Party audit (FSA) and has been
C O M PA N Y F O C U S
State-of-the-art Innovation Centre
awarded with certification. This states that SK complies with the requirements of: • S ANS 10049 requirements for prerequisite programmes (PRPs) • ISO/TS 22002 prerequisite programmes on food safety • Codex Hazard Analysis Critical Control Points (HACCP) principles • F ood Safety Management System requirements as guided by the Global Food Safety Initiative (GFSI). ‘Forging honest, hardworking and mutually beneficial relationships with our suppliers has been key in the success of our business. We are proud to have represented BBA and now IFF for over 20 years. This partnership is founded on respect and open communication. The same can be said for our other key suppliers including Nexira, a supplier of botanical extracts and nutraceuticals and Lycored a supplier of colours and cartoenoids. We are delighted to announce our new partnerhsip with VitaBlend, which provides innovative nutritional premixes for fortification of food products. The range includes vitamins, minerals, nucleotides, amino acids and other functional ingredients. We look forward to growing the market for its vitamin and mineral premixes in South Africa and Zimbabwe,’ Ferrao explains.
2018’S BIG TRENDS South African consumers are savvier than ever. They pay attention to what they put in their trolleys. Ferrao predicts a continuation of the growing trend towards natural and clean labels. Freefrom continues its meteoric rise, be it free from sugar, salt or gluten. This will see many product developers searching for innovative ingredients that match these claims. Fortification is generally the next step for FMCG manufacturers i.e. taking a flavoured yoghurt and adding functionality. It is predicted more brands will look at this. There is a rise in the use of the term ‘superfood’. The year should see an
REAL, TANGIBLE VALUE SK’s objective is to become a partner in product development. It does this through the provision of:
INNOVATIVE PRODUCT CONCEPTS • Combining a wealth of experience in flavours, natural ingredients and functionality into formulations. This offers customers a point of differentiation on shelf.
REDUCED TIME TO MARKET • T he Innovations Centre hosts expert food scientists. Formulations are designed faster and application samples are tested sooner. This results in speedier product launches. • T he team works in an open-door environment. Everyone is involved in a brief. This fosters open dialogue and brainstorming. The team is encouraged to be open and share ideas. • Customers simply choose a concept they like. A dedicated and bespoke formulation to requirement and/or a premix is then formulated. • O ffers short lead times and concept to launch capability within weeks.
REDUCED PURCHASING AND STORAGE COSTS • B lends and compound premixes take the hassle out of procuring numerous ingredients. A blend of ingredients can
increase in products using ingredients such as pomegranate, kale, spinach, moringa, spirulina, açaí and goji berry. ‘Manufacturers can quite simply outsource their product development to us. We have a library of pre-existing formulations for all sectors; beverage, confectionery, dairy, baked goods, savoury and health and wellness. This saves
include flavours, colours, botanical extracts, sweeteners and modulators. • SK stocks single ingredients where customers choose to control all aspects of their production in-house.
ACCESS TO INTERNATIONAL TRENDS IN PRODUCT DEVELOPMENT • Represents world leaders in flavours, vitamin premixes, natural colourants and carotenoids, salt and sugar reduction solutions, botanical extracts and nutraceuticals. Partners are enthusiastic to work in Africa, sharing trends shaping the international food and beverage category. International knowledge and expertise is incorporated into formulations for customers.
SMALL-SCALE NICHE PILOT BOTTLING LINE • 2018 has seen the implementation of a small-scale bottling line. • L imits launch risk for clients by lowering minimum order quantities. Raw materials are kept on floor and bottled accordingly. • No need for a customer to invest in a raw material warehouse. • Minimises teething mistakes by assisting clients with regulatory information in house. • Small order runs for the launch phase.
employee and lab equipment costs, time and energy in sourcing ingredients from numerous suppliers. We have everything required under one roof – with knowledge of what works well together,’ Ferrao enthusiastically concludes. •
SK Chemtrade – www.skchemtrade.co.za
March 2018 | Food Review
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S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E
Employee hygiene is a critical component of food safety. One of the greatest challenges in a food processing plant is controlling the ingress and spread of harmful bacteria into the production area. Proper employee hygiene is a significant critical system that should focus on areas where cross contamination is most likely to occur. Here are some guidelines to keep your organisation at the forefront of the safety and hygiene battle. By Linda Jackson
T
he identification of a source for this Listeriosis outbreak has seen the country in crisis and the food industry in shock. The harsh reality is that this could have happened to any food company and our goal should be prevention. It’s back to basics and reviewing the controls we may have taken for granted, and ensuring they are in place and effective instead of assuming this. Listeria monocytogenes is not the only food borne pathogen we should consider. The current focus on the organism has highlighted critical components in employee hygiene. Listeria is commonly found in soil, decaying plant matter and water. Focusing on footwear and control of personnel traffic is therefore essential as a first line of defence. Plants most at risk are those where post-CCP handling of ready-to-eat products takes place. Fortunately, listeria is killed by the pasteurisation processes and proper cooking. Where growth conditions in the food product are conducive, re-contamination after heat treatment is a serious hazard. This is the case with products with a longer shelf life, modified atmosphere packaging and/ or require refrigeration. These factors
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Food Review | March 2018
would favour listeria over other pathogens. We take a look at what the experts tell us.
BUILD THE BARRIER – The Chilled Foods Association For effective control to prevent crosscontamination between raw and cooked food, an effective barrier should be in place to separate low risk (raw) and high risk (cooked) processes. • Determine precisely what comprises a barrier. Bear in mind that if a wheel or foot can be enter high risk/high care, the barrier is not adequate. • Ensure wall/floor junctions are fully sealed. There must be no risk of seeping waste water from low risk to high risk/high care. • Do not locate contaminated equipment or materials near low risk/high care/high risk barriers. • Placement of equipment at barriers must consider the direction of process/product flow, drainage, gaps, product entrapment and interlocks. • Segregated/screened hygiene/cleaning areas should be provided within each production area to minimise the risk of cross-contamination during cleaning. For more information on specific requirements in this high-risk area, refer to SANS 10049.
IF THE SHOE FITS – USDA recommendations Shoe control systems must be in place to ensure a change-over occurs at the high-risk barrier. This is often referred to as a captive shoe system. Different coloured shoes or soles help to make control visible. Given that Listeria spp are soil borne and drains are often associated with persistent strains of Listeria monocytogenes, the USDA recommends the following procedures to minimise the potential for personnel to transfer L. monocytogenes from non-RTE areas of the plant to the RTE area. The use of foamers or footbaths containing liquid sanitisers or dry powdered sanitisers, is appropriate and useful when personnel enter areas where RTE foods are processed or exposed. • A foamer delivers an automatic spray of foam disinfectant on the floor where personnel (and portable equipment i.e. carts and forklifts that transport personnel through the plant) enter the RTE area. • A footbath is usually a low flat container or a water tight recess in the floor. It features non-slip surface and is filled with a suitable sanitiser. Foamers or footbaths are generally more appropriate in a wet processing environment. Dry powdered sanitisers are
S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E
used in a dry processing environment to keep the environment dry. The absence of water in dry processing environments prevents the growth of L. monocytogenes. Whether using foamers, footbaths, or a dry powdered sanitiser, these should be sited so personnel cannot avoid walking through them and cannot jump over them when entering the RTE area. These will need to be managed to ensure the current amount of disinfectant is sprayed over the intended area. Checks should be implemented at regular intervals (hourly) to ensure they are filled with sanitiser. The sanitiser must be diluted to the proper concentration. The FSIS compliance guideline further suggests that clean, dry floors are preferable to foot baths at point of entry. Effective concentrations of disinfectant are difficult to maintain and may become a source of contamination. If foot baths are necessary, the following is advised: • Wear rubber or other non-porous boots. • Maintain them properly, so they are clean and maintain effective levels of sanitiser. • Solutions should contain stronger concentrations of sanitiser than normally used on equipment (e.g., 200ppm iodophor, 400-800ppm quaternary ammonia compound). Chlorine is not recommended. • Use a minimum depth of five centimeters. Take note that you cannot disinfect dirty boots - washing is critical and must be properly managed. The same controls apply to the wheels of trolleys. Don’t forget to swab - your listeria monitoring programme should include foot paths to make sure these controls are working.
ADDING PEOPLE INCREASES THE RISK – FSIS compliance guideline It is essential that management have an in-depth understanding of the requirements to control listeria. This is stressed in the FSIS guideline that highlights that management must: • Provide hand washing facilities at proper locations. • Ensure the employee receives proper hygiene instruction before starting – use of hand soaps and sanitisers, notouch dispensing systems and boot and doorway sanitising systems. • Develop a system for monitoring employee hygiene practices. • Maintain a system for tracking training, testing and certification. • Retrain employees before placing them back into production if they are absent from the job or have failed to follow acceptable hygiene practices. This will help ensure employees are following current, acceptable hygiene habits. • E xclude maintenance employees in RTE areas during operations if possible. They may cause direct product contamination or adulteration if they touch or lay their dirty equipment or hands onto food contact surfaces. If this is not possible, require maintenance personnel to change outer clothing and any other soiled clothing. • Use separate tools for raw and RTE areas (or wash and sanitise tools and hands prior to entering RTE areas) and wear only freshly cleaned/sanitised footwear in such areas.
Protective clothing must be worn Hair net must be worn at all times Always wash your hands Foot protection must be washed
Place rubbish in bins provided This is a food production area back to basics and with urgency. Make sure you review your current controls rigorously and honestly. It could be a small thing that could cause a big failure in your food safety management systems. The result could be disastrous. •
Food Focus - www.foodfocus.co.za
REFERENCES: • Control of Listeria monocytogenes in Ready-To-Eat Foods: Guidance for Industry, Draft Guidance, January
… AND THE POINT IS? You may be reading this and thinking, ‘… but I know this stuff’. Yes, you do. These principles are so well-known that it almost seems unnecessary to consult experts. With the number of preventable deaths unprecedented, it seems that we need to get
2017, U.S. Department of Health and Human Services, Food and Drug Administration • C hilled Foods Association, Practical Considerations in the Management of Listeria, Edition 1, 15/10/08 • F SIS Compliance Guideline: Controlling Listeria monocytogenes in Post-Lethality Exposed Ready-toEat Meat and Poultry Products, January 2014.
