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MARCH 2021 Vol. 43 • No. 2
SOUTH AFRICAN JOURNAL FOR FOOD AND BEVERAGE MANUFACTURERS
Always the best way to weigh
Productivity boosters that will drive transformation Powerful solutions for full line integration Third line for food grade rPET installed
CONTENTS MARCH 2021 Vol. 43 • No. 2
32
FOOD SAFETY & COMPLIANCE Food analysis and quality control Pass your audit with these easy steps Calibration that gets you up and running in no time
11
Yamato South Africa announced the launch of the versatile TSDN3, which can be used for a vast range of applications and is especially well-suited for the processing of wet items.
6
12
Pushing the boundaries of new product development
Five predictions to drive transformation
WHAT’S NEW
8
NEWS CCPB recognised as top employer
Simplify pneumatics with these seven tips
FOOD PROCESSING TECHNOLOGY Servicing the trade on five continents
Support the local liquor industry now
The future of food, today
The count is on for SAAFFI’s annual seminar!
The benefits of effective oil management
How to eat for good
Inspection technology solutions that give you the edge
24
MEAT, FISH & POULTRY Powerful solutions for full line integration Driving innovation in processed meat alternatives
What influences the foaming properties of dairy and plant-based systems?
42
RECYCLABLE PACKAGING & PRACTICES
Testing drives efficiency and flexibility
Third food grade recycling line up and running
Safety solutions reduce food risk
Labels for the health of the planet
Grader performance enhanced with this new grader solution
Use RFID to transform your business
Eskort goes SAFE
www.foodreview.co.za
40
HOT BEVERAGES
MARKET WATCH
14
Secure your digital future, now
Get ready for EPR in plastics recycling
FOOD REVIEW | MARCH 2021
3
EDITOR’S COMMENT
THE TEAM EDITORIAL
Severely constrained consumers emerge from the COVID quagmire
F
study, Unlocking Consumption, in 2021 that identified a rapidly growing
Layout & Design: Naresh Budraj Contributors: Raymond Dube & Janusz Luterek ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za
South African consumers are navigating uncharted territory as they cope with the COVID-19 pandemic and its subsequent financial fallout. A whopping 78% of local consumers say they have changed their purchase behaviour since the pandemic began, with no prospect of this returning to 2019 levels anytime soon. indings stem from a new NielsenIQ
Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za
new consumer needs within their portfolios! In this edition, we really delve into some key issues that can impact profitability while
Sales Executive: Càndida Giambò-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
group of newly constrained consumers -
optimising output. Turn to page 14 for a
representing 66% of South African shoppers
comprehensive food processing technology
as compared to the 46% global average. Of
feature that looks at the competitive
the 15 countries surveyed, Thailand (73%),
advantage that can be gained through
Circulation Manager: Felicity Garbers felicity.garbers@newmedia.co.za
South Africa (66%) and Turkey (65%) had
functional ingredient and flavour system
PUBLISHING TEAM
the highest numbers of newly constrained
development, effective oil management and
General Manager: Dev Naidoo
consumers across the globe.
inspection technology solutions for greater
Production Controller: Mandy Ackerman
F&B output. To round off this edition, we look
Art Director: David Kyslinger
challenges faced by large numbers of South
at the latest innovations in the meat, fish
JOHANNESBURG OFFICE
African consumers, they are employing new
and poultry industry (page 24); how to keep
coping mechanisms to manage household
your facility audit-ready; and a very exciting
budgets - including selecting products
development at Extrupet with the installation
based on promotions, irrespective of brand,
of its third food-grade rPET line (page 42).
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EDITORIAL ADVISORY BOARD
4
Two doctorates in chemistry; leader in the field of palm oil; SAAFoST president 1993-2001 and honorary life member; past president, Society of Cosmetic Chemists SA.
With a PhD in biochemistry, an MBA and a Institute of Brewing and Distilling diploma Heidi also serves on the Innovation Hubs BioPark and UNISA’s Life Science advisory board.
Dr Aubrey Parsons
Dr Heidi Grimmer
Managing director of Symrise South Africa; chairman of SAAFFI.
CEO of Stratcom Branding, founding member of the glba (Global Local Branding Alliance)
Rudy McLean
Gail Angela Macleod
MARCH 2021 | FOOD REVIEW
Food Review is published by New Media Publishing (Pty) Ltd 11 times a year and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher. The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost.
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2- 3 INTERNATIONAL CONFERENCE ON NUTRITION AND FOOD SCIENCES New York, US www.waset.org 7 – 8 FOOD SAFETY TECHNOLOGY SUMMIT Online www.foodsafetytechnologysummit.com
May 18 - 20 FRUIT LOGISTICA Berlin, Germany www.fruitlogistica.com 18 - 20 SIAL CHINA Shanghai, China www.sialchina.com 25 - 29 THAIFEX ANUGA ASIA Pak Kret, Thailand www.thaifex-anuga.com
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FOOD REVIEW | MARCH 2021
5
WHAT’S NEW
Kellogg’s innovates on-trend products
Following the tremendous success of their current Granola range, Kellogg's has launched two delectable new flavours. Kellogg’s Nutty Delight, with almonds and cashew nuts, and Tropical Burst, with pineapple, papaya, banana chips, raisins and coconut, are the perfect way for consumers to indulge. This is in line with Granola consumers demanding variety and a multi-sensorial food experience through wholesome, tasty, and premium ingredients. In addition, Coco Pops has extended its range to include Coco Pops Fills – a more crunchy and chocolaty addition. This exciting innovation offers South African youth (and those who are young at heart) a breakfast or snacking offering that is great on its own or with milk. •
Enjoy an Eggciting new range of Easter eggs Cadbury is back with an eggciting new Easter range. There's the melt-in-yourmouth chocolate covered Fluffies Mallow Eggs and chocolate Hollow Eggs filled with Whispers or Astros. New to the range are the scrumptious candy-coated chocolate Hen’s Eggs and the delicious Dairy Milk 170g Top Deck Bunnies slab. Cadbury is also introducing delectable Mini Eggs as well as the popular Creme Eggs into the local market.
