Food Review March 2020

Journal for food and beverage manufacturers MARCH 2020 Vol. 47 • No. 03

Solutions to increase processing line profitability Food processing technology: Increase uptime and OEE

Hot beverages Machine solutions minimise coffee loss

Recyclable packaging & practices: The power of plastic

CONTENTS MARCH 2020 | Vol. 47 • No. 03

Vacuum pump ready for Industry 4.0 PAGE

22

PAGE

16

Digitalise your plant with IO-Link

28

SAFETY, HYGIENE & QUALITY TESTING

ECA is the natural hygiene solution

Audit to offset food safety risks

CPG helps keep you abreast of industry

Essential control for flies

10

NEWS

Blood pressure a top concern

Get connected with ABB

SA Cheese Festival cancelled

Chickens and eggs are not a risk

33

SUSTAINABILITY FOCUS

Tiger Brands opens new facility

Solar powers up production

High-level print for botanical RTD range

34

HOT BEVERAGES

Sorting technology puts the trust back into coffee

39

RECYCLABLE PACKAGING & PRACTICES

Mondi launches sustainable packaging solution

Plastics industry flexes its muscles

14

INDUSTRY TALK

Are you ready for a bright manufacturing future?

16

FOOD PROCESSING TECHNOLOGY

Digitalise your plant with IO-Link

Increase uptime and improve your OEE

How steam improves quality and productivity

Vacuum pumps fit for the future

24

MEAT, FISH & POULTRY

Coatings for a wide variety of products

Are your quality processes the best they can be?

PAGE

36

A flexible fix for coffee pod packaging

March 2020 | Food Review

3

EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: Andipha Nkoloti +27 (0)11 877 6168 andipha.nkoloti@newmedia.co.za Contributors: Anurag Mitra, Jake Norman, Jonathan Robinson, Mark Wilson

Why we need proper hand hygiene

D

espite the technological advances of the past century, there is one basic habit that people have not mastered: washing their hands properly. Diseases and germs will not spread so widely if people start executing correct hand hygiene.

This was the message from Prof Stephen Forsythe, a retired professor in microbiology at Nottingham Trent University in the UK and a fitting dialogue in the face of the current COVID-19 pandemic – in which handwashing plays such a critical role.

He is the author of The Microbiology of Safe Food, which is widely prescribed to university students. He was the opening speaker at an afternoon session on the future role of science in maintaining food safety. The event, hosted by the Centre for Food Safety at Stellenbosch University's Department of Food Science, was widely supported by members of the local food industry.

Forsythe gave an overview of future trends that he thinks will impact on food safety matters. He mentioned the influence of climate change and growth in insect farming and related products. Antimicrobial resistance, which relates to the way in which germs have adapted to current drugs and treatment, is also a growing source of concern in the food industry.

"We have no other choice than to adapt to these trends because they are here to stay," he mentioned. Forsythe said most of the 8 914 food products that were withdrawn from the market worldwide between 2008 and 2018 were raw fish, prepared food and nuts and fruit. This was mostly due to the occurrence of undeclared ingredients that could cause allergic reactions and the prevalence of germs such as E. coli and Salmonella that are associated with food poisoning.

Forsythe said technology to test for incidences of disease-causing organisms has improved drastically over the past years. Many problems related to infections and germs can

ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za

be curbed if people were just able to follow basic standards of hygiene in homes, factories and on farms.

Among the speakers at the afternoon session were Prof Mieke Uyttendaele of the Department of Food Technology, Safety and Health at the University of Ghent in Belgium, and Prof Wilhelm Holtzapfel, president of the International Committee on Food Microbiology and Hygiene (ICFMH). They addressed attendees on the value of making decisions on food safety matters based on good evidence and findings, and the role of the ICFMH in maintaining standards around food safety.

Isabelle Desforges from Biomerieux in France spoke about the value of microbial standards such as ISO and other microbiological testing methods.

The speakers were in Stellenbosch for the annual advisory committee meeting of the Centre for Food Safety in the SU Department of Food Science. It was established in November 2018 following the listeria crisis. The centre is still the only one of its kind in the country.

It is an uncertain time for South Africa and the manufacturing industry. Food Review’s feature on safety, hygiene & quality testing is so topical right now. Turn to page 28 where we discuss the benefits of ECA versus traditional chemicals, the need for audits to maintain food safety standards and certification and the latest information on FSSC V5 and the new SANS 10330, published early in February 2020.

Happy reading and remember to keep washing those hands!

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

@foodreview13

CEO: MEDIA24: Ishmet Davidson

SA_FoodReview

HEAD OFFICE New Media House, 19 Bree Street, Cape Town 8001 PO Box 440, Green Point, Cape Town 8051 Tel: +27 (0)21 417 1111, Fax: +27 (0)21 417 1112 www.newmedia.co.za

@SA_FoodReview

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

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

Dr Heidi Grimmer

4

Food Review | March 2020

Managing director of Symrise South Africa; chairman of SAAFFI.

Rudy McLean

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

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

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

Gail Angela Macleod

Food Review is printed and bound by CTP Printers - Cape Town Copyright: all rights reserved. ISSN 0257-8867 Readers are prohibited from using the contact details displayed in any advertisement or editorial within the pages of this publication to generate and/or distribute unsolicited bulk emails or other forms of mass marketing correspondence.

D I A RY

RE V IE W

ood f

SOUTH AFRICAN PHARMACEUTICAL & COSMETIC REVIEW

SOUTH AFRICAN

2020 DIARY Due to COVID-19 these events might not take place

April

2020 SUBSCRIPTION FORM

3 – 4 Mpumalanga Wine Show

Nelspruit, South Africa https://10times.com/fnbmpumalanga-wine-show

Please complete in block letters, select your subscription option, and return this form, along with your payment to:

25 – 27 South African Cheese Festival and Exhibition

NEW MEDIA, a division of Media24 (Pty) Ltd, PO Box 440, Green Point, Cape Town 8051 Email: felicity.garbers@newmedia.co.za

Stellenbosch, South Arica www.cheesefestival.co.za

SUBSCRIPTION OPTIONS (please tick) 1 YEAR Food Review Pharmaceutical

Cosmetic Review

Food Review + Pharmaceutical

Cosmetic Review

2 YEAR

R588

R905

R588 R1066

R905 R1620

South African Cheese Festival

Full Name:...........................................................................................

Designation: ........................................................................................

Company: ...........................................................................................

Postal Address:................................................................................... .................................................................Code:.................................

Country: ..............................................................................................

Tel: (

)....................................... Fax: (

) ..................................

E-mail:.................................................................................................

Main activity of company:...................................................................

Approximate number of employees: ..................................................

VAT No: ............................................................................................... ❑ I would like to receive the newsletters and feature announcements via email and may be added to the mailing lists.

Signature:............................................................................................

Please select your preferred method of payment:

❑

May 18 – 22 Approved Persons Course for Thermal Processing of Low-Acid Foods

Victoria, Australia www.csiro.au

9 Veg Expo

Vancouver, Canada www.vegexpo.ca

17 – 19 Foodservice Australia

Sydney, Australia www.foodserviceaustralia.com.au

o Veg Exp

Direct Deposit (Complete and email this form to: felicity.garbers@newmedia.co.za

Payee:

Bank:

Acc No:

New Media Publishing (Pty) Ltd .

Nedbank Seapoint

1069321540

Branch Code: 10-69-09-00

❑

June

Credit Card (Mastercard & Visa only) Name of card: .............................................................................

1 – 2 Food Label Conference

Washington DC, US https://10times.com/food-labelconference

Expiry Date: ................................................................................

Card Number: .............................................................................

CVC Number...............................................................................

2 – 3 Free From Food Expo

Date: ...........................................................................................

Barcelona, Spain www.freefromfoodexpo.com

Signature:....................................................................................

❑

Note: The above prices are applicable to South Africa only.

International rates available on request.

6

3 – 5 agrofood Ethiopia

TAX INVOICE REQUIRED

Food Review | March 2020

ia

agrofood Ethiop

Addis Ababa, Ethiopia www.agrofood-ethiopia.com

Savanna Jean delivers a juniper punch!

The first juniper-flavoured cider in the South African market has hit the shelves. The product challenges category norms and innovates in line with evolving consumer needs and category trends. Savanna Jean offers a crisp apple taste with a hint of juniper berries. It is bound to be a favourite among Savanna fans and new converts across the country.

A first in local non-alcoholic distilled botanical drinks

Vermont Vergin SA launched two ready-to-drink (RTD) botanical cocktails. Bloom Virgin Cosmo & Limón Virgin Mojito, both 330ml, taste just like their alcoholic namesakes but feature no alcohol, added sugar or sweeteners, artificial colours or flavours and preservatives. These 100% natural small-batch produced craft sodas are poised to disrupt the way consumers think about adult non-alcoholic beverages.

The perfect mix in RTD Gin & Tonic

Greenall’s Wild Berry Gin & Tonic and Greenall’s Original Gin & Tonic come pre-mixed, so you can enjoy wherever the party’s happening without any fuss. The bold packaging offers a colourful nod to the two flavours, with the pearlescent bright pink (Wild Berry Gin & Tonic) and bright green (Original Gin & Tonic) cans ensuring a high impact on shelf and strong appeal amongst its target millennial audience.

Meat producer joins plantbased movement Feinschmecker Deli Meats has built a formidable reputation in speciality deli meats in South Africa. The group launched a range of plant-based sandwich slices under the brand name Güdness. It is the first range of its kind produced in SA. Güdness Sandwich Slices are available in five variants, namely Original, Smoked, Piquante Peppers, Olive and Chives.

8

Food Review | March 2020

Kauai expands into new healthy frozen range with Pick n Pay Pick n Pay powered by Kauai frozen product range was developed to meet growing demand from customers seeking healthier ready-to-eat meals they can conveniently enjoy at home.

The new range includes a variety of healthy frozen smoothies, frozen meals and side dishes. The range will include some of Kauai's topselling meals and smoothies, like the Strawberry Stinger smoothie and Butta Chicken Bowl.

South African chip flavours hit the shelves

Simba has launched two more locally inspired flavours: Chakalaka and Shisanyama. These iconic South African foods are enjoyed by millions in their homes each day.

The brand owner wanted to capture these classic favourites into a bag of Simba chips and take people on a locally inspired flavour journey.

Make a

BIG

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

Innovation is at the heart of the competition.

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

NEWS

Blood pressure ranks as the top cardiovascular concern

H

ealthy blood pressure is consumers’ top cardiovascular wellness goal, research by Lycored has found.

The global carotenoid leader surveyed 505 men and women in the US and the UK All were over the age of 50, the demographic most likely to purchase supplements for cardiovascular health (CVH). Nearly seven out of ten (68%) ranked healthy blood pressure as one of the three CVH goals they most wanted to achieve. Healthy blood cholesterol levels (61%), healthy arteries (55%) and a healthy circulatory system (45%) also scored highly.

Last year, a clinical trial found that Lycored’s standardised tomato extract was linked to significant reductions in blood pressure in people with

hypertension. The extract is the basis of Cardiomato – Lycored’s proprietary mix for cardiovascular supplements.

Cardiomato has also been shown to help reduce levels of oxidised LDL cholesterol, the second greatest concern for the consumers surveyed. Nearly nine out of ten (88%) were aware that high levels of LDL cholesterol are considered bad for CVH, and 42% chose this as one of the CVH risks they most wanted to avoid.