SUPPLYING YOU, PROTECTING THEM. : 2015 SABS 1828: 2016 and SABS 1853: 2017 Registered products to kill Listeriosis Monocytogenes Registered Sodium-Free product range 5 Kelly Road, Hughes Ext 4, Boksburg, South Africa
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March 2018 | Food Review
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S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E
Hygienic work boots make a big difference
N
eptun Boot was established in 1977 in Westmead, Pinetown. It supplies high-quality PVC gumboots to general industry with a focus on the agricultural sector. Over the years the business has grown and developed to become a leading gumboot manufacturer in southern Africa. Neptun’s market reach includes territories as far afield as Ghana, Australia, China, UAE, Peru and the Republic of Ireland - making Neptun a truly global player. The mainstay of Neptun’s agricultural range of products are the Shova and Marina product lines. Shova is a full length unisex gumboot and Marina is Neptun’s ladies range of gumboots. Both are available in general purpose and blood and fat resistant variants. The Shova range is also available in Chelsea shoes and clogs, while the Marina range is available in a number of fashionable colour combinations. In 2015 Neptun further expanded its product offering by launching the Strident metal-free, dual density PU safety boot with a textile upper. The boot is available with a composite toecap and an anti-penetrative textile midsole. Strident is also available in shoe and combat boot versions to serve a wider range of industries. Neptun offers a comprehensive aftersales service for its customers with a dedicated team of technical sales representatives that are on call for any opportunities or challenges its customers face. The company prides itself on supporting its customers in delivering the best possible product and service to the end user. All Neptun’s safety products are certified to the latest EN 20345 and SANS 20345 certifications. Both the PVC and the PU manufacturing plants are internationally certified by SAI Global and the SABS. • Ladies range of Marina boots
Full length unisex gumboot
Neptun Boot – www.neptunboot.co.za
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Food Review | March 2018
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S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E
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Food Review | March 2018
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Handling the listeria fallout
On 4 March Health Minister Aaron Motsoaledi announced that polony and other products from an Enterprise Foods factory in Polokwane‚ Limpopo‚ were the source of the world’s largest outbreak of listeria. More factories and processing facilities are sure to follow.
I
n his statement, the Health Minister said this particular strain of Listeria monocytogenes was particularly virulent. It led to at least 180 deaths and infected almost 1 000 people. The Minister has advised the public to “avoid all processed meat products that are sold as ready-to-eat” and explained that the National Consumer Commission has issued manufacturers involved with food recall notices. The loss of life caused by this outbreak - along with the resulting publicity nightmare for Enterprise - highlights how critical impeccable hygiene in food production is. Listeria is a universal problem for food manufacturers. Even when all reasonable hygiene measures have been put in place, problems can still arise. The only solution is to understand the organism, so that food safety managers
S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E
“Good personal hygiene and clean working practices must be ensured. The emphasis falls on personal protective equipment, hand sanitisation and footwear cleaning”
can try and pre-empt problems before they arise. Listeria monocytogenes is found in soil and water and some animals, including poultry and cattle. Unlike many other food-borne illnesses, Listeria can grow in cold temperatures. This means that if bacteria migrates onto food, they may continue to grow even if the food is adequately refrigerated during shipping, storage, and display. Listeria is however killed by cooking and pasteurisation. Listeria multiplies by feeding off organic soils, which can be found in many places in a food processing facility including the insides of coolers, chillers and floor drains. Listeria can then migrate onto
control must also form an integral part of surfaces where food is processed and any food safety and hygiene strategy. handled, thus contaminating food. Good personal hygiene and clean Before listeria can be controlled working practices need to be ensured, and eliminated in a food processing with an emphasis on personal protective environment, it needs to be equipment, hand sanitisation and footwear eliminated from harbourage points cleaning. Rentokil Initial provides a range like drains. A good cleaning and of products that can assist with good hand sanitation programme for the entire sanitation practices in the factory setting. • facility is necessary. Drains are so frequently contaminated with listeria they need to receive special attention Rentokil – Initial – www.rentokil-initial.co.za and cleaning should be followed by regular disinfecting. There are also many ways listeria can move from a non-food surface (like a floor drain) to food contact surfaces, including employees’ clothing, hands, and gloves, and via pests such as flies and cockroaches, which One of Rentokil Initial’s thrive in unclean trained pest control and hygiene specialists will survey drains. These your food production facility free insects can spread of charge and suggest tailor bacteria from one made hygiene and pest area to another as control solutions that will they move about a provide peace of mind. food manufacturing facility. Along with disinfecting, pest
DID YOU KNOW?
March 2018 | Food Review
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S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E
Predict the future of maintenance
The need for factory maintenance often goes unnoticed. Gernut van Laak, group automation solutions leader of ABB’s food and beverage programme, explains how plant managers can budget for maintenance and ensure optimum efficiency for all processes.
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n terms of research and development, food and beverage is one of the leading industries due to its use of new and innovative technology. When it comes to maintenance, many companies still find themselves keeping paper records. While regulation and compliance requirements historically drove these companies to work with paper, advancements in digital tools mean this is no longer the case. Once paper-based systems are in place, they can be difficult to eradicate. Companies become stuck, which can lead them to ignore the significant cost savings, efficiencies and competitive advantages electronic systems can provide. The most important driving force for a company’s success is its employees. Today’s maintenance engineers have the computing knowledge to make the switch to digital. Providing them with a familiar interface that quickly connects employees across the organisation allows staff to work faster and smarter, increasing productivity. Electronic records also eliminate time-consuming and error-prone data entries that are necessary with paperbased systems. While staff is the most important factor of any company’s success, the biggest cost of manual maintenance comes from people. It costs companies time and money to perform tasks that could be automated. Human errors that occur during manual record-keeping can also result in redundant actions, rework and audits. Electronic records eliminate the costs associated with printing, reviewing and retrieving paper documents. Giving maintenance staff access to mobile phones, tablets and other electronic devices on the factory floor allows them to input data faster. This gives them more time to spend completing maintenance tasks. A digital record of the machinery that regularly needs work also means the engineer has easy access to
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Food Review | March 2018
data when it is time for the next round of maintenance.
ENGINEER TRAINING As digital processes and automation become more prevalent on the factory floor, engineering and maintenance skills are expanding. Engineers must use smart devices proficiently, while working alongside automation. There is no standard certification or qualification needed to become a maintenance engineer, resulting in discrepancies in skills globally. While education is important, plant managers should understand that each manufacturing facility is different. They must therefore invest in on-site training for all new engineers and regular updates for the entire workforce.
PREVENTATIVE MAINTENANCE Once engineers are trained and maintenance records are accessible, plants can start to consider the impact of preventative maintenance on their operations. Unplanned outages can often lead to waste, as the product manufactured during this time must be disposed of. If it doesn’t lead to wasted product, outages will most certainly cause varying degrees of downtime. This causes lost production and
cancelled orders and contracts if deliveries are not made on time. Taking into consideration potential problems on the production line, plant managers can reduce disruptions and help secure long-term competitiveness. All food and beverage manufacturers have periods where they are either not producing, or producing much less than during the high season. This is the ideal time to be carrying out maintenance on the production line. If a plant manager knows their motor is likely to need repairing every year, they can carry out the work during quiet periods, minimising the amount of downtime and lost production. Overall Equipment Effectiveness (OEE) is a versatile measurement for production efficiency. It takes into consideration three factors — availability, performance and quality. Availability is reduced by equipment failure, setup and adjustment; performance is reduced by idling, minor stops and reduced speed and quality is reduced by process defects and startup losses. Research has shown that improving any of these factors will have a major impact on efficiency. Carrying out preventative maintenance helps improve all three by reducing equipment failure, stoppages and defects. Plant maintenance has gone digital. Anyone can log into an online platform to keep watch of the apparatus and maintenance can be predicted. Doing so could save plant managers time and money, while keeping production on course. •
ABB – www.abb.com/africa
Maintenance schedules are a must to keep your plant running smoothly
— ABB’s food & beverage solutions Plant-wide solutions to optimize productivity, efficiency and uptime ABB’s broad digital portfolio enables Increased control and visibility to better optimize productivity with less energy and water, realize improved food safety and traceability, and minimize waste. ABB can help you build the flexible, costeffective production systems needed to manage your risks and gain the most from today’s trends. new.abb.com/food-beverage
S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E
In the belly of the
LISTERIA BEAST
The current spike in the incidences of Listeriosis serves as a stark reminder of the importance of identifying and acting on food safety threats.