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MARCH 2021 | FOOD REVIEW
Sir Fruit’s immunity health shot packs a punch South Africa’s favourite premium juice company has put together the new Immunity Booster Shot - packed with only the good stuff to keep you healthy throughout the period of COVID-19 and thereafter. Using a combination of cold-pressed juices, extracts and added vitamins, each health shot packs a punch. The immunity shot comprises of cold-pressed orange, apple, ginger, turmeric and lemon, with a good dose of Echinacea and vitamins. Each 100ml shot contains: • 1 6% RDA vitamin B3: Helps convert food into energy, keeping the nervous system and skin looking healthy. • 2 4% RDA vitamin B5: Like other B vitamins, pantothenic acid helps your body obtain energy from food and assists in hormone and cholesterol production – much like liver, fish, yoghurt and avocado. • 3 5% RDA vitamin B6: Helps the body use and store energy from protein and carbohydrates in food and form haemoglobin - the substance in red blood cells that carries oxygen throughout the body.
• 25% RDA vitamin B12: Perhaps the most well-known of all the B vitamins, B12 is vital for neurological function, DNA production and red blood cell development. • 100% RDA vitamin C: Helps to protect cells and keep them healthy. It supports healthy skin, blood vessels, bones and cartilage, and aids in wound healing. • 1 66% RDA vitamin D: Helps maintain normal blood levels of calcium and phosphorus, which strengthens bones, teeth and muscles. “The idea for this shot came about at the start of lockdown. We were talking about how we could help South Africans be as healthy as possible and specifically what we could do to play our part during the pandemic. We all agreed that getting the correct nutrients and a sufficient amount of these was an important part of building up people’s immune systems. So, we set about developing a health shot with as much good stuff in it as possible,” says head of marketing, Roanne Goldsmith. •
McCain launches the crispiest chip yet McCain SureCrisp is a new plant-based coated chip that holds its crispiness for up to 30 minutes, allowing chips to be served crispy and delicious, the way they’re meant to be served. Food items for delivery and takeaway have grown in big strides over the last couple of months. Ensuring that in-restaurant experience, when your customers are not dining in, is critical to maintaining loyalty. The extra holding time means you can maximise consumer satisfaction and loyalty – even with delivery and takeaways – and increase your order rate and profits.
Are you READY? 2020/2021 Food Review/ Symrise
New Product Competition Since its inception, the competition’s primary
platforms. The grand prize also includes a trip
goal is to provide local and international brands,
to SIAL Paris 2022, one of the world’s most
featured on local shelves, the opportunity to
exciting trade shows where future trends are
showcase their innovative new products.
set. Don’t miss this opportunity for your first-
Entrants and winners will receive extensive exposure throughout the magazine’s various
row view of the latest developments in global food and beverages.
Entries are now open,
and close on 1 June 2021! For more information, please contact Maryke Foulds at maryke.foulds@newmedia.co.za or give me a ring on 082 569 2330 to discuss.
NEWS
NESTLÉ FOCUSES
ON NUTRITION
Coca-Cola Peninsula Beverages once again recognised as a
TOP EMPLOYER
The company has been recognised as a top employer for 2021 – its 11th consecutive award. This year, CCPB joins 221 companies across 32 African countries who have all been certified as Top Employers for outstanding HR strategies and people practices. The Top Employers Institute programme awards the certificate based on people strategy, work environment, talent acquisition, learning, wellbeing, diversity and inclusion. “This award embodies the importance of culture and the role leadership plays in ensuring we have a great and enduring culture,” says Bryn Morse, culture and people development director at CCPB. Morse believes that everyone within the company is a leader, either of themselves, others, or both. “Having a clearly defined set of values and a purpose is essential and contributes towards having a great culture. At CCPB, a co-created purpose unites team members in striving towards a common goal – ultimately helping everyone understand the importance of the role they fulfil in the company irrespective of the position held. “Continuous improvement remains one of CCPB’s core values and has been in place for some time. The development of our team members throughout the organisation remains a top priority,” he explains. CCPB established a Leadership University in 2018 to further enhance the skills and development of team members. Attendance is open to all team members. The COVID-19 pandemic put companies to the test as many faced the challenge of being able to support their employees during the lockdown period. CCPB’s ethos of “people are no.1” was the leading light in protecting its people, their jobs and keeping them safe from the virus at the workplace. This included implementing health and safety protocols and adopting policies which included adapting to working remotely, counselling and medical support, through to adjusting to new operating processes. •
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MARCH 2021 | FOOD REVIEW
South Africa recently convened representatives of PnP, the University of the Free State and former executive director of the Human Sciences Research Council (HSRC), Professor Demetre Labadarios, to discuss a consolidated view of the state of childhood nutrition in South Africa. The webinar was hosted under the banner of Nestlé’s flagship nutrition programme, Nestlé for Healthier Kids, which aims to educate parents and caregivers on how to make better food choices for their children. The programme has a global ambition to support 50 million children to live healthier lives by 2030. According to the 2019 South African Child Gauge Report, child obesity continues to rise in South Africa. At least 13% of children under five are overweight or obese, while one in four has chronic malnutrition and stunted growth. This increasingly concerning reality has the potential to worsen and result in approximately 3.91 million overweight and obese school children by 2025. Zumi Njongwe, marketing director at Nestlé ESAR, explains: “Nestlé for Healthier Kids is dedicated to educating parents and caregivers on how to make healthier food choices for their children in a practical and easy-to-implement way. As part of our efforts, we established this group of experts to raise awareness of the impact of unhealthy eating habits on children and engage with multiple credible stakeholders on the roles to be played in supporting individuals’ and families’ access to healthy food and making healthier food choices daily.” The webinar focused on opportunities for collaboration between public and private sectors, innovation in nutrition marketing, as well as community nutrition. A key takeaway of the discussion was that many communities often don’t have the benefit of scientific knowledge and evidencebased information. “This provides an opportunity to correct nutrition misinformation and to promote nutrition in low-income areas where information often does not reach those who need it,” said Dr Lucia Meko, lecturer of nutrition and dietetics at the University of the Free State. •
WHY IT’S CRITICAL TO SUPPORT THE LOCAL LIQUOR INDUSTRY Diageo South Africa has assisted more than 400 on-premise establishments, including bars, taverns and restaurants, to rebuild their businesses after the COVID-19 lockdowns. A total of R200 million in stock replenishments, cash, and marketing support has been given. The #WeChoose campaign was also launched by Diageo in Johannesburg, Durban and Cape Town in March. It aims to promote responsible drinking as well as help rebuild on-premise establishments hit by repeated lockdowns totalling many months of closure or very restricted trade hours. “We want to see businesses thrive again and people to be able to come together, but we aim to do this responsibly in terms of both trading safely and consuming responsibly,” said Diageo SA’s marketing director, Zizwe Vundla. •
EVENT
THE COUNT IS ON FOR THE
19th ANNUAL SAAFFI SEMINAR If there is any truth in Rosa Parks’ illimitable quote ‘One person can change the world’, then how much faster and more effectively can an entire industry sector change the world for good?