"Cardiovascular wellness is one of the most important goals for healthfocused consumers. As our research shows, blood pressure and cholesterol are two of the most common concerns, and supplementation can play an important role in addressing both. The myriad active nutrients in Cardiomato work synergistically to offer significant, and scientifically substantiated, benefits for cardiovascular wellness," says Golan Raz, head of Lycored’s global health division. The findings come at the end of American Heart Health month, which aims to raise awareness of cardiovascular conditions. •

SA Cheese Festival cancelled following coronavirus concerns

T

he biggest outdoor culinary event in Africa, the 2020

Hard cheese on a board at a festival

South African Cheese

Festival, has been cancelled due to the national ban on gatherings of more than 100 people. The popular festival would have been held for the 19 th time this year from Saturday 25 to Monday 27 April 2020 at Sandringham outside Stellenbosch.

The Council of Agri-Expo, the organiser of the SA Cheese Festival, has consulted widely with provincial government and other stakeholders

to up to 30 000 festivalgoers. The

in the face of growing concerns

cancellation of the SA Cheese Festival

about the COVID-19 pandemic.

will have a definite economic impact.”

Johan Ehlers, chief executive officer

All paid tickets will be reimbursed

of Agri-Expo, thanked the festival's

by Computicket with ticket holders

partners, exhibitors and supporters

who will be contacted directly

for their understanding and patience.

by Computicket.

“The SA Cheese Festival annually

The 20 th SA Cheese Festival will

provides a platform for cheesemakers

take place from Saturday 24 to

and entrepreneurs from across the

Monday 26 April 2021 at Sandringham

country to showcase their products

outside Stellenbosch. •

10

Food Review | March 2020

ABB to launch predictive maintenance solution

T

he ABB Ability Condition Monitoring for measurement devices is an innovative, digital solution that will

keep continuous gas analysers under control to ensure clean air operations. The groundbreaking, first-to-market solution should launch at Hannover Messe in April 2020.

The new digital solution keeps track of the health of ABB measurement devices.

Performing real-time data analysis, the ABB Ability Condition Monitoring for measurement devices identifies problems fast, drawing attention to significant or undesirable changes in device conditions.

Regular health check reports provide users with recommendations based on health status, allowing on-site personnel to leverage their own expertise and enabling remote assistance from ABB when required.

"By implementing the predictive maintenance approach of ABB Ability Condition Monitoring for measurement devices, equipment can be actively monitored and managed to prevent problems from arising.

This enables customers to make informed decisions resulting in optimised operations," says Christine Declerck, global service manager measurement & analytics.

"Customers are facing increased emissions regulations. ABB is committed to helping them address environmental impact through solutions like the ABB Ability Condition Monitoring for measurement devices, improving energy efficiency and increasing industrial productivity," Declerck concludes.

Predictive maintenance reduces customers’ potential safety risks and helps them avoid fines. It also lowers operating and maintenance costs due to less emergency maintenance and fewer unplanned outages.

When carried out through Condition Monitoring it ensures the highest level of availability and reliability of equipment, reducing repairs and preventing downtime.

The new digital solution is part of the ABB Advanced Services offering for Measurement & Analytics which is dedicated to enabling improved utilisation and performance of automation equipment, processes, and personnel. Other services include ABB Ability Verification for measurement devices, and My Measurement Assistant. •

NEWS

SAPA disappointed with false broadcasting Coronavirus COVID-19 under the microscope in 3D

T

he South African Poultry Association has noted with dismay the misleading messaging by the SABC Morning Live transmissions on the novel coronavirus disease (COVID-19) through the consumption of chicken and eggs.

The disease spreads from human to human through droplet transmission.

There is currently no evidence that eating cooked chicken or eggs can put one at risk of contracting the disease or spreading the disease. “The spread of COVID-19 is a result

of human-to-human transmission. To date, there is also no evidence that companion and farm animals, or the products obtained from farm animals, can spread the disease.

"There is no justification in taking measures against companion and farm animals and their products,” explains Dr. Mike Modisane, chief veterinary officer for South Africa. Despite this, members of the public are advised to apply routine general hygiene measures when handling animals.

These include regular hand washing with soap and potable water after touching animals and animal products, as well as avoiding touching eyes, nose or mouth, and avoiding contact with sick animals or spoiled animal products.

“Food safety compliant hygiene practices recommended by the South African Department of Health and the World Health Organization and the use of Personal Protective Equipment (PPE) are highly entrenched and an integral part of the operations within the poultry industry,” notes Alic Sulliman, chairperson of the SAPA board. •

March 2020 | Food Review

11

NEWS

A new era for 100year-old supergrain

Put Urschel to the Test

T

As a valuable service to you our customers, Heat and Control AND Urschel offer sample test cutting.

This may assist with R&D, help explore different machines to decide on a capital purchase, or discover additional cutting capabilities for your existing Urschel machinery.

Urschel machinery produces precise cuts at high capacities within your designated parameters – meeting your production goals, improving your endproducts to reduce waste, and maximising your profits.

Schedule a visit with the Heat and Control South Africa team to test cut your product, or simply send samples so we can test for you.

www.heatandcontrol.com | info@heatandcontrol.com Cape Town +27 21 948 5934 The Global Leader in Food Cu ng Technology ÂŽ Comitrol, Urschel, Urschel logo symbol, and The Global Leader in Food Cutting Technology are registered trademarks of Urschel Laboratories, Inc. U.S.A.

12

Food Review | March 20201 SAFoodReview_Mar2020_88.5w x 262h_Urschel.indd

4/03/2020 10:59:43 AM

iger Brands officially opened its brand new, state-of-the-art Oat Mill for its first and oldest product, Jungle Oats, in Maitland, Cape Town. “With this state-of-the-art building and technology, the new mill has increased efficiencies and significantly improved output. Notwithstanding this, however, the overall carbon footprint has actually been reduced through the installation of higherefficiency motors which reduce the energy input per ton," noted Rees de Villiers, unit manager for Tiger Brands.

A total capital investment of R208 million was made to the manufacturing site in the Western Cape. In addition to this investment, a significant portion of the spend was allocated to local suppliers through civil engineering, building construction as well as engineering installations.

A total of 120 people were employed in the construction of the new mill. The infrastructure spend is further proof that Tiger Brands is proudly anchored in South Africa and committed to the country’s success. Other socioeconomic benefits of the new mill include investment in oat farmers. The company has invested in 10 black

South African farmers through its Smallholder Farmer Programme in the Western Cape who will in 2020 plant 100 hectares of oats.

The unveiling of Jungle Oats’ new mill coincides with a major milestone – its 100 th anniversary.

While a lot has changed since being launched as Tiger Brands' very first product offering, “Tiger Oats�, back in 1920, marketing director Lee-Anne Govender notes, the goodness of oats has remained consistently the same.

"The way in which we process our oats is unique and sets Jungle Oats apart from competitors, including international competitors.

Interestingly, the original campaign of Tiger Oats was ‘Health is Wealth’ – a trajectory that we continue with the repositioning of the brand around heart wellness and health and embracing the natural goodness of our products.

"This year, we celebrate 100 years of 'Doing Life with Heart'. Heart wellness continues to be a distinct benefit of Jungle Oats, given its beta-glucan content, and Tiger remains committed to promoting this message across South Africa," Govender concludes. •

NEWS

PYROTEC PACKMEDIA RELEASE FIRST DISTILLED NONALCOHOLIC PRODUCTS

A

fter launching South Africa’s first distilled alcohol-free botanical spirits in 2018, Vermont Vergin SA launched two ready-to-drink (RTD) botanical cocktails at the end of 2019.

Bloom Virgin Cosmo & Limón Virgin Mojito, both 330ml, taste just like their alcoholic namesakes but feature no alcohol, added sugar or sweeteners, artificial colours, flavours, and no preservatives.

These 100% natural small batch produced craft sodas are poised to disrupt the way consumers think about adult non-alcoholic beverages and are specifically designed for mindful, adventurous drinkers looking for the convenience of an RTD without compromising quality, taste or health benefits.

Cranberries are great at lowering your heart rate and blood pressure, and are fantastic for gut health and detoxifying your liver and kidneys.

Lavender, well-known for its calming properties, means this Virgin Cosmo will help take the edge off without the hangover.

Neutrons display details of freeze-drying process

Added benefits come from vitamin C in the citrus, which boosts immunity, and mint that adds energising refreshment and mental clarity.

These jam-packed-with-goodness, guilt-free cocktails can be enjoyed anywhere and at any time.

To complete the look and feel of Vermont’s latest Bloom Virgin Cosmo & Limón Virgin Mojito alcohol-free botanical cocktail offerings, Pyrotec PackMedia digitally printed the bottles’ 70 x 144.5mm body and 65.5 x 100.5mm neck labels on its Durst Tau 330 RSC digital press and finished them on its ABG Digicon Series 3 Finishing Machine.

The elegantly finished floral designed body and neck labels with gold foiling and a matte finish complete the look and feel Vermont wanted for these premium products.

The highest level of print production was required to achieve the design’s fine foiling requirements. As cold foiling was not an option because of the intricate design, a creative approach was employed using metalised polypropylene with a yellow print overlay to accommodate the gold foiling, as well as providing moisture control for refrigeration conditions. The matte varnish on the labels adds a soft, elegant overall finish. •

First locally produced non-alcoholic products

F

reeze drying has provided us with tasty dried fruits in muesli, long-life yoghurt cultures and many other important products. For the first time, using neutron beams from the HeinzMaier-Leibnitz (FRM II) research neutron source, a team of scientists has now been able to show us the drying process in detail.

The process engineering has gained a method of testing theoretical models in practice.

The technology that makes this possible is freeze drying. Scientists at the Technical University of Munich (TUM) and the Otto von Guericke University Magdeburg have now been able to examine this process more closely with the help of neutrons. They succeeded in observing the direct transition from ice to water vapour during the freeze drying of particles in an experiment.

"Freeze drying is a process which is mainly used in the pharmaceutical and food industries," explains Sebastian Gruber, lead author of the study and doctoral candidate in food technology at the TUM. When freeze drying, the objects containing water are frozen and placed in a vacuum chamber. Under low pressure, heat is

Johannesburg Head Office Seven Warehouse Complex 3 Bernie Street, Unit 3, Kya Sands Tel. No.: +27 (0) 11 708-0007

Durban Office Tel. No.: +27 (0) 31 942 9624

www.braganchemicals.co.za

Port Elizabeth Office Tel. No.: +27 (0) 71 213 9288

added which sublimates the frozen water and it transitions directly from its solid state to its gaseous state. The dehydrated, unchanged structure of the material remains.

This is why freeze-dried raspberries look as though they have been freshly picked. Foods retain their taste and medicines are preserved without losing their efficacy.

The neutron radiography instrument Antares at the Garching research neutron source provides the ideal prerequisites for the experiment. "Antares is also particularly wellsuited-to investigate samples under low pressure and low temperatures," explains instrument scientist dr. Michael Schulz from the TUM. "Our aim is to further advance the research on the freeze-drying process in order to create better process conditions in the future,” Gruber explains the motivation behind the research.

"Because if the particle size, pressure or temperature cannot be coordinated in an ideal manner during sublimation, this can lead to a structural collapse and thus a loss in quality or efficacy," Schulz concludes. •

Cape Town Office Tel. No.: +27 (0) 21 000 3121

WE DO WHAT IT TAKES March 2020 | Food Review

13

I N D U S T RY TA L K

Manufacturing trends for the decade ahead As we enter a new decade, the only way African manufacturers can stay ahead of competitors and win the market is to embrace change, writes Mark Wilson.

T

hose who wish to thrive and not just

comes in – the ability to manage volumes of

survive are leveraging the latest

data, generate legible insights and proffer

in growth-inducing Industry 4.0

solutions will greatly increase manufacturers’

technologies. The answer is simple: Leverage

responsiveness, improving efficiency and

new technologies and cater to changing

helping identify new business opportunities.

customer demands.