W
hen consumers fall ill because of food contamination, prompt action to identify and isolate the food items and facilities that processed and supplied the food, is needed to effectively deal with the threat. ‘Means include regulatory processes and procedures and an early warning system(s) to prevent or minimise the impact of such cases,’ says Dr Hennie Ras, principal specialist traceability and operations visibility at traceability experts, IQ Logistica. The Department of Health established that the current Listeriosis outbreak can be traced to a single source of food contamination, i.e. a single widely consumed food product or multiple food products produced at a single facility. ‘Until a specific food source and production facility where the manufacturing happened are identified, there is not much that can be done in isolating the spread of the disease,’ says Thomas Robbertse, CEO of IQ Logistica. Ras says isolating and recalling affected product/s in a speedy and efficient manner will depend much on the level of traceability inherent to the affected product/s. ‘To efficiently and optimally track and trace the movement of product in a value chain, a flexible item instance level traceability audit trail is required. That will provide a real-time overview of item-handling events that specific items are subjected to through the entire value
Production of sausage and ham in a meat factory
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Food Review | March 2018
chain, i.e. from primary production through all intermediate stages of value-add up to consumption.’ Rolf Uys, of food safety training and consulting company, Entecom, says during his almost 15 years as a food safety auditor he has audited well over 1 500 food factories. He has learnt a great deal about food safety and best practices, but also the dirty food safety underbelly of the industry. ‘The South African Listeriosis outbreak, which according to the World Health Organisation is the largest reported Listeriosis outbreak yet, has put the spotlight squarely on the importance of food safety, which in most cases leaves much to be desired.’ Although South Africa has stringent health and safety regulations, authorities lack the resources and infrastructure to implement them properly. This opens the door to abuse and shortcuts especially when there is pressure on the financial performance of a company. Some of Uys’s worst findings as a food safety auditor include: • dead rats in equipment and rodent droppings on raw materials • cockroaches • urination inside food factories • f ly maggots • mould and fermentation in product zones • insect infestation in flour silos and trucks • l ive rats/mice in food handling equipment • bypassing critical control points (metal detectors, sieves, pasteurisers) to increase production • f aeces behind an electrical panel ‘There are many more to add to the list and it is mostly centred on deep cleaning of equipment and the discipline of personnel. It should also be pointed out that these were not first-time audits of small backyard operations. Most were large, well known food manufacturers, with numerous
food safety certificates. If you know where to look, the food industry is often not a very hygienic place,’ he concludes. International experience shows foodborne illnesses are on the increase. In the US, figures from the Centre for Disease Control and Prevention show that annually roughly one in six people get sick, 128 000 are hospitalised and 3 000 die of foodborne diseases. •
IQ Logistica – www.iqlogistica.com
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F O O D P R O C E S S I N G T E C H N O L O GY
Benefits of hot-fill,
cook-seal pasteurisation A growing trend amongst processors of ready meal trays and pouches involves hot-filling and pasteurising in the package. This extends shelf life and reduces thermal processing time.
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ncreased use of pasteurisation improves the safety of many ready-to-eat (RTE) food products. This includes the adoption of a variety of pasteurisation technologies and methods - both pre- and post-packaging. Although pasteurisation is considered a highly effective means of removing pathogens, food processors should recognise that introducing new steps to their processes, including new pasteurisation, could significantly alter process efficiency. Unless the pasteurisation process is fully integrated into the production stream - from infeed to discharge - it can adversely affect other process outcomes. These include eating quality, taste, appearance and shelf life.
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Food Review | March 2018
During efforts to follow FSIS guidelines or enhance their own food safety protocols, some RTE producers are installing pasteurising equipment and procedures that are not integrated with their overall processes. They even use pasteurisation technologies that adversely affect the quality of their finished products.
HOT-FILL VS. CHILL AND REHEAT Traditionally, RTE foods are pre-cooked and then chilled. In dinners like lasagna this includes items in the meal i.e. the meat, sauce, pasta and cheese. Each item is prepared separately, chilled and then assembled into meals. If extended shelf life is desired, the RTE manufacturer will
process the product through an autoclave or some other type of post-packaging pasteurisation system. ‘If you have already cooked the product, then chill and assemble. Most post-packaging pasteurising systems involve reheating the product and then chilling it again,’ explains Adam Cowherd, director of product management of food processing equipment manufacturer Marlen International. ‘In essence, you’re cooking it twice and chilling it twice. By subjecting the product to additional thermal energy, you may increase nutritional loss and compromise finished eating quality.’ Food products like lasagna or macaroni and cheese are pasteurised in the tray to achieve better shelf life and finished product appearance. By pasteurising intray, you can market a top-baked product. These items offer better perceived value to consumers.
F O O D P R O C E S S I N G T E C H N O L O GY
After re-heating in a microwave, it appears and tastes like a truly oven baked product. This is achieved through the hotfill, cook-seal pasteurisation process. The photograph on the package is representative of the finished product coming out of the microwave. Many RTE processors are looking at pasteurisation systems that do not cook and chill twice, but rather hot-fill, cook once and seal and chill once. This concept applies to food items in trays or pouches such as ready meals, eggs, soups, and sauces. ‘By hot filling, the time required to pasteurise is significantly reduced,’ he says. ‘Two or three minutes should suffice. As the product is already hot, only minimal loss of heat during the hot-fill process needs to be recovered. You simply bring the temperature back up and hold for one to three minutes. From that point, it can be chilled.’ A key benefit of the hot-fill approach is the reduction of pasteurisation time. Equipment is mainly sized by the amount of time required to pasteurise the product. The strategy of the hot-fill and seal approach is to reduce pasteurisation time and the footprint of the equipment.
WATER-BASED HOT-FILL SOLUTIONS A large egg product supplier was looking for an optimum process for pasteurising liquid eggs packaged in pouches for food services. Consumers included restaurants, hotels and institutions such as schools. The pasteurisation process would require heating and chilling the liquid eggs successfully. This will also ensure the mechanical handling of the product maintains the integrity of the pouch – protecting the eating quality of eggs when served. Unitherm’s solution is to hot-fill liquid eggs into a pouch and transfer the pouches to a hot water bath where they are pasteurised while being cooked. Products 1396_DFS ADVERT.pdf
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are then transferred inline to a water chill system. ‘Chilling requires a combination of drenching and water bath, as the eggs float in the pouch,’ explains Cowherd. ‘The result is a product that is extremely shelf-stable. The final product is re-heated by microwave or in a boiling pot of water. The bag is then opened and scrambled into the serving pan. The same process will work for sauces, soups, and other pouched meals.’
AIR-BASED HOT-FILL SOLUTIONS A different approach was needed for a highvolume processor of baby food in trays. The challenge in this case was to pasteurise hot-filled trays with no water or humidity in the process. Unitherm developed a unique spiral pasteurisation system capable of advanced data tracking software to guarantee real-time pasteurisation. Multiple safety measures and checkpoints are in place. Pasteurisation solutions require continuous monitoring of air temperatures and residence time. A data tracking system monitors any variance in temperature. This could result in a failure to pasteurise products. Volume requirements stipulate continuous production for approximately 10 hours a day, six days a week. The complexity of the project was heightened by a critical headspace requirement for the packaging. There could be no deformation of the trays during the pasteurisation process. ‘This was a somewhat unique pasteurising approach that was developed specifically for the processor,’ explains Cowherd. ‘Water and steam as heat transfer 09:09
mediums are more efficient and stable than air. In the case of this baby food item, the product restricted the thermal energy medium to only the use of dry heat. Processors required a very fine margin of tolerance and air temperature fluctuation. This was critical for the validation of their protocol. The heat transfer mechanism within the spiral oven and temperature monitoring and tracking system had to prove the equipment could meet the pasteurisation requirement on a constant basis, which it did.’ Most hot-fill, cook-seal applications are product specific and are designed around very strict protocols within the USDA’s FSIS guidelines. Unitherm specialises in different thermal processes for efficient heat transfer, resulting in extended shelf life and optimum product quality. Unitherm is supplied locally through DFS Process Solutions. •
DFS Process Solutions – www.dfs.za.com Unitherm – www.unithermfoodsystems.com
The Unitherm Mini Spiral pasteuriser
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March 2018 | Food Review
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F O O D P R O C E S S I N G T E C H N O L O GY
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The process pressure transmitter Vegabar 82 with oil-free ceramic capacitive Certec measuring cell
P
DID YOU KNOW? Vegaflex 83 is the best choice for use in foodstuffs.
ressure vessels and process tanks must meet stringent safety requirements. Continuous monitoring of differential pressure plays a major role in minimising risks from hazards such as excess pressure, leak or dustexplosive substances. The VegaBar series 80 pressure transmitters are very effective at this task. The method is simple – just put two of them together. Two pressure gauges can quickly transform into a perfect electronic differential pressure system. Two sensors from the Vegabar series 80 determines process pressure with the help of two measured values: the tank pressure and the total pressure resulting from the pressure of the medium and overpressure. The user can simply take a pressure transmitter from stock, order another identical sensor with electronics version slave and have an electronic differential pressure system up and running in a short period of time. As opposed to conventional differential pressure systems, electronic differential pressure measurement with Vegabar series 80 is not affected by ambient temperature or strong vibration. When it comes to maintenance, the technology is in a league of its own. As the two sensors are electronically wired together to form a single measurement, easy maintenance can be done on the devices individually. It has another impressive feature: in this version, with oil-free ceramic Certec measuring cell, the pressure transmitter is completely resistant to temperature shocks. The extremely high overload resistance factor of 200 is not found on the market. Certec technology offers the major advantage of being installed flush with vessel walls. This eliminates possible blockages to impulse lines that are no longer required, which can cause blockages. •
Vega – www.vega.co.za
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Food Review | March 2018
F O O D P R O C E S S I N G T E C H N O L O GY
Sealing in product integrity and consumer safety H ermetic seals, created by induction sealers, protect food products by preserving freshness and preventing leaks. They also offer tamper evident benefits. The technology is popular as it seals out moisture, oxygen and bacteria – extending product shelf life. Rob Cassell of sub-Saharan Africa Machinery Enterprises represents induction cap sealing manufacturer Enercon Industries. He says, ‘Tamper-evident packaging (TEP) provides many benefits to businesses in almost every industry. It provides security throughout a product’s life cycle including post purchase. Understanding TEP, how it can benefit your business and the differences between tamper-resistant packaging (TRP) are important. Tamper-evident seals are FDA approved.’ Product integrity is critical to food safety. From the time a product is filled until it reaches the consumer it can be exposed to tampering throughout the distribution
channel. Over-the-counter pharmaceutical packagers are ahead of the curve. Their use of induction cap sealing as a means of tamper evidence has become an industry standard. Food packagers should learn from the more regulated world of medicine and consider adopting similar strategies for consumers. Induction sealing is a very simple process to add to existing packaging lines. Capped containers with an inside liner are conveyed under an induction cap sealer and exposed to an
electromagnetic field which heats the foil liner. The heat melts a polymer, which bonds with the lip of the container to create a hermetic seal. ‘In the past few years, Enercon has developed its Super Seal product line with greater capacity for high line speeds, integrated cap inspection and touch screen control, which simplifies operation,’ Cassell notes. Leading brands are working with Enercon to develope creative packaging that takes advantage of induction sealing. Recently Unilever won the Package of the Year award for its Hellmann’s Mayonnaise Squeeze Bottle. Unilever designated Enercon as its supporting Vendor of the Year due to the application expertise supplied. This made the development and execution of the package’s closure a success. •
Enercon – www.enerconind.com
FOOD INGREDIENTS
March 2018 | Food Review
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F O O D P R O C E S S I N G T E C H N O L O GY
Starch mogul upgrade ensures compliance
Tna has upgraded its flagship NID M3000 mogul. The equipment aims to improve operational efficiencies and ensure equipment adheres to the highest hygiene and safety standards.