T
he 2021 annual SAAFFI seminar themed “Save the Planet – WAKE UP, GROW UP, SPEAK UP!”, aims to highlight
online events.” Bolel continues, “The organising committee has been creative in putting together a
interesting additional angle of the effect of changed consumer behaviours due to Corona. The growing interest in plant-based
initiatives in the flavour, fragrance and
programme which incorporates world-class
foods and the impact on product concept
related sectors currently influencing thought
speakers, an interactive workshop and a
and development is sure to be of interest to
and practice in the areas of environmental
brilliant set-up to facilitate networking
the broader food industry. Neil Taylor, chief
awareness and actions towards sustainability.
and meetings.”
operating officer at Infinite Foods will share
The flavour and fragrance sector has much to
International speakers include Maxime
teach in this arena, and are viewed as leaders
Marchal, sustainability project manager for
in environmental initiatives internationally.
IFRA and IOFI, as well as public affairs manager
Much has been said about recyclable
at IOFI, and Dr Berangere Magarinos-Rouchat,
and refillable packaging. Dan Moleto of the
chief sustainability officer, Firmenich.
Refillery, will lead delegates on a journey
The virtual seminar, which will be held over two days, 20 and 21 April - offers a programme packed with exciting offerings.
Prof Nick Binedell, Strategy Professor at
some insights from the “inside” of this community.
through the refill revolution.
Sharon Bolel, assistant executive director
GIBS Business School, will present a keynote
Attendees are sure to take away added
of SAAFFI enthuses, “The online conferencing
closing address on economic implications for
skills, useful information, and a solid dose
package is a sophisticated platform that
South Africa resulting from the pandemic, and
of career-oriented motivation. For more
more-than replicates a live convention. We
strategies to deal with these effects.
information, and to book for the event, go to
are excited at the prospect of using ground-
Flavour and fragrance trends presentations
breaking technology partners to introduce
are always a highlight of the SAAFFI event and
our delegates to a new and exciting world of
this year the topic will be presented with the
https://saaffi.co.za/events/
SAAFFI - www.saaffi.co.za
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FOOD REVIEW | MARCH 2021
9
NEWS
EAT FOR GOOD
TO COMBAT CLIMATE CHANGE
Knorr, Unilever’s largest food brand, has teamed up with Mr. Potato Head, the world’s most famous vegetable icon, to call on people to change the world by changing what’s on their plates. While most people are aware that climate change is a global emergency, most aren’t aware that the foods they eat play a vital role in helping to combat climate change. Food is the single strongest lever we have to optimise human health and environmental sustainability on Earth, but 70% of people surveyed across 50 countries ranked plant-based diets last as a solution for addressing climate change.
KRONES
The food system is responsible for approximately 25% of all greenhouse gas emissions, with 60% coming from animals. If everyone takes action to consume foods that are better for people and the planet (Future 50
CONSOLIDATES BREWERY BUSINESS
Foods) grown in sustainable, restorative, regenerative ways, we can lower
For the past 145 years, the Steinecker brand has been synonymous with brewing technology. By combining Steinecker technology with its own portfolio, Krones has positioned itself as a one-stop supplier in the brewing and beverage space. Krones wants to be there for its clients as a partner they can rely on whenever they need assistance. As part of this thrust, Krones has decided to focus meaningfully on plant and equipment construction in process technology. Beginning in April 2021, the newly founded Steinecker GmbH will offer all the solutions and equipment required in a brewery, from raw materials reception right through to the finished product. The company’s portfolio will be supplemented by appropriate after-sales and service concepts. The Krones facility near Munich, Germany, will in future be Steinecker GmbH’s headquarters. The 450-strong team comprising experienced brewery and beverage experts, engineers, technologists, project managers, and automation and production experts - will continue to look after their brewery clients’ projects globally. The entire project planning and processing team, the engineering, production and erection/installation departments, plus the product development operation, will be represented at this facility. One major focus will be on a sustainable, energy-efficient, CO2-neutral brewing process. The company’s own experimental brewing facility, the Steinecker BrewCentre, is the perfect supplement here, offering a basis for developing innovations and upgrades of products used in the brewing process. •
25% of Knorr’s product portfolio will contain the Future 50 Foods, 50% of its
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MARCH 2021 | FOOD REVIEW
the impact of the food system on climate change and future-proof our favourite foods for generations to come. Knorr is committed to helping lower the carbon footprint of its products: portfolio will be plant-based and 100% of Knorr’s vegetables, herbs, cereals and top five spices will be sustainably sourced by 2025. Currently, 95% of Knorr vegetables and herbs are sustainably sourced, globally. Liam Walsh, sustainable diets manager at WWF-UK, says: “Many people aren’t aware that the global food system has a devastating impact on the environment. In fact, it’s one of the biggest drivers of climate change and nature loss on the planet. But we can all fight for our world through our everyday food choices by eating a wider variety of plant-rich meals and cutting down on meat.” April Redmond, global brand vice president, Knorr, says, “We want people to realise that what they eat has the power to change the world for the better. World Eat for Good Day is a significant next step in our mission to reinvent food for humanity. Our ambition is to make eating a wider variety of foods that are better for us and the planet. We want to get food that is good for people and the planet on billions of plates by 2025.” Knorr’s commitments and World Eat for Good Day are part of Unilever’s Future Foods commitments, which will help people transition towards healthier diets and contribute to a new annual global sales target of €1 billion from plant-based meat and dairy alternatives by 2025-2027. •
COMPANY FOCUS
Productivity boosting
semi-automatic weigher gives you the edge Yamato South Africa is based in Kyalami and is the SA subsidiary of Yamato Scale Dataweigh UK, based in Leeds. Yamato is a leading global manufacturer of commercial weighing and detection equipment.