Manufacturers are now understanding

1. Machine learning & AI

that IoT empowers them to make informed

Manufacturing is such a massive industry that

strategic decisions by providing crucial, real-

it can take time for changes to be implemented

time information.

across the board. The adoption of newer

3. Connected factories

technologies such as artificial intelligence (AI)

Smart manufacturing is the development

and machine learning will be no different.

of a connected ecosystem of people and

While the progress might be slow within

equipment that communicate in real-time.

the African manufacturing industry, it is only

The benefits of smart manufacturing range

going in one direction and that is towards the

far and wide: optimisation of organisational

ubiquitous use of these technologies.

systems, improved product quality, increased

AI, machine learning and advanced analytics offer manufacturers the opportunity to improve efficiency and increase profit margins.

“. . .the ability to manage volumes of data, generate legible insights and proffer solutions will greatly increase manufacturers’ responsiveness, improving efficiency and helping identify new business opportunities”

efficiencies in the allocation of resources and amplified customer satisfaction.

The new factory environment is being advanced by cloud computing and smart sensors. Smart sensors can convert information into different units of measurements, communicating with multiple machines, while recording statistics and feedback. It can also assist in shutting down devices if a safety or performance issue arises, says the World Economic Forum.

4. Attracting and maintaining

These benefits cannot be ignored as the more

tech-savvy employees

complexities manufacturers face, the greater

As manufacturers rely on technology, the

the opportunity to use these technologies to

need for tech-savvy employees increases. The

get the competitive edge.

challenge is that there are not enough skilled

These technologies aren’t just limited to one area of your business, they can improve your

employees to fill the number of open jobs.

Advocates for the manufacturing industry

performance in every area. Whether on the

are educating the next-generation workforce

factory floor, in your supply chain, or in your

about exciting opportunities for careers in a

customer relations, there are numerous ways

skilled trade. It will take more than marketing

machine learning, AI and advanced analytics

to bring these workers in the door and keep

can improve your business practices.

them engaged.

2. IoT becoming more prominent

The incoming workforce must be part of an

Manufacturers are leveraging the internet of

organisation that’s innovative, future-proof

things (IoT), which entails the interconnection

and understands the need for a collaborative

of unique devices within an existing internet

and flexible work environment. What keeps the

infrastructure. This can achieve cost reduction

next-gen worker coming back is the ability to

and increase efficiency, improve safety,

make a difference and contribute to the bottom

meet compliance requirements and product

line. If leadership in your organisation acts as

innovation.

a bottleneck by not providing tools to enable

The increased adoption of IoT will also

efficiency, you will ultimately lose talent.

see an increase in the amount of data that

5. Advanced food tracking & packaging

manufacturers produce. Data may be the crude

The World Health Organization indicates

oil of the 21st century, but without the ability

that around 600 million people suffer food

to analyse and action based on tangible,

poisoning every year and 420 000 die as a

accurate insights, it is simply taking up space.

result. When an outbreak occurs, investigators

This is where (AI) and machine learning

can spend days or weeks tracking its source.

14

Food Review | March 2020

FAST FACT:

The World Health Organization indicates that around 600 million people suffer food poisoning every year and 420 000 die as a result. When an outbreak occurs, investigators can spend days or weeks tracking its source.

Technology is playing a pivotal role in risk detection as opposed to disaster recovery. This is known as traceability, where technologies such as ERP allows manufacturers to meet consumer demands for food transparency while enhancing the ability to identify, respond to and even prevent food safety issues.

While the food and beverage industry is under pressure, changing trends in packaged goods continue to drive growth. Germanbased VDMA Food Processing and Packaging Machinery Association estimate that just over seven million tonnes of packaged food were sold in South Africa last year. It is expected that demand will rise by 6% until 2022.

THE HITS OF 2019 As we enter the new decade, we have the chance to look back at the technologies which after being successfully implemented, have had a positive effect on the African manufacturing industry. The hits of 2019 include: Future-ready solutions Advanced technologies, such as enterprise resource planning (ERP) systems hold power to disrupt Africa’s dominant agricultural, extractive and manufacturing industries.

This offers the continent unparalleled opportunities to transform and ultimately thrive for years to come.

Plugging in artificial intelligence (AI) into ERP reduces inaccuracies commonly felt throughout the supply chain, meaning better outputs for the entire business process.

Manufacturers must be agile to respond to market demands without increasing costs and waste or sacrificing efficiency. To unlock the sector’s potential, manufacturers should seek out an all-inone solution that provides them with both mobility and constant connectivity.

I N D U S T RY TA L K

Adoption of the cloud within South

Compared to the rest of the world, the current

African manufacturers

adoption and impact of Industry 4.0 on the

Mobility is gaining prominence as a concept of Industry 4.0; this is

manufacturers have fallen behind

echoed by the fact that 86% of computing as important As technology continues to evolve, we will see a rise in adoption rate within crucial industries.

the curve of rapid advances

DID YOU KNOW?

manufacturers rank cloud for operations.

Mark Wilson is the managing director for Syspro Africa

African continent remains low. African

in connectivity that makes advanced technologies

Currently, 66 % of South African internet users believe new technologies offer more opportunities than risks, according to a report by We Are Social

Mobile software for

possible.

Africa has shied away from the adoption of technologies due to fears of job loss, a popular misconception. 4IR will see a

information-sensitive systems

further 133 million jobs created in

such as (ERP) allows manufacturers

place of the 75 million that will be

hours, they could easily achieve 12 months of production in just three months, according to a report by Syspro in conjunction with Strathmore University.

The manufacturing sector in Kenya has not

displaced by 2022.

lived up to its full potential, with its growth

to relevant information while increasing

Kenya productivity remains low

contribution to GDP and merchandise exports

productivity, planning, forecasting and

According to the World Bank, a robust,

budgeting, all available at a touch of a button.

diversified and globally competitive

and employees to improve quality of service

trailing that of the overall economy, and its

to customers by providing them with access

have stagnated. •

manufacturing sector can, without a doubt,

THE MISSES OF 2019

contribute significantly to increasing the

While the manufacturing industry is

economic growth of the country.

undergoing many changes with the adoption

ABOUT THE AUTHOR

With most of Africa’s manufacturers

of new technologies, it is important to address

operating under capacity, valuable production

some of the missed opportunities and

time is being lost, and with it, lost revenue. In

challenges within the African manufacturing

Kenya engines typically run for 86 days a year,

industry. The misses of 2019 include:

with 50% only running three to five hours a

Low adoption of automation in South Africa

week. If manufacturers increased this to 24

MARK WILSON is the managing director for Syspro Africa.

Syspro – za.syspro.com

Getting Things Done: Our Recipe for Success Food Manufacturing ERP for Movers and Makers of the world.

At SYSPRO, we support people who get things done – people like you. It’s why we’re committed to delivering specialist ERP software that can help you track allergens, streamline production across your entire supply chain, improve forecasting and reduce waste.

Because we believe that the Movers and Makers of the world are the ones who move us forward.

Learn more at www.syspro.com

720083 OSFF

SYSPRO AFRICA

@SYSPRO_Africa

Copyright © 2019 SYSPRO (Pty) Ltd. All rights reserved. All brand and product names are trademarks or registered trademarks of their respective holders.

March 2020 | Food Review

15

F O O D P R O C E S S I N G T E C H N O L O GY

Digitalise your plant with IO-Link

IO-Link is a standardised communication technology (IEC 61131-9) that shortens commissioning time and allows plug-play device exchange.

This technology allows digital accessibility of basic devices.

W

ith ever-improving performance and functionalities,

instrumentation in the field requires time and knowledge for their selection, sizing and commissioning. Simple operations are thus important for basic functionality sensors. These sensors in the field need to be installed and be able to run autonomously to keep the focus on the major production lines.

Therefore, simplicity of installation and minimal maintenance are key.

• Reduced variety of sensors, e.g.

Key benefits of IO-link

with IO-Link.

• Easy and efficient integration, e.g. by using standardised function blocks.

• Ideal fit of Industrial Ethernet high end devices accompanied by basic IO-Link devices.

• Reduced variety of plugs and cabling, substitution of DI/DO/PNP/NPN/ Pulse/0…10 V / 4…20 mA signals.

configuration of switching points • Fast commissioning and start-up, e.g. by standardised cabling and automated parameter settings.

DIGITALISATION FOR ALL INSTRUMENTS Seamless integration of basic devices is necessary in a digital environment.

Endress+Hauser enables automation of plants with basic and cost-effective IO-Link devices.

This allows customers to achieve operational efficiencies while reducing

costs. Quite often, entry-level instrumentation is not considered because of their lack of compatibility with the rest of the instrumentation in the field. IOLink is a digital protocol that offers huge improvements in the implementation of basic sensors in the field.

The time and cost of project implementation can be reduced significantly thanks to IO-Link’s open protocol. Each IO-Link device is connected to an IO-Link master that acts as a gateway to a fieldbus such as Ethernet/IP. Since IO-Link is not a fieldbus dependent system, it can be added to existing control systems at a minimum cost. Other advantages of IOLink technology include the automatic transfer of parameters after a device replacement, as well as low wiring effort compared to conventional wiring.

In confined spaces where direct wired communication can be critical, some instruments even feature wireless communication capabilities such as Bluetooth which is included in Endress+Hauser’s Picomag as an example. •

Endress+Hauser – www.endress.com

16

Food Review | March 2020

Co n t a c t u s : E m a i l : i n fo. z a . s c @ e n d r e s s . co m Te l : + 2 7 1 1 2 6 2 8 0 0 0 We b : w w w. e n d r e s s . co m

F O O D P R O C E S S I N G T E C H N O L O GY

How to increase productive uptime and OEE Time is money. This is certainly the case when it comes to snack food manufacturing, with product packaging playing an essential role, writes Anurag Mitra.

E

nsuring efficiency and productivity

issues, may be the first thing that springs

by minimising downtime and reducing

to mind, but optimising performance to

rejects is essential to increase the

reduce planned downtime can also have a

profitability of a production line. Beyond

significant effect.

financial factors, increasing uptime helps boost sustainability credentials too.

The concept of overall equipment effectiveness (OEE) is considered the gold

THE TNA ROBAG 3 MAXIMISES PRODUCTIVITY • An advanced film feed system improves

standard when it comes to calculating

film handling and provides consistent

manufacturing productivity. It measures

film tension. With its single straight

how well a manufacturing operation is

through film pass, it offers easy film

running compared to its full potential.

threading and high accuracy.

An OEE score of 100% for example would

• Stripper tube-closers form part of the

mean a manufacturer is ensuring zero

tna robag jaw system. These stripper

wastage, with no downtime, as fast as

bars clear product from the seal area,

possible. Realistically, 85% is considered

after which the tube closers shut off the

an ideal benchmark.

tube of film while the stripping action is performed. This allows for clearing of

CALCULATING OEE

the packaged product from the sealing

OEE is calculated by multiplying availability,

area. The next batch of product can be

performance and quality.

delivered above the tube closers with no

Availability is the ratio of run time to planned production time. It refers to how

product falling through to the seal area • Product in-seal detection (PISD) software

its schedule. More specifically, it considers

monitors the jaw motion of the tna robag.

availability loss, including any events that

It triggers a reject mechanism if large

significantly slow production, whether

pieces of product are detected in the seal

planned (e.g. changeovers) or unplanned

areas or pleats. PISD also monitors bag

(e.g. technical or operator issues).

seal output and automatically selects the

is created when running at less than optimal

optimum speed to waste performance, ensuring maximum uptime.

speed. It takes into consideration anything that hinders the speed of production, from slow cycles to unexpected stops. Comparing the actual cycle times with ideal cycle times, performance ultimately highlights just how much production is lost by operating at less than ideal speeds.