S
ince the acquisition of confectionery specialist NID in March 2017, tna has made some considerable investments. This was aimed at accelerating the development process and to equip NID’s starch moulding technology with a range of new features. It is expected the upgrades will increase operational reliability, enhance quality control and improve overall system performance. As part of the latest upgrade, any internal parts of the feeder and stacker in regular contact with starch trays are manufactured in stainless steel for advanced hygiene and consumer safety. The new range of NID moguls was specifically engineered to achieve full compliance with the EU’s latest ATEX directive on the use of equipment in explosive environments. This resulted in the incorporation of ATEX-certified electrical devices, temperature sensors and repositioning and redesign of key mechanical components to mitigate the hazards associated with the handling of starch.
“…internal parts of the feeder and stacker in regular contact with starch trays are manufactured in stainless steel for advanced hygiene and consumer safety” ‘ATEX compliancy is becoming very important to our customers,’ comments Edward Smagarinsky, group product manager at NID (from tna). ‘Although starch moulding itself is not generally considered a high-risk process and accidents are extremely rare, there are hazards associated with the handling of dry, uncontained starch due to its combustible nature. The health and safety of our customers, in particular the operators, is our number one priority. Any changes we can make to our equipment that can help eliminate these risks take precedence. We’ve also made some operational improvements to ensure our starch moguls continue to deliver the highest level of performance and reliability.’ Some of the most notable changes include an upgrade to the recently introduced tray turntable. This is now equipped with a vibration mechanism to ensure starch is fully discharged when trays are emptied. Further improvements include a newly designed hopper with automatic starch gate and starch level
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Food Review | March 2018
F O O D P R O C E S S I N G T E C H N O L O GY YASKAWA WINS THE TRIPLE sensors for advanced control over the tray filling process. NID engineers developed a new mechanism for the automatic tray insert/eject station. This is offered as an upgrade on all new and some existing NID moguls. The new mechanism enables the insertion and removal of weight control trays without stopping the machine. It can also be used to eject inadequate trays, delivering advanced product quality assurance and a more continuous production process. ‘It’s not even been a year since tna acquired NID and the number of new developments and upgrades our team has
delivered are really impressive,’ adds Mark Lozano, sales manager – confectionery at tna. ‘Our engineers have worked tirelessly over the last few months to ensure our starch moulding technology meets the strictest guidelines. The hard work has paid off. We’re about to deliver four new moguls, with more orders in the pipeline. We’re also planning to set up an annual Starch Mogul Hazard Mediation Forum to start industry dialogue about dust control and mitigation strategies. This will ensure that we continue to develop solutions that meet all our customers’ requirements.’ •
NID M3000 starch mogul
tna – www.tna.com
THE JAPANESE TECHNOLOGY group is on the list of Top 100 Global Innovators for the third time in a row. Every year, this coveted report recognises the world’s most innovative companies. The selection criteria for a place among the top companies are: global reach, the number of patents applied for and the sustained impact of inventions shaping the future. Founded more than 100 years ago, Yaskawa is a pioneer in the fields of drive technology, industrial automation and robotics. The focus is directed primarily on solutions for tomorrow’s industry. ‘We invest heavily in areas associated with Industry 4.0 and sustainable energy use,’ explains Manfred Stern, chief executive officer and president Yaskawa Europe. ‘With its i3 mechatronics solution concept, the company is spanning a bridge between traditional mechatronics and digital technologies. i3 stands for integrated – intelligent – innovative. i3 mechatronics is increasing productivity and quality by enabling the generation of machine and process data,’ Stern concludes. www.yaskawa.co.za
March 2018 | Food Review
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FUNCTIONAL INGREDIENTS
Approximately one third of the world’s population is malnourished, caused in many cases by an individual being unable to access or afford a healthy, balanced diet. The rise in calorie-rich but nutrient-poor diets has led to a phenomenon called hidden hunger. This is where a person consumes enough, or even an excess of, calories but significantly lacks essential micronutrients. By Sarah Louis
SARAH LOUIS is the
segment market manager of the Nutrition Improvement Program at DSM.
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Food Review | March 2018
Managing malnutrition
with staple food fortification T his form of malnourishment is visible in both developed and developing countries and can be detrimental to a person’s health, particularly in childhood. To tackle this issue, food fortification programmes have been undertaken by governments and non-governmental organisations, in conjunction with food manufacturers and millers. Integrating essential vitamins and minerals into commonly consumed foods offers a simple and costeffective method of fighting malnutrition and associated health concerns. The success of staple food fortification can be attributed to the fact that it requires little to no conscious engagement from individuals. Advances in technology mean fortification does not impact the taste, texture or appearance of food. This offers at-risk populations the ability to improve their nutritional status without the need to change their dietary habits or food preparation methods. Fortification can help to significantly decrease the occurrence of numerous health conditions, including spina bifida, rickets and anemia.1
FOOD TO FORTIFY Selecting the right foods for fortification programmes is crucial to their success. Choosing foods that are already a staple in the average daily diet of a population means individuals do not have to change their food habits to receive fortification benefits. As one of the world’s most widely consumed staple foods, flour (particularly maize and wheat) is ideal. A key ingredient in many common foods, such as bread, pasta and noodles, the potential of fortified flour is recognised globally. Currently 86 countries have mandatory flour fortification in place. 2 Micronutrients can either be added alone or as a premix, depending on the needs of the target population. 3,4 In South Africa, mandatory fortification of maize meal and wheat flour, with Vitamin A, thiamine, riboflavin, niacin, pyridoxine, Vitamin B12, folic acid, iron and zinc, was introduced in 2003. This intervention has been linked to a decrease in the natural prevalence of vitamin A deficiency by more than 50 per cent among women of reproductive age.
It is important the flour is well mixed so the nutrients are spread uniformly throughout the product. This is achieved by adding nutrients at a rate compatible with the flow of flour along a conveyor belt, using adjustable feeders. In addition to flour, cooking oil is also a strong vehicle for fortification. In sub-Saharan Africa, vegetable oil consumption has increased steadily over the last decade and imports of oil are expected to expand annually at an average of 3.7 per cent. 5 As oils are frequently used in everyday cooking, fortifying with fat-soluble vitamins, including vitamins A, D and E, can help to improve the nutritional status of many atrisk groups.
PICK THE PERFECT PARTNER Successful fortification initiatives require co-operation from both governments and the global food industry. As a pioneer in food fortification, DSM has been actively engaged in tackling vitamin and mineral deficiencies since such interventions began. Through its Nutrition Improvement Program, DSM has been the industry’s partner for decades, providing the technical knowledge to ensure the correct concentration, distribution and stability of micronutrients to meet regulatory requirements and quality standards. Find out more in DSM’s whitepaper, Combating national malnutrition issues through staple food fortification at www.nutritionimprovement.com •
DSM – www.dsm.co.za REFERENCES: 1. G AIN, ‘Which five diseases can food fortification address?’, https://www.gainhealth.org/knowledge-centre/fivediseases-can-food-fortification-eliminate/ 2. F ood Fortification Initiative, ‘Global progress’, http://www. ffinetwork.org/global_progress/ 3. O . Shisana et al, ‘The South African national health and nutrition examination survey (SANHANES-1)’, HSRC Press, 2012. http://www.hsrc.ac.za/uploads/pageNews/72/ SANHANES-launch%20edition%20(online%20version).pdf 4. D. Labadarios et al, ‘National Food Consumption SurveyFortification Baseline (NFCS-FB-I): South Africa, 2005’ S Afr J Clin Nutr, 2008. 5. OECD and Food and Agriculture Organization of the United Nations, ‘OECD‑FAO Agricultural Outlook 2016‑2025 - special focus: Sub-Saharan Africa’, OECD Publishing, 2016.
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FUNCTIONAL INGREDIENTS
Ensure digestive wellbeing Scientific research on chicory root fibres shows a direct link between inulin intake and improved wellbeing.
W
hen it comes to the importance of dietary fibre intake for a healthy digestive system, public awareness is growing. Although fibre intake of vast parts of the world’s population is still below recommended levels, many consumers are actively searching for convenient food and drinks that include dietary fibres such as inulin and oligofructose. These well-researched and natural prebiotic fibres are proven to support digestive health. Three recently published scientific studies that build on previous findings show that Beneo’s well-tolerated chicory root fibres support digestive health and wellbeing in adults and children by improving bowel regularity and softening stools.
IMPROVING MICROBIOTA COMPOSITION Inulin-type fructans have long been studied for their positive impact on the human gut microbiota and their ability to stimulate the Bifidobacterium population. For the first time, a new study shows that Beneo’s prebiotic chicory
root fibre, Orafti Inulin, induces selective changes in the composition of the gut’s microbiota that directly correlate with improved regularity and wellbeing. The study, conducted by Professor Jeroen Raes, Department of Microbiology and Immunology, and Professor Kristin Verbeke from the Translational Research in Gastrointestinal Disorders unit at the University of Leuven, Belgium, has been published in the journal Gut. It highlights the very selective effect of Orafti Inulin on microbiota composition. Researchers used a highly sophisticated new technology known as next generation sequencing to assess the impact of inulin fermentation on the human colonic bacterial ecosystem. Results showed that inulin intake selectively changed three bacterial genera: Bifidobacterium, Anaerostipes and Bilophila. It increased the relative abundance of Bifidobacterium and Anaerostipes, both known as good bacteria, supporting a healthy microbiota. Bifidobacteria are known for producing vitamin B, antioxidants and conjugated linoleic acids. It also stimulates the immune system. Anaerostipes are known for butyrate production. This supports gut mucosa. The selectivity of Orafti Inulin was further demonstrated through decreased levels of Bilophila, a genus related to increased gas production. This decrease following inulin consumption was linked to both
softer stools and improved constipationrelated quality of life measures. Anke Sentko, vice president of regulatory affairs and nutrition communication at Beneo comments, ‘The results from this recent study are remarkable. They confirm that Beneo’s chicory root fibres induce changes in the microbiota that can be directly linked with improved regularity and quality of life. It is great to see how inulin selectively modulates the gut microbiota. The new association between the change in bacterial abundance, prebiotic inulin intake and enhanced wellbeing is further proof of the role a healthy gut microbiota plays in people’s health. It also opens the field for further research in this area.’