FAST FACT
T
he highly versatile TSDN3 can be used for a vast range of applications and is especially well suited for the
processing of wet items such as meat, poultry and fish, delicate products such as fruit and vegetables, as well as ready meals including noodles and pasta. Yamato Scale’s specialist engineers designed the TSDN3 to provide enhanced levels of hygiene with its stainless steel construction and easy, tool-free removal of conveyors to enable fast and efficient cleaning and sanitisation. The 14-head semi-automatic weigher is IP67 compliant and operates at speeds of up to 50 weighments per minute. It is suitable for both mixing and counting applications and its compact footprint means that it is the perfect space-saving option for growing businesses. The TSDN3 is fitted as standard with a 10.4 inch colour, touch-screen control unit
1. Yamato Scale Dataweigh UK, based in Leeds, is the UK business of Yamato, a leading global manufacturer of commercial weighing equipment 2. T he company celebrated its centenary in 2020. 3. A s a pioneer of multihead weighing technology, the company provides multihead weighers that are both eco-friendly and innovative to meet the needs of manufacturers today. 4. In 1988, Yamato was the first weighing company in the world to create mixing-software for multihead weighers that would enable the precise weighing of mixed applications. The introduction of the Touch Screen Command Console in 1989 revolutionised the handling and controlling of the multihead weigher. 5. Its range of multihead weighers and checkweighers are energyefficient, accurate, hygienic and easy to operate. The Dataweigh Omega multihead weigher boasts a 60% reduction in power consumption without compromising on speed or effectiveness. 6. Yamato holds over 400 patents worldwide and is continuously developing new technologies to provide better weighing solutions for customers. 7. Yamato has established an extensive worldwide network of local sales agents and agencies.
to have valuable control and insight into the cause of any problem so that it can be prevented for future production. Ian Aitchison, Yamato Scale’s product manager multiheads and export sales manager says, “The semi-automatic function of the TSDN3 increases yield and productivity, while at the same time reducing labour costs. Manufacturers that switch to automating this part of the production line will therefore benefit from a full return on their investment within six to 12 months. “Additionally, the TSDN3’s hygienic design and robust stainless steel construction means that it can be hosed down. The water will drain away freely – so there are no areas for water to sit and turn into bacteria traps, making it ideal for applications where the risk of contamination from unclean surfaces is highest. “The TSDN3 has two conveyor belt sizes to choose from, but each machine has a compact footprint. Plus, it’s a mobile system
which provides real-time data that can stored in a central computer. It is also compatible with Yamato Stats, a fully automated data collection system, running from a server
that can be moved around the factory, giving manufacturers flexibility and the ability to move it to a designated cleaning area to maintain maximum standards of hygiene.” •
or PC, that provides manufacturers with a complete inspection and data collection solution. This allows food processing firms
Yamato - www.yamatoscale.co.za
FOOD REVIEW | MARCH 2021
11
MARKET WATCH
5
Predictions to drive transformation
Phil Lewis
Unforeseen disruptions experienced in 2020 prompted F&B producers to future proof their businesses. Focusing on expediting time-to-market; food quality and safety; supply chain resilience and the creation of omni-channel models will place companies in the strongest position to embrace and capitalise on future opportunities. By Phil Lewis.
O
perational excellence is driving
the need to become more efficient and
supply chain outside of the four walls of the
successful outcomes across many
reduce food, water, and energy waste, only
factory and uses data from farm to fork to
of these initiatives, as firms look to
a limited amount of food processors claim
increase quality and productivity, reduce
optimise resource efficiency, whether people,
using IoT, with a staggering amount have no
food waste and minimise food safety risks.
energy or water. Precision is becoming
plans whatsoever.
In turn, this can turn challenges into a
imperative coupled to technologies such as
These findings could be explained by
competitive advantage.
IoT critical in minimising waste while
the fact that until now, we have seen some
maximising output.
experiments in isolated domains, such as
recognition and machine learning (ML) to
Other applications are using image
image recognition in inspection equipment, IoT
dynamically determine the quality of received
WHAT DOES THE FUTURE LOOK LIKE FOR FOOD PRODUCERS?
devices in farming or in production lines. Yet
ingredients and using that to determine the
there appear to be few examples of IoT being
purchase price. Something which would have
Prediction 1: Cloud… There’s little doubt
used widely to drive operations. For example,
a big impact on food safety would be the use
that cloud is set for huge growth as a means
production machines have sensors to capture
of IoT sensors to check whether equipment is
of creating robustness and agility. Frankly,
a lot of data like temperatures and other
clean, with the results triggering a cleaning
there is no other way when you look at what
quality parameters, but all data remains in
order to avoid contamination risks, which
the business is asking for. It’s crucial in fully
the machine and is lost and meaningless after
brings us on to the next big trend 2021 is likely
capturing data from IoT devices and the
the production run.