Quality highlights how much time is lost by producing products that don’t meet quality standards. It compares how many good parts are made versus those which are defected – therefore the percentage

patented pivot arm assembly design.

This unit facilitates the unloading and replacing of the former quickly and easily. The ability to change out formers using side access, rather than the traditional front access, shortens product changeover times, while reducing manual effort. From a manufacturer’s point of view, the ability to make quicker former changes increase production uptime and improves overall plant performance, aiding the performance element of OEE. •

to impede seal integrity.

readily available equipment is according to

Performance is based on how much waste

• Former unload assist is an innovative,

The robag promises productive uptime

BEYOND THE BAGGER

The tna hyper-detect 5 helps to achieve optimum productivity.

Created with a patented design, this metal detector can be positioned much closer to the multi-head weigher, dramatically increasing the speed at which the bagger can produce finished bags.

It also keeps products safe from contamination.

The unit offers smart thermal transfer overprint (TTO) date coder on the market, while the tna intelli-date 5 utilises an airless all-electronic system, integrated code defect detection and easyto-change ribbon drive to help improve uptime and productivity by reducing waste and rejects.

of time being spent on products that meet specification.

PLANNING FOR THE UNPLANNED Though these elements are essentially part of the OEE equation, they also highlight key considerations for manufacturers when it

ABOUT THE AUTHOR ANURAG MITRA is the product marketing manager at tna.

comes to general productivity.

Reducing reject rates is a key concern.

The biggest challenge for many lies in understanding how to reduce downtime.

Unplanned downtime, or unexpected

18

Food Review | March 2020

TNA www.tnasolutions.com/solutions/ packaging-solutions/

Scan me for more details

F O O D P R O C E S S I N G T E C H N O L O GY

Full steam ahead Steam is an important ingredient in the food processing industry. It can be the most effective and efficient cooking method in terms of transferring heat to your process when used correctly. By Jake Norman.

N

umerous decisions must be made to get the best results. Several technologies could be considered.

Two common technologies that use steam in food

processing are steam injection and steam infusion, but what are the differences between them?

WHAT IS STEAM INJECTION? Typical steam injection units are compact, inexpensive and simple to use. Steam injection is a direct contact heating

What do you want to create today?

process that passes steam through liquid to be cooked.

“Steam infusion has no moving parts, so manufacturers benefit from a near maintenance-free operation�

Steam is injected through a mesh or with a multiple nozzle arrangement that creates a dispersal mechanism so steam can pass through the fluid more effectively. Occasionally the design also incorporates spiral vanes, which mix the fluid while injecting steam.

WHAT IS STEAM INFUSION? This is also a direct contact heating process, but with steam infusion the core operating principle is controllable disruption.

This enables standardised batch cooking repeatedly. The disruption process creates a negative pressure condition to

Across industries and applications, we design specialised solutions.

For 70 years our solutions set the standard for yield, efficiency, and safety across a wide range of industries.

Our value-add technology can cook, coat, brand and sear a wide range of meat, seafood and poultry products.

Whatever your product needs, we can meet it with precision and passion.

www.heatandcontrol.com | info@heatandcontrol.com Cape Town +27 21 948 5934

20

SAFoodReview_Mar2020_88.5w x 262h_H&C.indd 1 Food Review | March 2020

4/03/2020 10:50:10 AM

aid thermal and kinetic energy transfer to the fluid. As the steam passes into the mixing chamber, it disrupts the fluid flow and breaks it into droplets, known as the vapour phase.

This vapour provides a significant surface area for the steam to condense into as the pressure rises, heating the fluid and producing a condensation shock-wave, generating a pumping effect, reaching a rate of up to 50 000 l/hr on water, and allowing steam infusion to heat, mix and pump with just one unit.

F O O D P R O C E S S I N G T E C H N O L O GY

WHAT ARE THE DIFFERENCES? There are numerous differences in the results achieved by the two methods, with the key ones being the speed of cook, product appearance, and reduced cleaning in place (CIP).

1) Speed of cook The primary difference is the speed at which steam is introduced into the product and the resulting operating conditions.

Traditionally, heating with direct steam injection results in a compromise between heating speed and efficiency because of an inversely proportional relationship as steam pressure is changed. This inefficiency increases as the temperature difference between the product and steam reduces, and can lead to increased variability within batches.

With steam infusion, food manufacturers can overcome this compromise. The disruptive processing environment decouples the steam addition rate from efficiency as steam infusion allows efficient heating at a higher steam flow rate.

Research confirmed that food manufacturers can eliminate burn-on, reduce fat in dairy products by up to 20% and create a creamier mouthfeel while cutting cleaning and cooking times and lowering energy consumption.

Filmatic is the official representative of steam infusion in South Africa, offering the benefits of the patented technology with local expertise and on-the-ground support. •

The disruptive way the steam is introduced causes rapid heat transfer and minimises energy wastage.

2) Product appearance One of the key challenges with direct steam injection is the

ABOUT THE AUTHOR JAKE NORMAN, is the head of sales and innovation at OAL.

exposure of the product to high-temperature steam. This can result in discolouring of delicate sauces like béchamel.

The unique processing conditions of steam infusion means the product is prevented from being exposed to excessive

Filmatic – www.filmatic.co.za

temperatures and the resulting Maillard reaction. This means it's possible to avoid discolouration and create a product that’s more attractive to consumers.

3) Cleaning & downtime Steam injection relies on a complex mechanical assembly with multiple voids and surfaces, leading to inherent cleaning challenges. Unfortunately, this also translates to more downtime as cleaning must take place after each batch.

Steam infusion has no moving parts, so manufacturers benefit from a near maintenance-free operation. The simplicity of the unit as a single, annular nozzle means that it is an inherently clean design, facilitating CIP. The elimination of burn-on further accelerates CIP processes.

Unlike steam injectors, which usually require complex installation on retrofits, the steam infusion In-Tank Vaction Pump is easily mounted at an angle into the top of the vessel, or the inline variety can be engineered into existing systems. There is virtually no maintenance involved in the operation of steam infusion pumps so operations can run without costly downtime.

FULL STEAM AHEAD WITH OAL The potential of steam infusion technology in food production was investigated by OAL together with the University of Lincoln.

FAST FACT

Research confirmed that food manufacturers can eliminate burn-on, reduce fat in dairy products by up to 20% and create a creamier mouthfeel while cutting cleaning and cooking times and lowering energy consumption.

March 2020 | Food Review

21

F O O D P R O C E S S I N G T E C H N O L O GY

Vacuum Pumps ready for Industry 4.0 Highly regarded manufacturer of vacuum pumps for the food industry, Busch Vacuum Solutions recently introduced its new range of vacuum pumps into the African market.

ABOUT BUSCH VACUUM SOLUTIONS

T

he Busch R 5 RA 0760 Plus vacuum pump introduces a new range for vacuum solutions in the Busch product

portfolio, featuring innovative functionalities.

This is a silent plug and pump vacuum unit, which is ready for Industry 4.0.

This new generation of vacuum pump embodies proven R 5 technology for leading performance and reliability. Its built-in control unit with a variable speed drive and a touchscreen interface allows flexible and easy control of the vacuum pump. With energy savings of up to 50%, the R 5 RA 0760 A Plus sets a new benchmark in terms of energy efficiency.

“Companies that package foodstuffs on several thermoforming packaging machines, tray sealers or chamber machines should consider using a centralised vacuum supply. Energy cost savings of 50% and more can generally be expected”

CENTRALISED VACUUM PACKAGING SOLUTIONS Companies that package foodstuffs on several thermoforming packaging machines, tray sealers or chamber machines should consider using a centralised vacuum supply. Energy cost savings of 50% and more can generally be expected. This is possible as fewer vacuum pumps are required for this than for a decentralised vacuum supply.

Performance control can be precisely adjusted to fit the requirements of overall operations. Centralised vacuum systems

The actual evacuation time in a packaging chamber where the vacuum is required only accounts for one third of the cycle time. The rest is taken up by transportation, sealing, ventilation and sometimes treatment with gas.

Using intelligent technologies in the vacuum supply chain, i.e. optimised control systems to frequency control offers several options for optimisation.

offer maximum reliability and safety as all systemically relevant components have a redundant design. If a vacuum pump fails or needs maintenance, full vacuum power remains intact.

Busch central vacuum systems can be equipped with various vacuum pumps. In addition to oil lubricated R5 rotary vane vacuum pumps and dry Mink claw vacuum

The company is a family-owned business founded in Germany in 1963. Over 55 years later, the Busch Group is still owned and managed by founders, Ayhan Busch and Dr Karl Busch and their three children. The Busch Group is present in 42 countries with 60 subsidiaries. This positions the company as a one of the world’s leading manufacturers of vacuum pumps, blowers, compressors and complete systems. The head office of Busch Vacuum South Africa is located in Johannesburg, with branches in Cape Town and Durban. All offices have workshop service and repair facilities and carry stock of vacuum and overpressure generators to support any industry.

The Busch South African company employs many engineers and its technicians are well trained to support its high-quality vacuum technologies and provide expert advice to industries in Africa for those seeking solutions to a vast range of manufacturing applications. Of these sectors, food packaging and processing is the most important market for Busch worldwide. Just over 95% of vacuum pumps sold into the food packaging and processing industry are rotary vane vacuum pumps and most of these are supplied by Busch. There are currently over R2.5 million R 5 vacuum pumps operating worldwide.

Today almost all reputable OEM suppliers of vacuum packaging machines in Africa deal directly with Busch South Africa and supply genuine Busch service kits and food grade oils when servicing their customers pumps.

pumps. Cobra screw vacuum pumps can also be used as components. The investment costs can be reduced during purchasing by including already existing vacuum pumps in the system installation. •

Busch Vacuum Solutions - www.busch.co.za

22

Food Review | March 2020

Worldwide No. 1 in Vacuum Packaging Discover the wide range of options for using vacuum in food packaging production and processes.

We offer dry-running and oil lubricated vacuum pumps, liquid ring vacuum pumps, blowers, full service and repairs.

Ask for vacuum technology by Busch!

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

M E AT, FI S H & P O U LT RY

Innovative coating equipment offers profitable advantages With popular end-products such as nuggets and hamburgers, consumers require more variation in flavour and appearance.

Producers of convenience products must produce high volumes, coupled to a wide variety of smaller volume products.

M

arel’s convenience portfolio combines high production capacity

The all-new RevoBreader perfect flawless homestyle products

IT ALL STARTS WITH FORMING

system for all coating steps, to make every

The process of creating convenience

conceivable coated end-product.

products often starts with forming a meat mass into shapes. Marel’s RevoPortioner

HOMESTYLE COATING

is an innovative solution for portioning

To get a typical crispy homestyle coating,

products. Its low-pressure portioning

the RevoBreader is the perfect match. This

technology enables processors to produce

machine creates top quality homestyle

a variety of products consistent in shape,

products and offers maximum flexibility.

weight and size.

Thanks to the large drum size of the machine,

The system retains the whole muscle meat

products are flipped and tossed into the

structure and texture where possible. There

breading, which results in a thick layer of

a variation of end-products, without

is also little to no waste (less than 0.3%

coating and a perfect product appearance.

compromising on product quality.

meat leakage). The RevoPortioner releases

with the flexibility to produce

The RevoBreader is a dual mode machine

products gently from the rotating drum,

that can be used in flatbed position for a

WIDE VARIETY OF PRODUCTS

using only air. The total cost of ownership is

more homogeneous product appearance.