SCIENTIFIC FOUNDATION FOR EFSA HEALTH CLAIM Faecal samples analysed in the study were collected from an earlier randomised, double-blind, placebo-controlled human intervention study by Micka, et al. It indicated that chicory root inulin improves bowel function in adults and contributes to improved digestive health. This clinical trial was a randomised, double-blind, placebo-controlled, crossover design trial involving 44 healthy, slightly constipated subjects (self-reported constipation defined as two to three stools per week). Participants were supplemented with 3x4g/day of Beneo’s chicory root fibre, Orafti Inulin, or a placebo (maltodextrin).
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Food Review | March 2018
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FUNCTIONAL INGREDIENTS
Supplements were delivered in a drink form that was consumed together with breakfast, lunch and dinner during a fourweek period and after a two-week run-in phase. The results showed that Beneo’s prebiotic chicory inulin significantly improved weekly stool frequency without resulting in gastrointestinal discomfort. It also contributed to improved overall wellbeing and satisfaction, as evaluated by a validated quality of life questionnaire for constipated people. The research design followed the EFSA guidance documents for studies addressing digestive function (EFSA Gold Standard) and the results of this study played a pivotal role in obtaining a positive EFSA opinion and an exclusive EU health claim for Beneo’s prebiotic chicory inulin for its contribution to normal bowel function. The fermentation process induced by inulin was addressed by EFSA as part of the mechanism behind the improved regularity. With the exclusive 13.5 health claim approval for the chicory root fibre inulin to improve digestive health, manufacturers can now build nutritional functionality into their products and, importantly, communicate these benefits to the consumer. The official wording for the
Orafti Inulin induces selective changes in the composition of the gut’s microbiota that directly correlate with improved regularity and wellbeing
claim is as follows: “chicory inulin contributes to normal bowel function by increasing stool frequency.” General health-related wellbeing claims under article 10.3 of the EU Nutrition and Health Claim Regulation are also possible. Amongst others, these may include wording such as “chicory inulin promotes digestive health” or “chicory root fibre supports a healthy and balanced digestive system.” Beneo is supplied locally through Savannah Fine Chemicals. •
“Inulin-type fructans have long been studied for their positive impact on the human gut microbiota and their ability to stimulate the Bifidobacterium population”
Savannah Fine Chemicals – www.savannah.co.za
Matching today’s expectations. Smart ingredients for healthy lifestyles. As part of their modern lifestyles, consumers expect their food to be tasty, healthy, convenient and functional at the same time. BENEO offers smart ingredients that help you meet these expectations. Our products cater for energy and weight management, improved digestion and healthy ageing as well as better taste and texture, just to name a few. Beyond that, your product development will be inspired by our insights and expertise!
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March 2018 | Food Review
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FUNCTIONAL INGREDIENTS
Frustration over regulatory framework The number of nutrition industry professionals who find the EU regulatory framework unhelpful has risen sharply over the past year.
O
ne in three industry professionals surveyed by the organisers of Vitafoods Europe said the current EU regulatory environment is unhelpful, up from 25 per cent at the start of 2017. Although 34 per cent find the framework helpful, this figure has dropped from 37 per cent. Experts believe dissatisfaction has risen because of the EU’s tough stance on health claims and the continuing regulatory deadlock on botanicals. ‘The increasing frustration is not surprising,’ says Dr Annegret Nielsen, senior consultant at Analyze & Realize. ‘Despite progress in some areas, the regulatory challenges for the industry have remained, or even increased, over the past year. It is currently very hard for companies to develop innovative products that comply.’
CALL FOR OVERHAUL OF HEALTH CLAIMS REGULATIONS
Dr Elinor McCartney, president, Pen & Tec Consulting Group. ‘Once they established the Generally Accepted Science (GAS) claims list, companies found it extremely hard and very expensive to achieve new claims. The industry has worked hard to comply but many feel the compliance pendulum has swung too far towards mission impossible. Dr Iris Hardewig, head of consulting and strategic Innovation at Analyze & Realize, says the low number of approvals is a disincentive to research and development. ‘Frustration is high because clinical trials are a major investment for food companies. If it doesn’t lead to any competitive advantage, they refrain from investing in science. The execution of the health claim regulation is not satisfactory, either for the industry or for the consumer.’
BOTANICAL BOTTLENECK
Over a quarter (28 per cent) of respondents Of concern is the current deadlock on the to the Vitafoods Europe survey said the EU regulation of botanicals. Thousands of policy change would help their business botanical health claims have if there were an overhaul of been on hold for several years health claims regulations. while EFSA considers how to This may be because evaluate them. it has become too ‘The regulation of difficult to get a health botanicals is a hot topic Vitafoods Europe is the claim approved. ‘I think and a legal disaster global nutraceutical event. many in the food area,’ Dr McCartney It features exhibitors in four and supplement explains. ‘The EC and key market areas: ingredients and raw materials; branded industry are member states seem finished products; contract frustrated with EFSA’s unable to agree on how manufacturing and private tough stance on the to sort out the anomaly label and services Nutrition & Health that health claims are and equipment. Claim Regulation,’ says allowed on traditional
DID YOU KNOW?
herbal remedies, but the same claims are prohibited on food botanicals unless a dossier passes EFSA.’ One solution that has been proposed is sector-specific regulation for botanicals. A fifth (19 per cent) of respondents to the Vitafoods Europe survey said this policy change would most benefit their business. Whatever the way forward, experts believe the current regulatory void is stifling innovation developments.
GUIDANCE THROUGH THE REGULATORY MAZE Vitafoods Europe 2018 will be held on 15 to 17 May in Palexpo, Geneva. The show offers a range of support and advice for visitors trying to navigate the regulatory maze. Resources include the Advice & Expertise Trail. This selfguided tour leads visitors to top consultancy agencies with expertise in regulation (as well as product development, clinical research, market research and marketing). Many of the event exhibitors will offer a wealth of knowledge on regulation. The EU is currently reviewing nutrition regulation through the Commission’s Regulatory Fitness and Performance (Refit) programme, which aims to keep EU law simple. Experts hope it will reduce the burden on the industry, ‘Refit will hopefully bring a sense of proportion and insights into how the situation can be improved,’ Dr Nielsen concludes. ‘There are useful products between conventional food and drugs that might evaporate due to the current regulations.’ •
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Food Review | March 2018
BeverageREVIEW SOUTH AFRICAN
March 2018 | Volume 8 | Number 03
www.foodreview.co.za
Quality
andflexibility in tea production
Must have ingredients for 2018 Choose the right hose for your pump
NEWS
MUST HAVE INGREDIENTS
F
orget bagels and cupcake frosting, cream cheese is now being served as a whipped topping on tea, like the creamy milk foam on a cappuccino. The concoction, which would make any conservative tea-lover snigger, originated in southern China. It is predicted to be one of the hot trends in hot drinks in 2018. The innovative cheese tea or tea macchiato is an example of how an unexpected ingredient, in this case cream cheese, can be used in new categories to create unique textures. Increased demand for cream cheese partially driven by sales of cheese teas, has resulted in New Zealand dairy co-op Fonterra investing NZ$150 million in two new cream cheese plants.
New excise duty hikes could impact brandy recovery
THE SOUTH AFRICAN Brandy Foundation has expressed concern about the announced excise duty hikes for brandy. It could pose a major setback for producers and impede recent entrepreneurship, training and job creation initiatives. Speaking on behalf of the country’s brandy industry, foundation director, Christelle Reade-Jahn, said aboveinflation hikes came just as the industry was seeing the first green shoots of recovery after many lean years. The excise duty for blended brandy will rise by 8.5 per cent, resulting in an increase from R175.19 per litre to R190.08 per litre. Potstill and vintage brandies will be harder hit. The 14.6 per cent excise tariff increase will push the per litre level from R149.23 to R171.07. ‘Not only are both these new tariffs significantly above inflation, but they could impact the trajectory of the industry’s recovery path. The granting in 2016 of a 10 per cent lower differential excise tariff for potstill brandy compared with other spirits, has given this premium brandy category a muchneeded boost. With the increase in potstill sales, greater awareness and support have begun to develop, generating exciting new opportunities in craft brandy. Now, the reduced differentiation for potstill brandies could dent our initial headway in developing the craft sector and make it more difficult to bring additional craft players on board. ‘At the same time, our concern is that the 8.5 per cent excise tax could hurt the nascent recovery of the blended brandy category, which is where the most significant job multiplier economic impact lies, since it accounts for the biggest volume of brandies consumed,’ she notes. At its peak, South Africa’s total annual brandy consumption was close to 49 million litres. With the withdrawal of the brandy tax rebate in 2006, sales began to plummet year-onyear, eventually falling in 2015 to just over 30 million litres. After extensive lobbying by the industry in 2016, the Ministry of Finance introduced the differential relief, stimulating a slow but steady recovery for the industry. Currently consumption levels are back up to almost 33 million litres a year and growing. Apart from nudging up sale volumes, the move has helped to premiumise brandy. Annual sales value is currently up by 22 per cent on 2016.
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Beverage Review | March 2018
CROSS-CATEGORY POTENTIAL FOR CHEESE TEA While unexpected, cream cheese can produce thick, foamy textures and new flavours in many different beverages. It can also be added to coffees, lattes and even hot chocolates. To appeal to Western consumers, cream cheese foams should be paired with familiar flavours, such as cheesecake or other baked goods, to help introduce consumers to the concept. For example, a cinnamon roll flavored latte could feature a thick, cream cheese foam. Creating a dense, velvety foam is as much a work of art as it is a demonstration of scientific principles for baristas and bartenders alike. Foam is a key attribute in many beverages and certain cocktails, including fizzes and sours, are known to have a dense layer of foam from aerated egg whites. An indulgent cream cheese foam could also work well in cheesecake-inspired cocktails. The relationship between desserts and alcohol is a familiar one, with products such as dessert flavored spirits and spiked milkshakes blurring the lines between drink and dessert.