to see. Prediction 5: Transparency to the
extended supply chain. There’s little point in
Product recalls are one of the greatest
having temperature readings in a structured
financial risks food and beverage companies
consumer… Consumers want more in-depth
ERP database that sits safely within the
face. Yet research shows that no firms claim
information about products to help
company’s firewalls.
to be completely digital for track and trace
drive their purchasing decisions. It’s
and quality management. The good news is
important to demonstrate the efforts being
kind of technology at hand as a service
that in 2021 more food producers will have
generated into sustainability credentials to
instead of having to do a lengthy IT project
paved the way by having a digital platform in
consumers. We are seeing a growing number
to implement something that will not scale.
place to capture data and connect this to the
of retailers putting pressure on producers to
Cloud also represents an opportunity to
transactions in their ERP system.
provide information.
A big advantage of cloud is having this
implement changes faster opposed to having
Prediction 4: Data driven… A digital
to do technical migration projects which often
platform makes it possible to use IoT in a
be expanded to more product categories and
require teams to take a step backwards before
more holistic way. The first benefit of this
used to differentiate producers and prove the
being able to move forwards.
is that faster and more targeted recalls
sustainability of the supply chain. This means
will be possible, with the ability to identify
extended control of the supply chain from
producing companies have seen a huge
and analyse the root cause of the issue
farm to fork and identifying whether the crop
shift in demand, with home deliveries
immediately. The second is that data can be
is GMO-free, what kind of crop protection has
taking precedence over restaurants and
used to drive decisions and create a smarter
been applied, and other factors. •
supermarkets. This trend is unlikely to snap
company. A good example is having insight
back to pre-pandemic levels as consumers
into the inbound overseas shipments of crops,
have simply become more used to ordering
not only with regards to their estimated time
their food online. Being omni-channel makes
of arrival, but also the storage conditions
the business less vulnerable and able to take a
during transportation so that quality and
larger piece of the market.
use before dates can be predicted more
Prediction 2: Omni-channel… Food
Prediction 3: Industry 4.0 tech… Despite
12
MARCH 2021 | FOOD REVIEW
accurately. This extends the control of the
In 2021 and beyond we will see that this will
About the author: Phil Lewis is Infor VP Solution Consulting for the EMEA.
Infor - www.infor.com.
SOUTH AFRICAN MANUFACTURER OF
SPECIALISED FOOD PROCESSING EQUIPMENT
With our experienced design team and Paarl based factory, our production capabilities are endless.
With over 45 years experience in the production of Industrial Cooking Equipment, we have extensive expertise to custom design and manufacture quality, highend equipment to meet your food production needs.
2000Ltr Cooker/Mixer pot in production
Our range is not limited to: • Steam Jacketed Kettles ranging from 20-2000 litres
• Pressure Kettles • Bin Hoists
available in various configurations • Vacuum Cookers
• Combi-Ovens
• Sauce / Jam Pots
• Conveyor Ovens
• Mayonnaise Plants
• Homogenisers
• Continuous Conveyor Fryers
• Confectionery Cutting Tables
• Transfer Vessels
• Foot Operated Wash Hand Basins
• Holding Tanks
• High Shear Blenders and more….
• Steam / Electric Tilt Frying Pans
CAPDAN AND ALLIED EQUIPMENT (PTY) LTD Benoni Office: +27 (0) 11 969 3407 Paarl Office:
+27 (0) 21 862 6110
sales@capdan.co.za Soup Plant with Hoist
www.capdan.co.za Jam Plant
FOOD PROCESSING TECHNOLOGY
Crowning excellence for 110 years
Crown Ingredient Solutions is a wholly owned subsidiary of Crown Food Group and is a proud member of the Bidcorp Group which originated in South Africa and now serves the food and hospitality trade on five continents.
E
very day, these products make their way into millions of kitchen cupboards around the world. “We subscribe to
a philosophy of ‘We’re here to help’,” says Francois Van Schalkwyk, general manager at Crown Food Ingredients. “By upholding values of transparency, accountability, integrity, excellence and innovation in all our business dealings, we have secured an exemplary reputation in both the local and the international business arenas.” Crown is driven by a steadfast commitment to customers and aims to provide service excellence through innovation and technology. This mission is augmented by synergistic partnerships with customers by understanding their needs and offering bespoke solutions using reputable
“Our state-of-the-art Centre of Excellence, which is staffed by food scientists, microbiologists and food technologists, gives the group a competitive advantage in groundbreaking product design and research of functional ingredient and flavour system development”
associations with prominent international food bodies, suppliers and marketing resources within the industry. Crown also has a close association and joint venture with Griffith Foods.
HERBS & SPICES Crown is proud of its heritage. Coupled with a passion for quality, thirst for knowledge and a drive for transformation in this ever-evolving industry, it has become a prominent food ingredient manufacturer and supplier of functional ingredients, spices, herbs, dehydrates, seasonings, sauces and condiments to sub-Saharan Africa. “We ensure that all materials are procured from GFSI certified establishments globally, who are audited to maintain excellence. We further remain vigilant about improved and safe farming from our suppliers, production
international supplier ingredients.
and processes. Our range of ingredients is
“Our state-of-the-art Centre of Excellence, which is staffed by food scientists,
to conduct pilot plant trials. All production
sourced and procured against EU and Codex
microbiologists and food technologists,
remains mindful of our customers’ religious
compliant specifications and our inbound/
gives the group a competitive advantage
requirements,” he points out.
outbound controls include quality control,
in ground-breaking product design and
To ensure that the company remains
quality assurance, chemical safety
research of functional ingredient and flavour
relevant to market needs with access to
and microbiological analysis,” Van
system development, as well as a facility
global trends, they have secured close
Schalkwyk explains. continued on page 16
14
MARCH 2021 | FOOD REVIEW
CROWNING FOOD WITH
EXCELLENCE
With great pride in our heritage, a passion for quality, a thirst for innovation, and a drive for excellence, we have secured our reputation at kitchen tables across the globe. This has been achieved through our stringent Microsafe® Food Safety Programme, and our dedicated food scientists and processing specialists who perfect stabilising solutions for our dairy customers. We have further demanded improved and safe farming standards for our herbs and spices range. So, when it comes to upholding the highest standards that exceed both your needs, your customers’ expectations and that of your favourite food, you know you can count on Crown Ingredients Solutions.