The right production line enables processors

extremely low, mainly due to very low meat

Changing the configuration of the

to produce all kinds of profitable products

leakage and low maintenance cost.

RevoBreader is a one-person job that can be done in less than ten seconds. This makes

that are convenient for the end consumer and add value to the production process.

YIELD INCREASING COATING

changeover times extremely short and

These processing lines require maximum

Presentation plays a key factor in the

gives producers more flexibility during the

flexibility to produce a wide variety of

consumer’s choice for a product. It is of vital

production process.

convenience products.

importance to get the coating right when producing convenience products. Coating

AN ATTRACTIVE GOLDEN FINISH

like nuggets and homestyle crispy wings;

influences yield and will largely determine

Frying is an important heat treatment step in a

natural looking tenderloins and fillets. These

the appearance and bite of an end-product.

production process. The coating is fixated and

These could vary from known classics

products are traditionally made from bits

Options for possible coating processes are

the products acquire their attractive, golden

and pieces sourced during calibrating and

numerous and depend on the desired end-

crispy finish and taste. Frying contributes to

the trimming of fillets.

product. Marel can supply an appropriate

food safety, product quality, taste, presentation and prolonged shelf life. Marel fryers are equipped with an oil management system for

RevoPortioner produces perfectly portioned products with virtually no waste

extended oil life and thus higher yields.

STEAMING, COOKING OR GRILLING Cooking is another form of heat treatment that adds value to a product. Marel ovens are equipped to enable processors to control core temperature, colour, crispiness and flavour to perfection, without compromising on strict food safety requirements and yield.

DID YOU KNOW? Marel fryers are equipped with an oil management system for extended oil life and higher yields.

The ever-changing market for convenience products provides plenty opportunities. Marel can support processors at every step in the production process and are ready to help them get ahead in the convenience market. •

Marel – www.marel.com

24

Food Review | March 2020

REVOLUTIONARY COATING EQUIPMENT Marel's new coating equipment combines a high production volume with maximum flexibility and unmatched product consistency. It is the ultimate solution for a wide range of coated end products with homestyle or homogeneous coating.

• Create high quality, attractive end products • Optimum product coverage • High flexibility in line set-up Marel’s convenience food production line offers innovative solutions for forming, coating, frying and cooking. +27 11 823 6940 | marel.com

M E AT, FI S H & P O U LT RY

The magic between heat and meat Thermal treatment is very topical especially during the preparation of ready-to-eat meat or products containing meat. Knowing how to control heat during these production processes allows tasty, attractive and safe food to be prepared.

O

ne of the most popular thermal treatment techniques used in the

MEET THE MASTERS

food processing industry is smoking, specifically for flavouring

Schröter understands the intricacies of smoking and processing

meat, fish and poultry.

Conventional hot smoking involves cooking meat at a low temperature in the presence of smouldering wood chips. This allows the flavour to develop gradually and uniformly. Alternative methods such as cold smoking, steam smoking and liquid smoking are also possible. Each of these processes offers a specific taste or processing benefit.

Strict safety standards apply when smoking meat. During hot smoking, the air temperature inside the smoker and the internal temperature of

meat. Its business model revolves developing systems to help clients produce quality meat products for the past 70 years.

In its systems, heat distribution, air flow and climate conditions are controlled precisely to ensure that products develop optimal flavour and mature in a uniform manner, without compromising final product weight, texture or safety. The company also offers intensive chilling and defrosting systems

the meat must be monitored continually to ensure food stays out of the

in addition cooking systems to provide clients with a complete

so-called danger zone for bacterial growth. After smoking, meat must be

thermal treatment solution.

cooled and packaged rapidly. This keeps food out of the danger zone.

“During hot smoking, the air temperature inside the smoker and the internal temperature of the meat must be monitored continually to ensure the food stays out of the so-called danger zone for bacterial growth” Its approach to thermal treatment systems is based on a solid understanding of not only the physical principles of using heat

Production lines for meat and fish processing industries

in food processing, but also of what clients’ specific needs are.

They can then tailor systems to ensure an efficient workflow in whatever configuration is needed.

'We are committed to quality, performance and innovation,' says Dietrich Schröter, a fourth generation at the helm of the family-owned company. 'We strive to offer our clients systems they can rely on.'

HYGIENE MATTERS Heat can be both a help and a hindrance in a food processing system. If not handled correctly, thermal treatment can cause temperature fluctuations that may create conditions that promote bacterial growth. Some harmful microorganisms can also withstand high temperatures, and therefore food processing systems should minimise microbial action at each production step.

PHT understands the hygiene challenges in food processing and are passionate about helping their clients install and maintain tailored hygiene systems. 'Food hygiene is about more PHT is the representative of Schröter equipment in South Africa Unit 17, Edison Square, 137 Edison Crescent Centurion, Pretoria, 0157 Tel: +27 86 177 7993 | Email: info.za@pht.group www.pht.co.za

26

Food Review | March 2020

than compliance; it’s about creating a culture of preparing safe food,' concludes Deléne Boshoff, managing director of PHT South Africa. •

PHT – www.pht.co.za Schröter – www.schroter-technologie.de

M E AT, FI S H & P O U LT RY

Are your quality processes the best they can be?

In the meat industry quality control is critical. The quality process needs to be accurately documented from farm to retail to packed products.

With ever evolving processes and product lines, it is important for quality control to evolve too.

T

his process can be time consuming and tedious, often leading to reactive corrections after results

are collected. These challenges have led to the need for instant, bespoke solutions that fit each level of the production line. With instant data collection, data analysis can be done faster and pro-active solutions can be implemented.

Matrix Software has developed a customisable, integrated quality control

“Matrix Software has developed a customisable, integrated quality control module that allows for the elimination of paperwork by allowing users to electronically capture predefined customised templates”

module that allows for the elimination of paperwork by allowing users to electronically

The platform is aimed at being easy to use,

capture predefined customised templates.

customisable, and able to fit into and evolve

These documents are web-based giving

your quality control system. This is done

support to use with tablets and mobiles.

through the creation of your own document

These templates can be populated with information from processes automatically, as well as update relevant data within the

templates which is used to capture your data instantly.

The easy to use platform gives quality

process for Matrix Software. These allow

controllers the chance to manage the

for improvements to quality control to be

process on the move and as part of the

pro-actively managed resulting in quality

production process, with visibility of product

products for the customer.

flows at all times. •

Matrix – www.matrixsoftware.co.za

March 2020 | Food Review

27

S A FE T Y, H YG I E N E & Q UA L I T Y T E S T I N G

Are you still using traditional chemicals?

Electrochemically Activated Water (ECA) is a natural hygiene solution. Comprised of water, salt and electricity, ECA hygiene solutions are said to be three times more potent than traditional chemicals.

R

adical Waters’ ground-breaking

Sanitising is best carried out just prior

ECA technology is fast becoming

to equipment use because a variety of

the choice solution for many

micro-organisms may remain on food

blue-chip companies as an alternative to conventional, halogen-based chemical disinfectant and cleaning agents.

ECA is suitable for a wide range of

processing surfaces after cleaning.

Once implemented, Radical Waters’ ECA solutions have proven to reduce the incidences of foodborne illnesses

hygiene applications, especially where

by eliminating up to 99.9% of all

the use of hazardous chemicals poses

dangerous tested bacteria, while also

a risk to the environment, product and

ensuring optimum final product quality

personnel safety. Many micro-organisms

due to reduced levels of contamination

develop a tolerance or resistance to

and spoilage. ECA is safe and can

conventional chemicals as a result of

be applied directly to food and

continuous exposure. ECA solutions have

food surfaces.

a unique mechanism of biocidal action

It is non-toxic, free rinsing and does

distinct from chemicals. The technology

not affect the nutritional status, colour

has proven its consistency in destroying

or texture of the final food or beverage

bacteria, biofilm, spores, fungi, viruses

product. Interestingly, ECA has also

and yeasts.

shown to improve certain products’

“Radical Waters’ ECA solutions have proven to reduce the incidences of foodborne illnesses by eliminating up to 99.9% of all dangerous tested bacteria”

ECA technology is an alternative to halogen-based chemical disinfectant

shelf life.

procedures. ECA generators used to make the solutions are European grade and highly specialised; tailored to suit various applications and customer requirements in any product sensitive manufacturing environment.

Radical Waters’ ECA generator onsite offers ease of operation, complete user safety, cost savings because of a reduction in the use of water, energy and a much lower lifecycle cost than chemicals. Big industry players who initially bought into the technology picked from an array of ECA suppliers in the market with varying degrees of experience and reliability.

This often costs the ECA brand a bit of its reputation. When choosing Radical Waters, you choose proven professionals in the industry with over

ECA solutions are Kosher and Halaal

20 years of experience.

approved, providing a safe, fast and

"ECA is our speciality, and we will

powerful alternative which is highly effective in the fight against food and

ECA solutions are generated onsite

beverage contamination and spoilage.

and can be used on multiple surfaces,

Without the correct sanitisation, a rapid

eliminating the logistical nuisance

build-up of micro-organisms will occur.

of ordering and storing specialised

This can result in severe recontamination

chemicals. It is easily and safely applied

of the foodstuff when reusing equipment.

without requiring special handling

food & beverage ECA hygiene technology

strive to deliver first class service and maintenance no matter where you are in the world," Nikki Wilson, vice president of Radical Waters concludes. •

Radical Waters - www.radicalwaters.com

* of tested organisms

* k i l l s 9 9 . 9 % m i c ro

Trusted by QA around the World. www.radicalwaters.com

28

Food Review | March 2020

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

Focus on food safety

Audits are crucial to maintaining food safety standards and certification. They provide transparency and assurance that your organisation is maintaining necessary standards.

T

his transparency increases the

A GLOBAL REACH

benchmarked against widely-accepted,

collaborative capacity of stakeholders

Increasing complexity within supply

recognised food safety and quality

across the supply chain, and enhances

safety, efficiency and continual improvement within your organisation. Auditing is also a required component of becoming certified to a standard.

Alignment to the relevant safety standards is not a static exercise – no single organisation can perform the necessary due diligence as a once-off exercise and claim complete compliance. Adherence to industry requirements is dynamic, so whether you’re a seasoned audit participant or new to the game entirely, there is always room for growth and development within your audit process.

Auditing is also a great opportunity to drive value within your organisation. It enables an organisation to: • evaluate its management system or management priorities • refocus its commercial objectives • thoroughly assess supplier evaluations or customer requirements • review incidents at other facilities • meet regulatory or contractual requirements.

chains means the need for standardised, internationally accepted food safety plans has grown. In response to this need, international committees (such as the Global Food Safety Initiative (GFSI), have created a system whereby certain food safety schemes are benchmarked against specific criteria.

Certification to a GFSI-recognised global standard, such as FSSC 22000, SQF or BRC, assures customers that specific food safety and quality guidelines are routinely met, confirming your organisation as a trusted source in the market. Aside from increasing the efficiency of transactions in the supply chain, food safety certification increases the cost efficiency of the food safety audit process, as it allows your business to consolidate numerous and costly supplier audits into fewer, standards-based audits.

Businesses will subject themselves to a ream of proprietary or second-party

criteria, allowing you to consolidate the number of required audits. Conducting fewer audits has the following three organisational benefits: • it reduces downtime • it frees up your resources • it greatly increases cost efficiency.

GFSI-recognised schemes validate and monitor auditors that work for them, which in turn requires them to meet internationally recognised accreditation rules. This provides a system of checks and balances that will help you to safeguard the integrity of each GFSI audit, and ensure audits are carried out in a consistent manner.