NOW IS THE TIME FOR BEVERAGES TO EMBRACE DECADENT FOAMS Changing the texture of a beverage will change the perception of how it tastes. The science behind how we perceive flavour is complex, with taste, aroma, and sensation all playing a role. As discussed in Mintel’s 2018 Food and Drink Trend New Sensations, experimenting with texture has the potential to engage younger iGeneration consumers who are hungry for experiences. In the US, young male respondents aged 18 to 34 are most likely to express interest in unique textures, including bubble tea, nitrogeninfused coffee, or sparkling iced tea or coffee, compared to other demographics. •
H O T B E V E R AG E S
Improved quality and flexibility in tea production BOH Plantations (BOH) in Malaysia recently installed a high quality Matcon IBC system. The technology offers hygienic manufacturing, superior quality standards, increased capacity and flexibility.
T
he company has operations spanning the entire spectrum of tea manufacture – from cultivation and processing, to packing and marketing its wide range of black teas and instant tea mixes. BOH was the first tea company to be awarded ISO 22000 Certification for complying to food safety standards. To keep its position BOH realised the need for further investments in manufacturing processes. It looked to improve: •P roduct quality – processing systems must be state-of-the art, with exemplary hygienic manufacturing and quality standards of homogeneity and product safety •P roduction flexibility – design of systems should allow multiple recipes to be produced simultaneously, with rapid recipe changeover and fast, simple clean-down •S pace utilisation – system needed to fit into existing floor space, but allow for future expansion in capacity and number of recipes. Matcon was commissioned due to its ability to deliver a lean manufacturing system, which could accommodate short run, high variety portfolios. The system splits up process steps of filling, blending and packing by using intermediate bulk containers (IBCs) to transport material throughout the production line. This helps to optimise overall equipment effectiveness (OEE) rates of all equipment. With a
SPECIFIC BENEFITS INCLUDE: • Flexible production allowing multiple recipe creation • Protection of blend homogeneity for a quality finished product • E xemplary hygiene standards • Rapid changeovers with easy, fast clean-down • Ability to grow the portfolio • Reduced cost/kg of final product.
reduction in waste, the cost/kg of final product is improved.
AUTOMATED RECIPE FORMULATION Four major ingredients are dosed using a compact formulation system. Four ingredient IBCs are placed on a platform, where they automatically dispense into a receiving batch IBC below, on a gainin-weight basis. The Matcon discharge station provides an accurate dosed amount of powder without the use of secondary feeding equipment. This means recipe changeover can be done with the minimum amount of downtime as cleaning is quick and easy. Minor ingredients are pre-weighed and added by hand into the batch IBC. Keeping this task manual retains a very high level of flexibility as there are so many variations to recipes. Time taken to formulate a batch is shortened as minor ingredients can be processed in parallel to major ingredient batching.
IBCs transport material through the production line
“Matcon was commissioned due to its ability to deliver a lean manufacturing system” FAST MIXING The IBC blender achieves a homogenous blend for a wide range of recipes. Blending takes place within the IBC itself so there is no need to clean between recipe changes as there is no risk of cross-contamination. This offers the ability to mix any recipe at any time. BOH has full flexibility to fulfil orders on demand. The small footprint of the blender means it can fit easily into the space allocated.
A QUALITY PRODUCT EVERY TIME BOH had been hand-feeding low speed packing lines. With the advent of the Matcon IBC system, they could purchase high speed lines. The IBCs supply higher volume, demanded by the packing equipment, while the single blender can supply enough batches to feed a series of packing lines. A Matcon discharge station feeds directly to each packing line providing an automatic, controlled flow of product. The unique cone valve within each of the Matcon IBCs ensures product is discharged without any risk of segregation. Refilling of the infeed hopper is reliable and steady, therefore the accuracy and speed of the packing machine is optimised. This results in a quality product in the final pack and reduced risk of waste. BOH has adopted Matcon’s lean manufacturing philosophy and achieved desired throughput rates and superior product quality. The fully flexible manufacturing facility has reduced cost per kilogramme of finished product. This gives it the ability to respond to customer demand. •
Matcon – www.matcon.com
March 2018 | Beverage Review
39
H O T B E V E R AG E S
HOSES that stand apart V
from their competitors
erderflex offers reliable, innovative, high performance peristaltic pumps that can pump difficult products in tough conditions. These units are renowned for providing top-quality solutions to an array of problems within process industries around the world. They are used in original equipment manufacture (OEM) as custom solutions. The pumps can be incorporated wherever accurate dosing is required. The Smart and Scientific models are easily programmable tube pumps and ideal for use with chemicals or in a laboratory setting. This range is complimented by the industrial tube pump range. Specifically designed to be used in hazardous areas, they provide a compact pumping solution for automated systems, as standalone pumps or as part of OEM. These pumps have multiple power options and quick and easy tube change features.
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Beverage Review | March 2018
Verdiflex hoses work to optimum safety specifications
A range of tube materials are available to handle a range of different chemicals as well as hygienic options for food and beverage dispensing. The hose is the most important feature of any hose pump. Verderflex has designed its hose to long lasting in the market, capable of withstanding corrosive and abrasive applications. The Verderflex
hose can be used in many other peristaltic pumps on the market. Due to the challenging nature of the products pumped by Verderflex hose pumps, the range has been designed to provide maximum safety to the workforce and environment. Both the VF and the Dura’s hose connection is disaster-proof, totally containing the hose inside the pump casing. Unlike other peristaltic pumps, this eliminates any danger. Verderflex pumps are incredibly accurate at dosing: they offer repeatable accuracy of approximately one per cent without any slip. They also have a vacuum capability of 95 per cent or a 9.5m/31’ lift of water. The largest peristaltic hose pump can pump 90m3/ hour or 390 US GPM at pressures up to 16 Bar or 230 PSI. •
Verder Pumps – www.verder.co.za
PackagingREVIEW SOUTH AFRICAN
March 2018 | Volume 43 | Number 3
www.foodreview.co.za
Industry gets
proactive on waste
management plans
INSIDE: How to recycle plastics
Choose the right inkjet tech for your business
NEWS
A push in the right direction
G
OVERNMENT’S NATIONAL WASTE Management Strategy and its call for Industry Waste Management Plans from packaging producers have caused a stir. We know that improving recycling rates in the country is non-negotiable. The principle behind the Waste Management Act is to reduce the amount of packaging used for FMCG and other products with the end goal of protecting the environment. But how does the industry perceive these regulations and their impact? Extrupet’s Chandru Wadhwani says for those who continue to use packaging not widely recycled, the cost of doing business could become problematic. ‘If the strategy is rolled out, with the subsequent environmental gains, the sentiment behind these developments will be positive. It is impossible to ignore the push back against some forms of packaging given their environmental impact.’ Wadhwani hopes the government intervention will have a positive impact on packaging items poorly designed from the outset. ‘This is certainly the experience in many other countries around the world.’ You can read more about this on page 46. I hope you enjoy this month’s PACKAGING REVIEW section.
Assistant Editor Aarifah.Nosarka@newmediapub.co.za
Celebrate with
top recycling ambassadors A TOTAL OF 12 pupils from Mashemong Primary School in Tembisa were recognised for being top plastic waste collectors in their community. The initiative forms part of Dow Packaging and Specialty Plastics’ Project Butterfly clean-up competition and environmental learning day. The aim of the competition is to educate and encourage children to take an active role in keeping their surroundings clean and to collect plastic for reuse. With waste collecting experts from Project Butterfly’s partner, Destination Green, each child collected kilos of waste at source, with Discover the benefits of recycling with Dow Packaging
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Packaging Review | March 2018
a plastic recycling focus. Plastics were collected, sorted, and distributed to local recyclers. Winners were invited to a day of fun and learning, starting at the Dow Innovation Centre in Johannesburg. They received a certificate and prize for being top collectors. Dow South Africa representatives shared interactive presentations around the importance of recycling, becoming recycling ambassadors in their community and the many benefits and uses of plastics and packaging. Javier Constante, commercial vice president EMEA at Dow Packaging & Specialty Plastics and sponsor of the project explains, ‘Dow aims to teach the leaders of tomorrow the value of our planet’s resources. This social impact project is specific to Dow and specific to Africa. It indicates Dow Packaging’s commitment to the region, gaining understanding of some of the waste management and end-of-life packaging challenges and issues facing different regions in Africa.’ Alessandro Corticelli, sustainability leader for Dow Middle East and Africa concludes, ‘It is important for us to partner with grass-roots organisations locally to deal with end-of-life packaging. We collaborate with all industry partners from converters to brand owners and retailers. It makes sense for us to join forces in tackling some of the plastics packaging challenges.’
Talking to... Tim Stewart RECENTLY ACQUIRED BY printing giant Novus Holdings, ITB Manufacturing has grown into a formidable company supplying flexible packaging products. PACKAGING REVIEW takes a closer look at the person behind ITB Manufacturing’s success, managing director Tim Stewart. Inspired by watching his father build a packaging and manufacturing company, Stewart has always had an uncanny interest in plastics and packaging. ‘Packaging 40 Tim Stewar years ago was t predominantly cotton, calico, hessian and paper-based. We are at the cutting edge of manufacturing and producing innovative packaging materials,’ he enthuses. ‘Polymer to extrude film became commercially available during the 1960s and the technology to blow film, cut and seal plastic bags was only in its infancy when I started out.’ After school Stewart worked at the Durban Bag Company where his father was managing director. The opportunity to see exactly what it took to build a company in the manufacturing industry was the spark he needed to enter the fray. Reflecting on the future of the packaging industry Stewart believes exciting technologies and changing attitudes about the environment will revolutionise packaging and manufacturing. ‘Technological improvements in polymers and extrusion processes to achieve improved packaging performances and the light weighting of films will be one of the next trends shaping our industry,’ he says. ‘Companies in this sector will also need to act with increased environmental awareness and implement better solutions to improve the threat that comes from pollution.’ To keep abreast of the latest developments in the industry, Stewart clears his diary for visits to international trade shows. ‘Being at shows gives us the opportunity to invest in the best film extrusion and converting equipment to stay ahead of the curve,’ he concludes.