FOOD PROCESSING TECHNOLOGY
The future of food processing today Food manufacturers face a wide variety of challenges. These include the need to offer a wider variety of products and reformulating recipes more often. This is the view of John Mössner, head of applications engineering at HG Molenaar.
F
ood processors are constantly looking to improve manufacturing, production and supply chain efficiencies. At the
Equipment design has been improved, there are new and better laboratory
same time they need to meet demand for
services, and companies have adopted
greater volumes, reduce manufacturing
Industry 4.0 technologies, which has been
costs, and maintain production output.
accelerated due to lockdown caused by the
Many producers use food retorts for in-container sterilisation. It is a reliable
global COVID-19 pandemic. Different heating options are more
process to achieve commercial sterility
suited to specific types of food and
while preserving product flavours and
beverage products. This typically limits the
nutritional value.
use of the retort based on the application
This traditional technology has benefitted
John Mössner
deal with their complex requirements.
required. Consequently, when consumer
from several innovative advances as well as
behaviour changes, demanding different
supporting technologies and services to help
types of packaging, advances today make
modern food processors and manufacturers
it possible to retrofit different modules to
continued from page 14
MICROSAFE FOOD SAFETY PROGRAMME
FSSC22000 compliance, Microsafe demands
flavoured milk, desserts or beverages, the
Crown understands that food safety is one
the implementation of a range of additional
Stabilait range of superior-quality stabilising
of the biggest risks faced by food processors
food safety initiatives including, but not
solutions meets the complexities of any
and it proactively responds to global demand
limited to:
dairy product.
for food safety standards. For this reason,
• Near-infrared technology for the QC of
the Crown Food Group implemented the Microsafe programme to ensure absolute food safety.
Complementing its stringent BRC and
dairy ingredients. • Procurement from suppliers who have passed the SQA or supplier quality audit. • Quality control of incoming shipments.
FAST FACT
Crown Ingredient Solutions represent these international principals: • Cargill - Hydrocolloids, texturising solutions and cocoa • Dr. Suwelack Fermentation flavours • Emsland Group - Potato and pea starches and protein • Novozymes - Enzymes and microbes • Crown - Emulsipro and derivatives • ICL - Tari, Joha, Brifisol and Solva
• High pressure liquid chromatography for
optimum stability in the fresh, fermented, long life dairy and beverage industries, as well as processed cheese. Its strength lies in its range of characteristics:
capsaicin content of chillies.
• Quality - ingredients
• Microbiological analysis of pre- and poststerilisation samples. • Metal detection and X-ray scanning to
• Reliability - FSSC22000 and BRC • Suitability - formulation principles/ international associations
detect possible ferrous and non-ferrous
• Efficiency - processing experts
contaminants.
• Functionality - viscosity, moisture binding,
• Microsafe steam sterilisation of herbs and spices to ensure conformance with government regulations for microbial loads. • Quality assurance of finished products, with certificates of analysis to customers.
fat reduction stabilisation and enhanced texture • Optimum - all the above in a one-bag solution “With excellence at our core, Crown Ingredient Solutions will continue to
STABILAIT
innovate products and solutions of the
In its quest to be a dairy and beverage
highest standards that exceed both our
stabilising solutions leader in Africa,
customers’ needs and their expectations,”
dedicated food scientists and processing
he concludes. •
specialists develop and perfect stabilising specifications of dairy customers.
MARCH 2021 | FOOD REVIEW
Stabilait offers advanced, specialised, and custom ingredient solutions for achieving
the detection of aflatoxins, Sudan Red and
solutions to fit the demands and
16
Whether yoghurt, processed cheese,
Crown Ingredient Solutions – www.crowningredientsolutions.co.za
FOOD PROCESSING TECHNOLOGY
“Laboratory services that help the food processors understand the heat distribution and heat transfer are increasingly invaluable in meeting stringent quality requirements,” he says. “Equally, laboratory services that lean on that skill and experience help food processors improve recipes in competitive and saturated markets.” Maintaining the equipment and ensuring maximum production output is a key focus. Industry 4.0 technologies are being rolled out to support field operations, resulting in different levels of remote support via online access to the equipment and the use of augmented reality (AR) technologies. “Helping food processors overcome the change the heating option most suited to that specific packaging.
food processing operation.” There is more to a retort than just the
“Having one retort that is capable of
challenges they encounter, has shaped these innovative new solutions and services that
mechanical components. It is the sum of
we offer,” says Mössner. “We’ve put all of
both steam and spray gives food processors
the experience and skills that go into the
our more than 70 years of experience into
options that make them more flexible in
design, which is crucial to the scientific
creating the most advanced solutions based
meeting market demands,” Mössner points
process behind achieving commercial
on dependable and reliable engineering.” •
out. “It also maximises the returns on their
sterility. Heat distribution and heat transfer
investment in the retort itself as well as
are two separate yet ferociously important
the baskets that go into it. That becomes
considerations. They determine the quality of
increasingly important as you scale up the
the product that emerges from the retort.
HG Molenaar – www.hgmolenaar.co.za
RETORTS YOU CAN RELY ON. EVERY TIME. Commercial Sterility that’s accurate and preserves flavours.