The right auditors will understand that applying a standard is not a paintby-numbers exercise; small, medium and large organisations will require a system assessment that will ensure the application is appropriate for the business in question. •

audits annually. For some companies this can run up to as many as 10 to 20 audits a year. Globally recognised standards are

NOSA – www. nosa.co.za

Monitor and reduce risk in the food and beverage supply chain with NOSA Testing NOSA has established an independent risk management programme that will help bridge the current food safety control gaps that exists between government regulation and industry best practice.

NOSA’s team of industry experts will be empowered, where necessary, through selected partnerships that give us direct access to the latest technology in areas such as genotyping.

The NOSA Testing team’s 9 step process • • • • •

Monitoring Data analysis Risk assessments Microbiology and molecular screening ‘Genetic fingerprinting’ for IDs, source identification and resistance profiles

• • • •

Audit Process/supply chain evaluation Certification to ISO 22000 Training

NOSA Food Safety and Testing, with its expertise and food safety sector knowledge, is ready to assist with a third-party food safety programme to ensure your risk mitigation and food safety benchmarks are flawless.

Contact: Steven Lashmar NOSA TIC Sales and Marketing Manager Tel: 021 850 0510 | Email: Steven.Lashmar@nosa.co.za

NOSA Testing half page ad.indd 1

2020/03/03 15:41:35

March 2020 | Food Review

29

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

Essential fly control for food environments A fly infestation can spell disaster. Flies are one of the most likely insects to cause damage and disruption to a food service or food production business. countries to understand the impacts of

days, a zero-tolerance approach to flies and

pest infestations. The results revealed

any form of pest contamination within the

that a single fly infestation can cause staff

food environment is crucial.

illnesses that lead to businesses losing over nine working days every year. Staff

THE BEST WAYS TO CONTROL FLIES

absences are just the beginning. There are

Adopting standard hygiene practices will

many other reasons why flies are a threat to

go some way to preventing fly infestations.

food businesses and need to be controlled.

Practical measures that all businesses can

Without proper prevention, businesses could

implement to deter flies should include:

suffer from: • contamination of stock and product, while being a risk to health by carrying disease such as: o Salmonella o Shigellosis o E.Coli o Cryptosporididium o Myiasis

T

hey disturb the production process, hit revenue and pose major threats to health, safety and sanitary

compliance. There are 120 000 species worldwide, posing a health risk to staff, customers and livestock by spreading disease and contaminating goods. They also have a short lifecycle and can multiply rapidly, with some fly species able to mature from eggs to adults in just seven days. As you can imagine, that can cause a lot of risk to your business.

Rentokil commissioned the Centre for Economics and Business Research (CEBR) to survey decision-makers across five

Food Review | March 2020

early stages of decay • Regularly cleaning production areas and equipment, while also inspecting regularly • Disposing of garbage regularly — especially in hotter seasons • Ensuring there is sufficient storage volume for waste produced • Keeping supply areas clean

• an economic impact on businesses

• Cleaning drains and making sure that

• a negative influence of reputation

they are kept free of accumulating

• contravening compliance and legislation.

organic matter

Understanding the risk flies pose to food

• Using appropriate insect light traps (ILT’s).

safety is critical. Well-publicised incidents

Exclusion is another key measure that will

of foodborne illness outbreaks continue to

help to keep flies at bay. These measures

reinforce and increase public awareness

could and should include:

of food quality and safety, meaning any fly

• The use of screens on windows and vents

infestation can lead to long term loss of

• Appropriate door design and doors kept

trust from customers and damage to brand reputation.

No food environment is exempt from

shut when not in use • The prevention of gaps in any part of the building fabric.

responsibility. Flies can affect kitchens,

Taking a proactive approach to fly control

restaurants, pubs and clubs, poultry farms,

will help you avoid more costly treatments if

local food retail, food manufacturing and

an infestation becomes more serious. Once

processing – anywhere food is present. With

standard hygiene and exclusion practices

food safety at the top of the agenda these

have been implemented, the best way to

13717 - PROPAK CAPE 2020 EXPROM ADVERT - QUARTER PAGE_177w x 65h_NEW MEDIA.indd 1

30

• Disposing of any supplies which are in the

2020/03/17 09:56

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

WHY BUSINESSES SHOULD CHOOSE THE LUMNIA RANGE

keep infestations at bay is to use an LED ILT for effective monitoring and control.

Having the right protection in place to

INTRODUCING THE BEST LED RANGE OF ILTS ON THE MARKET:

prevent fly infestations is imperative - and

The Lumnia range provides commercial fly

LED ILT on the market and ensures your

Lumnia is the solution. Its optimised LED lamps can catch flies faster than any other business is fully compliant and helping to

control solutions designed to effectively attract, kill and encapsulate flies in a hygienic

WHY ARE FLIES MORE ATTRACTED TO LED LAMPS?

manner. Lumnia’s innovative LED ILTs are the modern solution to an age-old problem – attracting and containing flying insects quickly and securely and keeping them out of sight.

Lumnia works by using high-attraction LED lamps. These lamps can reach up

The graph shows the sensitivity of the photoreceptors in a house fly’s eyes to different wavelengths of light. This shows that the fly’s photoreceptors are tuned to wavelengths around 350

to 80% further than traditional units. Once removed from the environment, a nonpesticide glueboard and encapsulation cassette inside the unit reduces the risk of insect fragments escaping and

DID YOU KNOW? There are 120 000 species of fly worldwide.

Lumnia LED lamps produce intense light in the most sensitive part of the UV spectrum

environments, therefore, the LED

clean and service, the units have

of glue boards.

LEDs (365nm).

is little UV light in indoor

contamination. Simple to

mechanism to allow safe access and removal

the UV output of the Lumnia

that flies can see. There

helps to prevent cross-

been designed with a sliding

nanometres, which is close to

lamps will appear to the flies as bright sources of light and attract them to the unit.

mitigate the risk of food contamination.

Lumnia’s LED lamps also save up to 70% of energy use compared to fly traps that use fluorescent bulbs. Lumnia LED lamps even reduce carbon emissions by 62%, so you can now reduce your carbon footprint and save on electricity bills. As well as all that, LED lamps also last longer – around three years – so you won’t have to spend money on replacing them every year.

The highly effective out-of-sight glueboard can be serviced quickly and easily, with minimal disruption to your business operations, but most importantly, the Lumnia range complies with all legal and health and safety requirements, giving you peace of mind and letting you concentrate on the day-to-day running of your fly-free business. •

Rentokil - www.rentokil.co.za

The Science of Attraction

Luminos by Get in touch with us!

0800 736 86545 or www.rentokil.co.za

March 2020 | Food Review

31

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

Certification Partner Global (CPG) keeps you abreast of industry changes There have been a lot of changes in the last few months for the food industry. The new FSSC V5 was published in 2019 and the new SANS 10330 early in February 2020.

C

PG is a JAS-ANZ Accredited Certification

INFORMATION REGARDING THE CERTIFICATION PROCESS

body and is also a SANAS Accredited

Initial certification process

Certification body for SANS 10330. The

Three year certification cycle

company can assist you with upgrade training, upgrade audits as well as all the audits/ certification listed below.

CERTIFICATION/AUDITS ON OFFER: HACCP SANS 10330 HACCP Codex FSSC 22000 GFSI Basic GFSI Intermediate ISO 22000 ISO 9001 ISO 14001 ISO 45001 ISO 22301 ISO 27001 ISO 20000 ISO 50001 Integrated audits

Application to CB

Quote From CB based on requirements

Stage 2 Audit

Report is reviewed

by Techical reviewer

Approval and Certification

Surveillance 1

Surveilannce 2

Recertification

Takeover audit At any stage can an audit be taken over by certification body. The certificate will show the same certification cycle dates, for example if take over is conducted during Surveillance 2, then recertification will still be the following year to complete the three year cycle.

"Although we are an international company, we own the Africa agency. This enables us to

Stage 1 Audit

Request

Quote from CB based on Audit cycle ( surveillance/ recertification)

Audit

Review and approval

Continue Certification cycle

assist with local requirements and demands as well as charge our clients affordable South African rates," Thea Laufs of CPG explains.

Special

For all Food Review readers we are offering a discount till end June 2020 Use Code: FR2020 Contact:

Elsie.stricker@cpg.global

DETERMINING AN AUDIT DURATION • Scope of audit • Based on IAF documentation • Based on the following: • Size (staff numbers, full time, part time, contractors etc.)

• Risk assessment / rating

32

Food Review | March 2020

• Nature, specific regulatory requirements • Standard operating hours – single shift or multiple shifts per day.

CPG – www.cpg.global

S U S TA I N A B I L I T Y F O RU M

The Caterserve facility runs a 200kW batter-solar off-grid system

Power-up production Many players in the food and beverage industry would doubt that a food manufacturer, producing over 1 000 bottles of tomato sauce and mayonnaise daily, could go off-grid and pay less for power.

C

aterserve in Windhoek, Namibia proves them wrong.

SolarSaver, a provider of customised rooftop solar

Quality Control of Food with FT-NIR Spectroscopy Whatever your application is ... grain, flour & milling products milk and dairy products meat & sausages oil and oil seeds feed & feed ingredients

photovoltaic solutions in Namibia and South Africa, has

installed a 200kW battery-solar off-grid system, taking the manufacturer completely off-grid. Caterserve now runs 100% off solar power 24 hours a day - increasing its production capacity.

The company’s model offers zero installation costs, fully inclusive maintenance, monitoring, insurance and flexible purchase rights.

SolarSaver makes it possible for companies to rent the sun, paying only against the actual performance of the system and benefitting from the cheaper, greener power produced.

"We had to upgrade our production line and found that we needed more power than the municipality could reliably provide," says Nic Geldenhuys of Caterserve. "The cost of off-grid solar has previously been very high. The solution from SolarSaver, which required no upfront capital investment on our part, was very appealing. We are running well on off-grid solar and have reduced our electricity costs.

We also know the power costs that we’re in for over the next few years and can plan accordingly."

Stefan Kleemann of SolarSaver masterminded the installation over a two-month period. "To ensure we could reach 200kw to supply all the energy needs of the business, we installed 600 panels from Canadian Solar which have a 330W capacity each. An inverter

Bruker offers solutions for the analysis of raw materials, ingredients and finished products in the laboratory, at-line or on-line. With the FT-NIR spectroscopy standard parameters like dry matter, fat or protein as well as more complex parameters like amino acids can be measured in seconds in different sample forms like powders, solids, pastes or liquids.

A set of pre-calibrations for various industries is available for a quick and efficient start.

with a 200kW capacity and a 300kWh lithium-ion battery bank helped the business go off-grid through a hybrid battery and solar off-grid system.”

Kleemann notes that while photovoltaic hardware systems are long-lasting, panels must be kept clean to ensure that the system operates at full capacity, which can be expensive and challenging.

Results from SolarSaver installations concur with international studies that show solar panel output is boosted by up to 80% after professional cleaning. "The fact that we take care of all monitoring, cleaning and maintenance is a big win for clients. It makes sense for us to ensure that these systems are always operating at peak performance."

It is expected that solar photovoltaic energy will be the fastestgrowing renewable technology by 2022. "With electricity costs increasing, solar energy efficiency for businesses is a low-risk investment which yields substantial rewards. Manufacturing companies like Caterserve are increasingly turning to solar to supplement energy needs, go green and bring costs down," Kleemann says. •

Bruker South Africa (Pty)Ltd. Ltd. Homestead Office Park, Block B 65 Homestead Avenue Bryanston - 2021 Tel: +27 11 463-6040 Fax: +27 11 463-6289

Innovation with Integrity

Contact us for more details: www.bruker.com/optics info.za@bruker.com F T- I R

SolarSaver - www.pressa.africa/SolarSaver

March 2020 | Food Review

33

H O T B E V E R AG E S

Sorting technology leaves no stone unturned Ishida’s advanced X-ray technology has enabled one of Slovakia’s leading tea and coffee suppliers to enhance its quality and safety standards for the introduction of retail packs of roasted coffee beans.