I N D U S T RY TA L K
Inkjet label printing and you When choosing the right label printing technology for your in-house production requirements you need to know what technologies are available including their strengths and weaknesses.
I
n this and future editions of PACKAGING REVIEW, we will analyse various label printing machine options. This month we look at inkjet label printing. These machines print using liquid ink. This requires specially coated printing substrates to preserve the durability of the print. Some high-end label printing machines offer single pass technology. This means the substrate moves through the printing plain while the print heads remain stationary. The world’s two major suppliers of print head technology for inkjet in the label printing arena are Epson and Memjet. A number of brands of inkjet label printers on the market use print heads obtained from one of these two manufacturers.
Smartload was established to address the need for pooling of hygienic, re-usable plastic load carriers in Southern Africa. Pooling? Pooling is a sustainable way to ship goods as sharing asset trips reduces carbon emissions, improves availability and meets the need for improved hygiene. By getting more companies to use Smartload pallets, we can reduce overall supply chain costs. Transport costs, investments, quality issues and the stress of managing assets are reduced. Other solutions In addition to pooling we also offer short and long term rental solutions with additional services such as pooling and cleaning where needed. The big advantage of renting is that you keep your CAPEX for the projects that add value to your product.
HOW DO INKJET LABEL PRINTING MACHINES COMPARE TO OTHER TECHNOLOGIES? Inkjet label printers require coated materials for best results. This often means production costs per individual label are higher than those of competing technologies. It remains an attractive option as initial equipment investment for inkjet printing machines is usually much lower. Another attraction for inkjet is even colour distribution across solid colours with no evidence of blotching or banding. It tends to offer superior results when printing vector graphics and solid colours, while some suggest marginally inferior print quality when printing photographic images
“The advantages of printing labels in-house are endless. Key benefits include a constant supply of labels for your project, reducing costs and high volumes of unwanted inventory. In-house labels allow you to customise labels to suite your product needs. It also gives you the flexibility to customise your labelling to reflect your clients’ expectations of the professionalism of your brand”
– Jacques Roux, Intellistor, SA distributor for leading label printer brands including Epson and Afinia Label.
and vignettes. Globally there is a strong correlation between manufacturers with product labels featuring vector designs and solid colours, and a preference for inkjet technologies when choosing an in-house label production system. Inkjet printing offers higher print resolutions, up to 2880dpi. With competing technologies printing at 1440dpi, it is highly debatable whether this difference
Plastic Pallets Smartload only offers the highest quality pallets in our pool. Our pallets are proven in supply chains all over the world as being extremely durable and able to carry heavy loads while offering superior hygiene and quality to their users. Pallets are professionally washed and inspected after each use and in cases of damage they are repaired or recycled. Are you stuck in the past?
Experience the future
Powered by Contraload Smartload is the exclusive license holder of Contraload with offices in Antwerp (HQ), Birmingham, Paris and Barcelona. Contraload is the market leader for plastic pallet pooling in Europe serving 3000 customers in 25 countries. Smartload has the ability to offer clients in Southern Africa the same service clients have been benefiting from in Europe for the last 15 years.
March 2018 | Packaging Review
43
I N D U S T RY TA L K
is observable to the naked eye at such high resolutions. Inkjet offers the fastest print speeds of all mainstream label printing technologies, producing product labels at impressive speeds of up to 18 linear metres per minute. One of the great advantages of inkjet is the high production capacity and the way the technology functions best when running the equipment consistently close to production capacity. The harder it works, the better it works. This makes it a good industrial partner for high capacity manufacturing plants.
IN WHAT CIRCUMSTANCES IS INKJET THE RIGHT CHOICE FOR MY BUSINESS? ‘Digital inkjet printing is the ideal way to achieve affordable short-run production with fast speeds and high-resolution images. Bringing digital inkjet label production in-house gives users the ability to print exactly what they need, when they need it – eliminating minimum order quantities. With low capital cost solutions, like those from Colordyne, trends such as variable data and personalisation become easier and more affordable than before,’ says Andy Matter, president of Colordyne Technologies, a leading label printer manufacturer. Inkjet label printing technology is traditionally favoured by high capacity
manufacturers with busy production lines of a number of different products. One machine can handle the full label production requirement, while separate automated label applicators can be set up in-line as part of the bottling process. It also finds favour with manufacturers who prefer a lower equipment investment as the individual label costs are calculated into the selling price of the product. They save money on machine costs and the label production costs are covered by the clients purchasing the products. This type of printing technology is also popular when the label design lends itself to the strengths of the process. This means solid colour labels with very small text and vector graphics make a good match with inkjet technology. Only a handful of inkjet suppliers in South Africa offer expertise and experience with the backing of successful international brands, whilst offering good onsite local technical support. ‘With label printing technologies experiencing unprecedented world growth, more fly-by-night suppliers are jumping on board without
the expertise or experience to meaningfully assist their clients. The ideal supplier is one like NSI 4 Africa that is well established and offers options across the full spectrum of available technologies, thereby able to honestly assist clients in choosing the best solution for their unique requirements. You essentially want to partner with a supplier who can offer the best local technical support while not having a vested interest in selling any one technology over another,’ concludes Shawn Bezuidenhout of NSi 4 Africa. •
NSi 4 Africa – www.nsi4africa.com There are various benefits to printing your labels in-house
Get the load there smartly
S
martload was established to address the need for re-usable plastic load carriers in southern Africa. The company aims to be the market leader by offering high quality load carriers, an innovative pooling system and firstclass service. Pooling is a sustainable way to ship goods, as sharing assets during trips reduces carbon emissions, improves availability and meets the need for improved hygiene. ‘The more companies to use Smartload pallets, the more we can reduce overall supply chain costs. Transport costs, investments, quality issues and the stress of managing assets are reduced,’ enthuses managing director David Botes. ‘In addition to pooling, we also offer short and long term rental solutions with additional services such as pooling and cleaning where needed. The big advantage of renting is that you keep your Capex for the projects that add value to your product.’
POWERED BY CONTRALOAD Smartload is the exclusive license holder of Contraload with offices headquartered in
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Packaging Review | March 2018
Antwerp, and regional offices in Birmingham, Paris and Barcelona. Contraload is the market leader for plastic pallet pooling in Europe serving 3 000 customers in 25 countries. The system offers clients in southern Africa the same service clients have been benefiting from in Europe for the last 15 years. ‘Smartload only offers the highest quality pallets in our pool. Our pallets are proven, in supply chains all over the world, as being extremely durable and able to carry heavy loads while offering superior hygiene and quality to their users. Pallets are professionally washed and inspected after
each use and in cases of damage they are repaired or recycled,’ Botes concludes. •
Smartload – www.smartload.co
KEY POINTS TO OPTIMISE DELIVERY • Hygiene control • Cost reduction • Track and trace solution • Customer satisfaction • Carbon reduction • Benefits of outsourcing
RELIABLE INJECTION MOULDING TECHNOLOGY Cabletech Marketing | +27 (0)11 704 0824 | info@cabletech.co.za | www.cabletech.co.za
R E C YC L A B L E PAC K AG I N G & P R AC T I C E S
Rolling out industry waste
management plans Are you aware of the latest developments in the IWMP saga? Aarifah Nosarka gets a perspective from two industry professionals about the perceived impact, government’s expectations and how to ensure compliance.
I
n December, The requisites included in the plan were the Minister of separation of sources, including household Environmental separation, and a call for all industry players Affairs, Edna to participate. Molewa published Despite these efforts and the significant the section 28(1) costs involved in writing the plan, notice, with gazetted Jhetam says it was largely disregarded requirements for the by government. He explains that in 2014, paper and packaging, another draft plan outlining how best electric and electronic and to deal with paper and packaging waste lighting industries to submit Industry in our country were resubmitted and Waste Management Plans (IWMP) by again, unheeded. 6 September 2018. In 2015, government published All “producers” as defined in the gazette an official notice for plans were also expected to register by 6 February. regarding waste, but as Shabeer Shabeer Jhetam, the executive director at some of the contents were Jhe tam Packaging SA discusses the history behind unclear and ambiguous this implementation. Minister Molewa decided to In the late 2000s, the industry opened withdraw the document. up negotiations with the then Department ‘Communication with of Environmental Affairs & Tourism (DEAT) government resumed. We to discuss the pressures the paper and made it clear as an industry packaging sectors were facing. By then the that we could not afford to Vest Type Carrier (supermarket shopping be taxed.’ bags) regulations were in place and there Jhetam comments that was talk of further punitive legislation the implementation of any and bans. additional taxes are a major In 2009/10, the then concern for an already struggling Packaging Council of SA (PACSA) paper and packaging put together a sectorial industry, coupled with the plan on how best to deal reluctance of government to with paper and packaging “ring-fence” these funds and waste in the country. This giving it back to the industry was done with the help of for environmental initiatives. international consultants. ‘We are concerned that ‘An industry waste the dispersing of funds will management plan, comprising be problematic. If this occurs, of 142 pages was written and the sector’s many successful Chandru submitted to the DEAT in Producer Responsibility Wadhwani August 2011,’ Jhetam adds. Organisations, our world-
THE GAZETTE INDICATES ALL PRODUCERS MUST: • register with the DEA as a producer • belong to an industry waste management plan or compile their own on how waste will be dealt with.
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Packaging Review | March 2018
class recycling rates and other initiatives could be severely compromised.
A CRISP APPROACH Chandru Wadhwani, joint MD of Extrupet, says the Act provides a degree of clarity on the expectations of government and has galvanised a call to action for industry.
PRODUCERS ARE DEFINED IN THE GAZETTE AS: Any person or category of persons or a brand owner who is engaged in the commercial manufacture, conversion, refurbishment or import of news/and or used paper and packaging material, lighting equipment, electrical and electronic equipment or goods wrapped in primary or secondary packaging material, which are intended for distribution in South Africa.