The Molenaar range of Steam, Water Spray and Full Immersion retorts offer unparalleled processing quality due to their proven heat distribution and heat transfer characteristics. This ensures the highest safety standards in food processing. They offer flexible multi-mode functionality to process a wider range of products. Molenaar retorts can be further enhanced using innovative energy recovery systems, automated loading, and materials handling technologies. Contact us today for innovative equipment, proven systems, and skilled service that meet your needs. hgmolenaar.com
FOOD REVIEW | MARCH 2021
17
FOOD PROCESSING TECHNOLOGY
The secret to frying success:
3 lesser-known benefits of effective oil management For over a decade, concerns around acrylamide have put frying processes and oil management under the spotlight, writes Arnaud Jansse.
I
n the wake of announcements from the
becoming increasingly aware of the nutritional
World Health Organisation (WHO) that
value of the foods they consume, and more
the formation of this chemical during the
selective in their preferences. The frying
frying process posed a ‘major concern’ to
process is critical to the development of the
public health, food producers and equipment
flavours, textures and colours consumers
manufacturers quickly began incorporating
expect of fried foods such as potato chips
innovative oil filtration systems, precise
and French fries, but it also has significant
temperature controls and best practice on
implications for the healthfulness and overall
choosing the correct cooking oil for each application into their production lines.
quality of the finished product. Cooking in Florigo conti-pro PC 3 oil circulation system
It has since become common industry knowledge that these measures help mitigate
degraded oil for instance, can increase the risk of acrylamide formation, in addition to causing
An effective filtration system, however, can
products to develop off-flavours and an uneven
the factors that can lead to oil degradation
significantly improve oil turnover and reduce
and the formation of harmful chemicals, but
unnecessary waste by continuously cleaning
less well understood are the host of additional
the current batch of oil and blending it with
particles and used oil from the frying kettle, an
benefits effective oil management can offer
a controlled amount of fresh oil to return
advanced oil filtration system ensures products
food producers. Here we discuss three lesser-
the fryer to ideal levels. This helps keep total
known benefits of effective oil management
operation costs (TOC) to a minimum and
that can help food manufacturers create the
promote sustainability by allowing each oil
high-quality, craveable products consumers
batch to be used for as long as possible, without
expect while improving ROI.
compromising product quality.
1. Less waste, more profit
2. Food safety first
When producers overhauled their oil
The current coronavirus crisis has put an
management strategies to comply with the
intense focus on hygiene and food safety
new guidance on acrylamides, many might
and having efficient oil filtration management
not have realised that this would also help to
systems can benefit producers on this front
are always cooked in the highest quality oil
improve turnover, by optimising the amount
too. In frying operations, it is imperative that
for the best final result – keeping even the
of time an oil batch can be used before it
equipment be kept clean to maintain the
most discerning consumers coming back
either degrades or is absorbed by products.
integrity of the cooking oil. Fortunately, oil
time after time. An efficient oil management
Factors such as the physical characteristics
management measures adopted by producers
strategy also opens the door to using a wider
of the raw product or the type of oil being
in recent years can help streamline system
range of cooking oils with varying handling
used can all affect the turnover rate, but
cleaning and prevent cross-contamination
requirements, allowing manufacturers to
in most applications the total volume of oil
within lines.
cultivate the attractive nutritional profiles that
will eventually dip below optimum levels,
The continuous circulating motion created
colour and appearance. Through the continuous removal of loose
CIP nozzle
appeal to health-conscious shoppers.
necessitating an infeed of fresh oil into
by a good oil filtration system can help shorten
the fryer.
cleaning cycles by ensuring particulate material
acrylamides, savvy producers are already
left behind from sliced products does not settle
well versed in the oil management techniques
at the bottom of the fryer kettle. The reduction
they need to prolong the life of even the
in burnt-on debris allows for quicker and easier
most delicate oils, but many may not have
changeover between frying batches, reducing
recognised that this also enables them to
downtime and promoting a higher throughput
assure product quality and ultimately
of product – all while adhering to the highest
maintain profitability. •
After years of concern surrounding
safety and hygiene standards. 3. Quality is the best policy
About the author: Arnaud Jansse,
An additional benefit of efficient oil
applications engineer-product development
management, which producers often overlook,
(food technologist)
is the production of healthier, higher quality Florigo vac-pro 3
18
MARCH 2021 | FOOD REVIEW
products. As the current health and wellness trend gains momentum, consumers are
tna Solutions – www.tnasolutions.com
Materials Handling
Performance
Flexibility
Simplicity
Controls & AI
Project Management
Processing
End of Line
Coating & Seasoning
Packaging Cooling & Freezing
We put a lot into
Distribution
this one perfect fry.
Scan me for more details
FOOD REVIEW | MARCH 2021
19
FOOD PROCESSING TECHNOLOGY
Inspection technology solutions for greater F&B output
Consumers require high-quality, uniform appearance for point-of-sale products. This has driven the inspection business to solve many quality and productivity issues, beginning with empty container inspection, right through to full packs at the end of the line, writes Raymond Shead.
I
nspection systems now perform many
distortion to ensure that no closure defect
vital checks on every container at each
is missed. Typical defects include skew and
stage of food and beverage production.
broken caps, skirt colour and texture, bullnose
They quickly detect defects to help increase
defects and broken tamper bands.
productivity, reduce waste and downtime,
Other INTELLECT modules with compact
while protecting health, legal compliance and
form factors include Vision Pressure
the product’s brand name.