S

ince the installation of the Ishida IXEN-2493 complaints resulting from stones in the beans have

been eliminated.

Residual stones in coffee beans are a common problem. Despite rigorous quality control procedures, including using magnetic separators and passing the beans through a de-stoner machine, stones can still be present.

This impacts on the perceived quality of the coffee and stones can also damage the blades in domestic and professional grinders for espresso machines if they go undetected.

“A special diverting reject system quickly removes any rejected product to minimise losses” Prior to the installation of the Ishida X-ray inspection system, quality checks for stones were carried out by hand. Operators could not detect all the stones, leading to frequent consumer complaints. Having used Ishida weighing equipment for several years, the

Stones can impact on the overall perceived quality of a product

Close-up with coffee beans in the Ishida IX-EN-2493

company turned to Ishida to help solve this problem.

"We knew that Ishida was easy to work with, that the company takes a detailed approach to every

Classic bag of espresso coffee

project and that if we have an almost impossible task, Ishida is the most likely to find a solution," explains Peter Paciga, Baliarne’s production director.

Initially the IX-EN-2493 was tested on packed product, but the number of bags still containing stones proved to be too great. The

that the machine is easy to set up, operate and clean.

Currently beans are packed into pre-made

decision was taken to inspect bulk product

bags, but Baliarne is now introducing packs

prior to the bagging of the coffee beans.

for the foodservice sector and if demand

"From that moment, we have not had any

continues to grow, the intention is to create

further instances of stones in the beans,"

a fully-automated inspection and bagging

Paciga confirms.

line. As part of this, the Ishida X-ray has the

The IX-EN-2493 features Ishida’s unique genetic algorithm (GA) technology, which uses image data analysis over several

capacity to check up to 30 tonnes of coffee beans each day.

"The highest product quality and

generations to achieve an extremely high

safety is essential for us to maintain our

level of inspection accuracy with the machine

premium brand image," he concludes.

being ‘trained’ to spot certain foreign bodies.

"The Ishida IX-EN-2493 has enabled us to

In addition to the supply of the X-ray system,

deliver this. The machine is very reliable

Ishida project-managed the installation,

and user-friendly, and Ishida provides

designing the infeed, gantry and elevator that

great service and support." •

takes product for bagging. A special diverting reject system quickly removes any rejected product to minimise losses. Baliarne reports

34

Food Review | March 2020

Ishida – www.ishida.com

Retail ready. Smarter, faster, together.

Every business has its own challenges; ours is to help you overcome yours. If you need to improve productivity, we can help you produce more, in less time. If accuracy is an issue, we can help you get back on target. If you need to adapt to higher standards, we’ll help you raise the bar.

Smarter Faster Together

To set the wheels in motion see us at Propak East Africa, 17-19 March 2020, Stand 36 or visit ishidaeurope.com

H O T B E V E R AG E S

A flexible fix for coffee pod packaging Unroasted coffee beans are one of the world’s most traded agricultural commodities. Market forces behind its distribution and presentation are equally impressive. Multiple varieties, formats, serving options and packaging solutions offer consumers choice when it comes to purchasing and brewing their caffeine fix.

Mark Brooker, director of Cama UK, says,

P

opularity and market demand filter down the supply chain, placing immense pressure on suppliers,

roasters and grinders as they try to keep pace

needed a machine-based solution that could

packaging design department, Masteroast

package tubes and trays, using a continuous

developed a new box design that comprises

stream of individual products fed from a

a top opening tray with an insert that allows

downstream capsule filling and sealing

the capsules to be presented - like a gift box.

machine. The machine had to offer easy

This approach allows us to offer a packaging

changeover, to rapidly adapt to the different

format with a sense of occasion – created by

style production runs. Coupled with delivering

a theatrical product reveal of the contents of

the necessary flexibility, this would also make

the carton."

significant contributions to OEE. Cama’s solution was its Break Through

with consumer demand for convenience and new innovations.

A company that has undertaken investment to cater for these varying market forces is Masteroast, one of the UK’s largest independent coffee roasters/packers. Its reputation for high-quality coffee and innovative packaging has allowed it to grow sales in a highly competitive retail sector.

Following a recent investment in process and filling for coffee capsules, pressure was building to reduce cost and increase throughput on the

“From a technology perspective, Masteroast needed a machinebased solution that could package tubes and trays, using a continuous stream of individual products fed from a downstream capsule filling and sealing machine”

create differentiation in the market.

Standard 1 x 10 tube formats for Nespressocompatible capsules are well recognised, but for a point of difference for higher-end products, a unique format with more drama and customer engagement was required.

To take this next step, Masteroast explored the machine-builder market for a suitable

Generation (BTG) machines that incorporates precision feeding of the aluminium capsules, robotic manipulation of capsules into a single row for tubes or a double row for trays, before presenting them to a Cama CL intermittentmotion side load cartoner.

The key to the flexibility of the line is Cama’s MN (‘Y’ shaped) robot at the infeed.

With the innovative design of the robot’s pick head, the facility can minimise the changeover time between the different packaging formats.

Both these run at 120 capsules per minute.

packaging line. Masteroast’s problem was that customers wanted different packaging styles to

From a technology perspective, Masteroast

"Working in collaboration with our dedicated

"Cama has experience and market know"Cama helped us," Fawkes adds. "We knew

how," Fawkes elaborates. "The team ended

the format we wanted, but at the time it did

up holding our hand throughout the entire

not exist. The packaging design team helped

process – from design through rollout and

us with technical advice, relating to the best

through to implementation. This was a huge

types of cardboard, how it was folded and

comfort factor. With anything new, there’s

manufactured. The Cama team also talked

always the fear that you don’t get what

to our supply chain, helping us to bring it

you ask for. Cama understands our needs,

all together."

namely flexibility and reliability, which was so

secondary packaging machinery supplier.

They tasked Cama to develop a solution for its coffee packaging requirements.

Andy Fawkes, managing director of Masteroast, explains, "We’ve held a unique position in the market and we are known for our ability to offer flexibility, short-run capabilities and high levels of quality. When we moved into the capsule market, we knew we had to exploit automation for capacity and cost reasons – but we did not want to give up flexibility. Cama offered us significant coffee packaging experience and we knew it was well established in this market. Its capabilities to deal with short runs and different packaging formats ticked all our requirements."

36

Food Review | March 2020

Industry know-how and technological expertise drive highly effective coffee packaging collaboration

H O T B E V E R AG E S

1 essential to us. Other companies wanted to

and worked with our team to ensure that

talk technology, engineering and price, but our

installation and commissioning went without

principal need was for someone to understand

a hitch. Training support was also very strong

the flexibility we needed in production. Cama

and within four to five weeks we were very

was the one that listened properly and came

comfortable with the machines."

back with a solution, not just a quote.

"We were the first to introduce aluminium

Masteroast now packs three times the number of products per day compared

capsules into the UK," Fawkes explains. "No

to its previous manual process. Quality

one had done this before outside of the

and consistency of the packaging has

obvious main players, so we expected teething

also improved. "We’ve seen a reduction in

problems. Cama’s engineers came onsite

packaging material usage," Fawkes concludes.

2 1 & 2: Masteroast needed a machinebased solution that could package tubes and trays

"This saves costs and makes the process sustainable. A true win-win situation. We would certainly come back to Cama and we are already looking with them at other processes that currently involve manual packing." •

Cama – www.camagroup.com

March 2020 | Food Review

37

H O T B E V E R AG E S

Supply chains can ensure a fair trade Businesses are rewriting the rule book about what success looks like.

Many businesses are using products and brands as vehicles to be social activists and drivers of change. By Jonathan Robinson.

B

rands like Patagonia and MiiR

It’s been shown that focusing on

cooperative-based farmers in Ethiopia,

are leading the way in building

all the elements of a business’

Kenya, Rwanda, Burundi, D.R. Congo

businesses that create positive

operating environment can positively

and Tanzania. We’ve invested time in

change. By using positive social currency,

influence share prices and improve

building meaningful relationships with

these companies build even deeper

operational performance.

the people who own the coffee trees,

loyalty among customers.

harvest the cherries and who process

As the first certified fair trade coffee roaster in South Africa, Bean There spent years exploring the industry and adventuring into new countries and regions. One of the aims of the brand was to meet new people in its quest to build a business that offers success for everyone in the supply chain.

Success is not just about how much value you extract at the end. We believe that if our farmers are successful; our employees are paid well and we remain profitable, we’ve done well.

and sort the beans by hand.

“Ethical purchasing decisions are part of the triple bottom line of people, planet, and profit reporting format that transcends the traditional financially focused measurements of a business’ success”

Ethical purchasing decisions form part of the triple bottom line of people,

The company works closely with the local cooperatives to help the farmers boost their yields by applying the best possible agronomy principles. This means that trees offer greater yields of better fruit, they can build bigger businesses and earn more money.

This has been our strategy as social activists and drivers of change, but we’re continuing to look for new ways to make our business even more sustainable.

We are determined to reduce the impact of local operations on the environment

Bean There launched in 2005. It believes

and continue to adapt to the needs of the

planet and profit. This reporting format

that direct fair trade is not merely an

country and local communities and remain

transcends the traditional financially

obligation, but an opportunity to actively

a business that is a force for change. •

focused measurements of a business’

support development, growth and social

success. It encourages companies to

empowerment. We believe that building a

measure their performance in terms of

sustainable business should benefit every

positive and negative impacts on the

stakeholder in the supply chain, even if it

environment in which they operate, and

means paying a premium price.

the people they engage with while doing business.

38

Food Review | March 2020

We’re buying among the best single-origin coffee in the world from

ABOUT THE AUTHOR JONATHAN ROBINSON is the founder of Bean There coffee.

R E C YC L A B L E PAC K AG I N G & P R AC T I C E S

Recycling advances circular economy goals Mondi’s award-winning BarrierPack Recyclable all-polyethylene film is now certified for recyclability. This lightweight mono-material offers a sustainable packaging solution for diverse applications and ranges from stand-up pouches to resealable pouches.

T

he Institute for Recyclability and

be wrapped in a water-soluble film instead

Product Responsibility in Germany

of polypropylene (OPP) wrapping, further

independently tested the material

reducing waste.

and issued a certificate. It rated it as 95%

"We believe that there is no single route

recyclable in those areas where suitable

to sustainability. We collaborate closely with

recycling infrastructure is in place.

our partners to create bespoke solutions

Mondi recently partnered with Yarrah

ensuring that our customers can deliver on

Organic Petfood to develop sustainable

their sustainability commitments," Graeme

packaging for its certified organic Yarrah

Smith, head of product sustainability,

and Dano pet food brands. Yarrah wanted to

flexible packaging and engineered materials

introduce a fully recyclable pouch to replace

at Mondi points out.

a multilayer laminate packaging, which was

Mondi’s new allPE recyclable packaging earned green certification

Mondi is a signatory of The New Plastics

difficult to recycle to keep it in a circular

Economy Global Commitment, committing

economy. The pouch needed to be resealable

to 100% of plastic-based packaging being

to keep pet food and snacks fresh.

reusable, recyclable or compostable and

Working in partnership with the

25% being from recycled content by 2025

manufacturer of a private-label product,

(food regulations permitting) and are co-

centric EcoSolutions approach, it continues

Mondi helped UK supermarket chain

founders of the Circular Economy for Flexible

to explore new opportunities to close the

Tesco bring to market a fully recyclable

Packaging (Ceflex).

loop in the circular economy. •

mono-material pouch for its dishwasher

The company offers many more

tablets. With the switch to BarrierPack

applications for fully recyclable mono-

Recyclable, the individual tablets can now

material pouches. As part of its customer-

Mondi – www.mondi.co.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

Plastics industry flexes its muscles The South African plastics industry is defined as a priority sector by government and forms an important part of the South African economy.