‘The critical aspect at this juncture is to ensure compliance with the specific aspects of the call for IWMPs. These go beyond environmental objectives, but also include, amongst others, a call to formalise the informal sector and allow for greater participation in the waste economy. There are also requirements on transformation that need to be met and industry, in many instances, is already preparing itself in the drive to be compliant.’ With Producer Responsibility Organisations (PRO), given a prominent position in this process, an alignment with recyclers becomes critical if plans are to be successfully approved and targets met. ‘For the extended definition on “producers” of waste, those not signed up with a PRO will either need to do so, or come up with their own plans. In either instance, it is imperative the whole value chain is engaged when formulating a plan.’ According to Wadhwani, while there is still a level of scepticism and uncertainty about the ultimate roll out of this legislation, it is hoped that all stakeholders involved in the process will come together to ensure a better environment for future generations of South Africans. ‘With this ultimate goal in mind, Extrupet stands willing to participate in the process with government and industry to ensure mutual value for all stakeholders,’ he concludes. •
Extrupet – www.extrupet.com Packaging SA – www.packagingsa.co.za
Keeping our food safety standards world class
A A
For a second time in a row, Extrupet again reached a new milestone by achieving an AA audit grade for BRC Global Standards for Packaging and Packaging Materials. The BRC Global Standard for Food Safety is a framework to manage product safety, integrity, legality and quality, and the operational controls for these criteria, in the food and food ingredient manufacturing, processing and packing industry. The AA rating is the highest grade possible for an announced audit. This BRC rating, together with the value proposition of PhoenixPET, has again changed the landscape of the local rPET industry and has opened up new opportunities to our customers and brand owners.
To our customers and stakeholders, we extend our sincerest thanks for your ongoing support. Extrupet is proud to share this achievement with all of you.
AFRISTAR AWA R D S
2016
GOLD MEDAL
Product of
Proudly associated with SAN BWA
SOUTH AFRICAN NATIONAL BOTTLED WATER ASSOCIATION
Food Grade Plant
Contact: 011 865 8360 | Email: info@phoenixpet.co.za | Website: www.phoenixpet.co.za
LAUNCHING THE NEW STATE-OF-THE-ART PRO-TEN PET/PP STRAPPING Contact us: sales@pro10strap.co.za Tel: +27 21 521 2200 • +27 83 627 3331
MADE IN SOUTH AFRICA
R E C YC L A B L E PAC K AG I N G & P R AC T I C E S
Recommendations
for plastic recycling in South Africa Plastics|SA, the umbrella organisation for the South African plastics industry reports excellent progress with the recyclability of plastic products. Under difficult and often strenuous conditions, members met to debate complex and far reaching issues. By Anton Hanekom
T
he working group included representatives from Plastics SA, Sustainability Retailers Forum, Plastics Recycling Organisation (SAPRO) and Plastic Converters Association (PCA). The common goal was to find suitable and workable solutions that benefit the environment and consumers and result in job creation. The Working Group concluded work late last year and confirmed general agreement on the recommendations. These deal with the recyclability of plastic products and should not be seen as targeting only plastic bags. • Recommendation: The quantity of fillers be limited in terms of the initial extrusion and moulding materials where the density of the material does not exceed the SG target of <1. It will guide product specification discussions between retailers and converters/suppliers of plastic products. The amount of filler, if any, will vary depending on the product and the type of plastic raw material used in the production process. These discussions have already started between retailers and converters. • Recommendation: The provisions of ISO 14021:2016 Environmental labels and declaration - self declared environmental claims (Type II environmental labeling) be adopted as an industry voluntary standard to convey the recyclability status of a product. Discussions initiated a review of current information on labels and messages printed on plastic products to ensure the correct recyclability status of products are communicated to the consumer in a clear and simple message. The need exists to clearly and correctly indicate the polymer
48
Packaging Review | March 2018
identification codes on the product itself. This will help collectors, sorters and recyclers to correctly identify raw materials and subsequent sorting of products into homogeneous polymer types for recycling. Training sessions are scheduled with retailers to provide knowledge and skills in the implementation of The Design for Recyclability Guidelines developed by Packaging SA. These will assist in the design of products with the focus on end of life solution/application and the environmental label and messages. • Recommendation: Concerned bodies must participate in consumer education and recycling activities that are paired with the proposed labeling standards. Education and creating awareness of the need to recycle and the benefits thereof are ongoing. It is important to ensure education starts at grassroots level in schools. It is also aimed at consumers of all ages. Littering is a human behavioural issue. We must find ways to empower and equip people to do the right thing for the environment. Recyclable packaging and the recycling of single-use packaging alone is not going to rid us of litter. Human interaction with used packaging must be addressed at all levels. Packaging can only be recycled if captured in waste collection, whether formal or informal. Current programs and initiatives must be expanded. Education and awareness creation need to be stepped up. These activities will be linked with proposed government initiatives such as “Billy Bin”. Development of new markets and the drive to increase the demand for recycled content also needs attention. • Recommendation: The recycling processors to adopt standard/s similar to ISO 15270 for
their quality of materials, both incoming and output. Currently more than 74 per cent of our waste collected for recycling is post-consumer waste and is collected on landfills. Materials are very contaminated and often not correctly sorted. This has an impact on the quality of recycled material. More needs to be done to improve the quality of recycled material and to stimulate the demand for recyclate. • Recommendation: Waste management companies should invest in advanced processing plants for the separation of waste, geographically distributed to fit the available waste. This is a very complex long term activity and might require substantial investment. Work needs to be done and it requires broader consultation and liaison with local government structures. Separation at source is a vital component of the value chain. The activities of the working group were unique. For the first time, various role-players in the broader value chain, sat around a table to discuss packaging problems. Industry remains committed to reducing the amount of plastic waste that lands up in the environment and in the oceans. Plastic waste remains a valuable resource. In line with the circular economy, products must be collected for recycling and re-used in a durable product. •
ANTON HANEKOM is the
executive director of Plastics|SA.
TRAINING | JOB VACANCY | LABORATORY SERVICES | CONSULTING SERVICES | TO LET | MACHINE FOR SALE | RECRUITMENT | TEMPORARY EMPLOYMENT SERVICES | COURSES
CLASSIFIEDS
WALL SCALE ................................................................................... R5 500.00 BILTONG SLICER ............................................................................. R4 265.00 DOUBLE LEVEL CONVEYOR ........................................................... R22 000.00 PHANTOM METAL DETECTOR ........................................................ R50 000.00 BILTONG ROOM .............................................................................. R445 502.00 BILTONG DRYERS QTY 2 (EACH) .................................................... R20 000.00 FOMACO INJECTOR ........................................................................ R250 000.00 CASING SPOOLER .......................................................................... R15 000.00 HANDTMAN PATTY FORMER .......................................................... R285 000.00 HANDTMAN VF612 .......................................................................... R500 000.00 HANDTMAN FILLER & GRINDER VF616 ........................................... R850 000.00 GROUND MEAT PROCESSOR ........................................................ R285 000.00 TFS-200 ........................................................................................... R1 025 000.00 VACUUM TUMBLER ......................................................................... R15 000.00 TRP- BLENDER ................................................................................ R10 500.00 52 MINCER ...................................................................................... R24 500.00 52 MINCER OKTO............................................................................ R30 000.00 SLICER............................................................................................. R35 000.00 TENDERIZER .................................................................................... R8 500.00 HENCOVAC VACUUM ...................................................................... R32 000.00 ASHIDA OVER WRAPPER ................................................................ R250 000.00 ULMA TAURUS ................................................................................ R700 000.00 ULMA TAURUS ................................................................................ R700 000.00 RETAIL DRYER CRATE WASHER...................................................... R50 000.00 All prices exclude Vat
Ferdi Lemmer Tel: 033-569 0660 Email: admin@triple-a-beef.co.za For More Machinery Equipment on Sale Visit: www.triple-a-beef.co.za
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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
info@entecom.co.za www.entecom.co.za
DINNERMATES
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formulating services in our fully equipped labs, as well as blending
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www.flavourome.co.za
FORMPAK
KHS
For over 40 years Formpak has supplied specialised processing, packaging and printing machinery to the pharmaceutical, cosmetic, plastic, glass, chemical, food and dairy industries.
The KHS Group is one of the leading manufacturers of innovative filling and packaging systems for the beverage, food and non-food industries. The group has an international production and service network.
Tel: +27 (0) 11 828 8870/1/2 Fax: +27 (0) 11 828 8880 email: haase@formpak.com or service@formpak.com www.formpak.com
We are the leading provider of hygiene, food safety and PARTNER für HYGIENE und TECHNOLOGIE PARTNER for HYGIENE and TECHNOLOGY technology solutions for food and beverage companies of any size. We will help you with design of your food processing plant to comply with hygiene and technology equipment you need for your food processing plant. We will supply you with the knowledge, service and expertise you need. Tel: +27 (0)86 1777 993 Email: info@pht.co.za www.pht.co.za
www.khs.com
QUANTUM COLOURS SA Your No. 1 industry leader for the most comprehensive ranges of both synthetic and natural colours – used in food, pharmaceutical, cosmetic and industrial applications. Our technical team is available to shade and colour match to specific requirements and / or Pantone references and to give legislative support on colours. www.quantumcolours.co.za
Innovative, high quality, nutritional solutions DSM’s technical expertise allows us to provide customized products for the most complex of situations. Our dedicated Nutrition Improvement Program means it is fully equipped to support effective nutrition interventions of all kinds, to fight hidden hunger across the globe. The World Bank concurs on food fortification: The control of vitamin and mineral deficiencies is one of the most extraordinary development-related scientific advances of recent years. Probably no other technology available today offers as large an opportunity to improve lives and accelerate development, at such low cost and in such a short time. World Bank
DSM provides: • Custom-designed premixes, tailored to specific fortification requirements • Quality and consistency • Focus on achieving the right taste & texture in the end product For more information email us at Marketing.DNPE@dsm.com or visit www.nutritionimprovement.com