T

he sector employed roughly

carbon, climate-resilient and sustainable

60 000 people during the past

society. The plastics industry can play

financial year. It also converted

a valuable part in assuring this gaol. It

just over 1.8 million tonnes of polymer into

is keen to partner with government to

plastics products during 2018. Another

demonstrate how plastics products and

positive is that converter demand grew the

recycling can help to create an adaptive

period – reaching 1 544 million tonnes of

strategy; strengthen the country’s

virgin polymer in 2018.

resilience and reduce our vulnerability to

As a commodity, almost every conceivable sector and industry uses

climate change.

• Life cycle assessments indicate

or relies on plastic with food packaging

that plastic products are more

just one sector that relies heavily on

environmentally friendly than other

this material. The sector is a valuable

materials if disposed of correctly and

contributor to the country’s output

recycled effectively

growth and employment with a multiplier

• Fit for purpose plastic, designed

effect of 3.7 per cent for every job created

with recyclability in mind offer

and 3.5% for every Rand invested.

a low carbon footprint and low environmental impact – often lower

THE HIGH COST OF LOADSHEDDING

than biodegradable products • Plastic bag manufacturers have

Conversion methods for plastic

removed fillers to produce fully

fabrication are electricity-intensive

recyclable bags. A 100% certified

and account for about 15 to 18% of

plastic material can now be used to

a manufacturer's operating costs.

produce carrier bags. This creates

Manufacturers and recyclers rely on

an end-market for recycled plastic

a consistent supply of high voltage

products and helps reduce waste

electricity for their machines to operate

to landfill

at maximum capacity and Eskom’s current

• Products become part of a circular

difficulties impacted negatively on supply and output.

• Persistent energy shortages disrupted businesses and machines that usually run 24 hours a day. This was due to lost power during the day and mid-operation • Raw materials and resources are wasted as machines must be scraped clean for start processes to start anew • Local plastics suppliers were unable to meet deadline and supply orders in time • Local suppliers are seen to be

economy by reusing products • The number of plastics recycled in South Africa during 2018 saved enough oil to fuel 200 000 cars for one year – travelling 30 000km per annum • Saved 246 000 tonnes of CO2 in 2018 – the equivalent of 51 200 cars • Provided direct employment to more income-generating jobs • R2.3 million was injected into the informal sector through the purchase of recyclable plastic waste.

government's plans to negotiate

SMART CITIES WITH WASTE MANAGEMENT INFRASTRUCTURE

supplementary power purchase

A smart city is taking shape in Lanseria.

agreements to acquire additional

The process is being led by the

capacity from existing wind and solar

investment and infrastructure office

plants. It is also in favour of the idea

of the Presidency with provincial

for successful municipalities to procure

governments of Gauteng and North West,

its power from independent power

working with Johannesburg, Tshwane

producers. A restructured power supply

and Madibeng.

The plastics industry welcomes the

in 2020 will go far in assisting the sector and allay fears about job cuts.

The plastics and packaging industry has been working closely with the Department of Environment, Forestry and

PLASTICS AND THE GREEN ECONOMY

Fisheries and other interest groups in

President Cyril Ramaphosa is committed

plan This will be built around the

to transitioning South Africa to a low-

beneficiation of waste. The development

40

Food Review | March 2020

Finance minister Tito Mboweni announced an increase in the plastic bag levy from 12c to 25c at the beginning of April 2020.

The Budget Review revealed that National Treasury will also be consulting on extending the current levy on plastic bags to all single-use plastics used for retail consumption, including plastic straws, utensils and packaging in 2021. An assessment of the current levy, including a clarification of the tax treatment of compostable bags, will be undertaken.

According to Plastics SA executive director Anton Hanekom, Minister Mboweni’s announcement of the increased plastic bag levy was clearly framed within the context of the green economy and conveyed the impression that the funds raised will be used to mitigate climate change.

"If the expected R250 million generated from raised levies is used to boost recycling and grow a circular economy, we would welcome and support the Minister’s announcement. Past experiences (such as the failed Buyisa e-Bag initiative) have shown that government views the plastic bag levy as an easy way to raise funds to pay for other projects that have nothing to do with the environment," Hanekom points out.

than 7 800 people and created 58 000

unreliable and more finished products are being imported into the country.

BAGGING HIGHER LEVIES

preparing an Industry Waste Management

of an Extended Producer Responsibility Scheme is also well underway.

In conclusion, Anton Hanekom executive director of Plastics|SA says, "We are carefully optimistic about the plans and strategies unveiled during the recent SONA. We are calling for a strong political will and decisive action to see these plans to fruition." •

Plastics|SA – www.plasticsinfo.co.za

To advertise in

Coffee

time

Anita Raath

Sales executive +27 (0)82 976 6541

Carla Melless

Sales executive +27 (0)83 260 6060

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

ADVERTISERS’ INDEX MARCH 2020 Aspirata.................................................29......www.nosa.co.za Bragan Chemicals...............................13......www.braganchemicals.co.za Brüker SA..............................................33......www.bruker.com/optics Busch Vacuum SA..............................23......www.busch.co.za Cama Group.........................................37......www.camagroup.com Certification Partner Global..............32......www.cpg.global Emirates SkyCargo........................ OBC......www.skycargo.com/emiratesfresh Endress & Hauser ..............................17......www.endress.com Eptech ..................................................42......www.eptech.co.za Extrupet .................................................7......www.phoenixpet.co.za Filmatic.................................................21......www.filmatic.com Heat & Control SA........................ 12, 20......www.heatandcontrol.com Huhtamaki........................................OFC......www.huhtamaki.com

Ishida.....................................................35......www.ishidaeurope.com ISW Shrink......................................... IFC......www.iswshrink.co.za Marel Further Processing BV...........25......www.marel.com Matrix Software...................................27......www.matrixsoftware.co.za PHT SA..................................................26......www.pht.co.za Plastics SA............................................41......www.plasticsinfo.co.za Polyoak Packaging..............................39......www.polyoakpackaging.co.za Radical Waters SA...............................28......www.radicalwaters.com Rentokil Initial......................................31......www.rentokil.co.za Specialised Exhibitions.....................30......www.propakcape.co.za Syspro ...................................................15......www.za.syspro.com TNA Packaging System SA .............19......www.tnasolutions.com Trempak Trading..................................5......www.trempak.co.za

NEW & USED FOOD MACHINERY – IN STOCK • A&K Corn Cutters & Huskers • FAM Dice, Slice & Strip Cutters • FAM TS-1D Transverse Slicers • FAM PMD Poultry & Meat Dicers • FAM 7944 French Fry Cutters • FAM 7407 Bean Cross Cutters • Feuma Apple Peelers • Femia Bean Snippers • Herbort Bean Top & Tailers

• Eillert 2-stage vegetable washers • Key 4” Hydro Food Pumps • Key Vibratory Shakers • Kronen GS10 Slicers • Kronen KUJ Dicers • Kronen Gewa 3800 Washers • Mado Meat Mincers • Ramon Bowl Cutters • Many Other Machines Available

CALL US NOW FOR A QUOTATION

Food Processing Systems & Technology, Paarl Tel: 021 - 868 -1594 | Fax: 021 - 868 - 1599 Visit us on http://www.eptech.co.za or mailto:info@eptech.co.za

KRANZLE KRANZLE STEAMER STEAMER

www.kranzle.co.za sales@kranzle.co.za sales@kranzle.co.z www.kranzle.co.za

WEB REVIEW HOME

NEWS

ABOUT

C O N TA C T

ELECTRA Electrically heated high pressure cleaning www.kranzle.co.za

sales@kranzle.co.za

BUTCHER MEAT PROCESSING EQUIPMENT

MATRIX SOFTWARE

BMPE is the leading supplier of superior quality New and Refurbished Food Processing equipment. Providing professional Service, equipment & spares. BMPE has extensive knowledge of current machines, technologies and consumables and provide a modern Service & Maintenance Department to support our customers throughout their process. Servicing a diverse range of customers, from large & small Butcheries, Abattoirs, Supermarket Groups and Franchise Outlets in the Food, Pet Food and other Manufacturing Industries.

BUTCHER MEAT

Matrix Software, specialist leading ERP software providers for the Meat and Food industry, offers various solutions to assist the factory floor function in production plants.

PROCESSING EQUIPMENT Tel: +27 11 664 8212

Tel: +27 11 664 8212info@bmpe.co.za info@bmpe.co.za www.bmpe.co.za www.bmpe.co.za

BMPE is the leading supplier of superior quality New and Refurbished food processing equipment to the African market.

Our primary focus is to provide a professional service to the food industry with regards to Equipment, Spares and the latest Technological innovation.

With more than 30 years hands-on experience, we provide our customers with an excellent service in all areas of the food processing industry and have over the years achieved a good For over 40 years Formpak reputation for being efficient, cost-effective and professional.

We import machines for our local clients across the whole of has supplied specialised Africa, ensuring that they benefit from machines of the highest qualityand at an excellent price. processing, packaging Our staff have extensive knowledge of current Machines, printing machinery to the and Consumables and we also provide a modern Technologies Service and Maintenance Department to support our customers pharmaceutical, cosmetic, throughout the process. plastic, glass, chemical, We service a diverse range of customers, from Large & Small Butcheries to Abattoirs, Supermarket Groups, Franchise Outlets food and dairy industries. and Corporates.

FORMPAK

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

DINNERMATES

Our diverse range of software offerings features a unique module listing of more than 700 modules (program nodes).

Our software solutions are tailored for the Feedlot/Abattoir/ Debone / Production Retail industries. Matrix Software is deployed in 8 countries throughout Africa, Australia, New Zealand and Seychelles. www.matrixsoftware.co.za

PARTNER FOR HYGIENE AND TECHNOLOGY Leading through Innovation PHT is the leading provider of state-of-the-art technology for hygiene and food safety. Our unique systems offer efficient, effective and sustainable solutions for your hygienic challenges.

We develop both individual and integrated hygiene solutions for your company. We are always there for you and we support you through our actions, professionally and reliably. Hygiene and food safety is our passion. We care about our customers, our suppliers and our people – we measure our success by the way we touch their lives. Because we care, we design innovative and holistic solutions.

Tel: +27 861 777 993 | info.za@pht.group | www.pht.group

QUANTUM COLOURS SA

• Supplier to the hospitality trade and food factories • Service excellence, Your No. 1 industry leader for the most comprehensive • Quality, portion controlled products ranges of both synthetic and natural colours – used in food, (chilled/frozen /dried) pharmaceutical, cosmetic and industrial applications.

• Innovation & Flexibility Our technical team is available to shade and Full demonstration positioned on the andrequirements this will match tostands specific and / or • Meat & chicken products tailored forof exclusive machines will be strategically colour receive a great deal of attentionPantone which references and to give legislative support special applications in the food industry will be of great interest to you our customer. We look forward to seeing you at the show.

• Dried meat products – real meat THE BMPE TEAM on colours. real flavour! www.quantumcolours.com Tel: +27 (0)11 032 8600 Manufactured, marketed and distributed under email: sales@dinnermates.co.ca

licence of SPECTRATEC INC. CANADA Tel: +27 (0)15 516 1515/4 email: factory@dinnermates.co.za/www.dinnermates.co.za Canada . South Africa . Ireland . Germany . Australia . UK