Inspection for bottles and cans, Vision
These units must be modular in design with
Inspection Solution for empty cans and
open operating architectures so that they can
Photon Inspection Solutions for full packs.
easily integrate with other compliant systems to provide information sharing solutions at
DID YOU KNOW?
each stage of production both on the line and throughout the plant. Inspection solutions must perform precise, critical inspection
The RB001 model
A filler management solution operating on a can line running at 1 200 cans per minute can
of every container using fast sensing and
INTEGRATING NEW SYSTEMS INTO EXISTING SYSTEMS WITHOUT PROHIBITIVE COSTS
return an estimated $225 000/
Platform addresses these requirements
New inspection technologies for the food
reduced downtime.
with its comprehensive family of unique
and beverage industries are considered
solutions that integrate measurement,
a requirement to elevate quality and
inspection and control technologies to
productivity. They must be designed to be
examine each container. Its modules utilise
easily installed at a low cost while taking
three principal non-contact technologies
minimal time to commission and train the
to inspect and track each container, namely
operators. This avoids the need to rebuild part
TECHNOLOGY TO BETTER SERVE YOUR CUSTOMERS
vision, photon and sensors. Vision modules
of the line to install a new piece of equipment,
The following inspection solutions summarise
inspect fill level accuracy, closure integrity,
something that all customers seek to avoid.
Filtec’s most common products that help
high-speed image capture to either accept or reject them according to quality standards. Filtec’s INTELLECT Container Inspection
label attributes, container condition and
INTELLECT Solutions come with
year through reduced overfilling, reduced sampling time and
save time and energy, while increasing
many more properties. Photon technologies
compact form factors that help avoid costly
productivity and preserving a premium brand
measure container fill levels when the content
engineering line reconfiguration. For example,
image for its customers:
is not visible. Sensor modules examine each
FILTEC’s unique Compact INTELLECT Photon
• Empty can inspection (ECI) is an intelligent
container for damage and the presence of
Filler Management Solution can be installed
automated machine vision system that
foreign objects. Powerful processors perform
between the filler and seamer on can lines.
tracks and inspects every incoming
each inspection with speed and precision to
It monitors and analyses the performance
container to prevent damaged or
ensure that both the quality specifications
of each filler valve to provide a complete
contaminated cans reaching the filler and
and productivity goals are met.
statistical data analysis of the entire filler.
seamer. Vision technologies examine the
Level measurement carried out between
shape and condition of the empty cans
connectivity from the plant floor (PLC,
the filler and seamer provides the exact fill
such that only high-quality items enter the
SCADA) to manufacturing execution systems
level for each container avoiding any spillage
process. This ensures that the downstream
(MES) with flexible open integration tools.
errors. It also supports efficient maintenance
filling and seaming processes can work at
Communication protocols include Modbus
planning and process optimisation.
the highest efficiency to reduce downtime
INTELLECT also provides complete
TCP/IP, OPC UA and OMAC. Inspection
The INTELLECT Compact Vision Closure
due to jams and increase productivity.
data is logged by each INTELLECT solution
Solution for bottles is another example of a
• Vision sorting solution for empty bottles,
and transferred to the MES platform for
form factor designed to fit into tight spaces
examine the shape, size and condition of
further analysis, process optimisation and
during the capping process. This module
bottles so that only correct, high-quality
plantwide reporting.
has a maximum depth of field with minimum
bottles enter the process.
20
MARCH 2021 | FOOD REVIEW
FOOD PROCESSING TECHNOLOGY
This ensures that downstream filling, closure
leaking containers prevents sealing failures,
terms of productivity, quality and profitability
and labelling processes work properly and at
product contamination and potential
for the food and beverage producer including:
the highest efficiency.
collapse of packaged cases.
- Base inspection
• Filler management solutions for cans and
• Vision shrink sleeve inspection: detects
bottles: comprises four applications that
label quality defects including sleave
- Finish inspection
includes fill level, filler valve monitoring,
positioning, bar code presence and label
- Foreign object detection
sampling and filler performance analytics.
damage. This helps reduce waste by
- Inner and outer sidewall inspection
The Solution tracks each container through
alarming and rejecting defectively labelled
- Date code inspection
the filler and closer or seamer and inspects
containers from proceeding further down
- ACL inspection.
the fill level, removing each non-conforming
the production line.
container. A quantitative analysis application
• Vision glue-on label inspection for bottles
- Capping flaws
THE BOTTOM LINE:
analyses the fill level performance of each
and applications include paper, plastic and
Automated inspection solutions improve
filler valve to pinpoint faulty and non-
ceramic labels where the discrete neck and
operations through continuous, high-
performing filler valves.
body labels cover part of the container. The
speed inspection of empty containers, full
inspection capabilities cover over twenty
containers, labels and cases. They improve
defects including skew and broken caps,
different label conditions, helping produce
both quality and productivity through process
skirt condition, bull nose defects and broken
uniform appearance and improved quality
visibility and process analysis that helps
tamper bands. This helps ensure consistent,
by rejecting of defectively labelled bottles.
pinpoint maintenance requirements that
• V ision technologies identify all closure
accurate and safe (non-contaminating) container closure. • V ision pressure inspection for bottles
• Full pack inspection: technologies are to ensure that each pack has no missing
and cans: Ultra high-resolution cameras
or underfilled containers that are neither
and laser optics provide an accurate 3D
damaged nor leaking.
topography image of the closure area. A sophisticated application detects any
optimise the process. •
applied at the packing stage of manufacture
In addition, there are a range of
deformations in the closure due to pressure
applications that can be integrated with these
variation. The inspection and removal of
solutions that provide even greater benefits in
ABOUT THE AUTHOR: Raymond Shead is the product marketing manager for Filtec in the US.
Filtec – www.filtec.com
NE W !
Jet Cleaner TANKO® MX150 Cleaning in three-dimensional Space Powerful jet cleaner removes heavily adhering media from tanks and vessels.
Made by
Van der Molen S.A. (Pty) Ltd. • 29 Wessel Rd • Edenburg • Sandton, 2128 • South Africa • T +27 (0)11 234 1627/1723 • vdmsa@van-der-molen.com
FOOD REVIEW | MARCH 2021
21
FOOD PROCESSING TECHNOLOGY
Simplify food & beverage pneumatics selection with these 7 tips
Pneumatic component selection in the food and beverage industry requires special care and consideration. Strict quality and hygiene standards must be followed, and the environments in which equipment operates can vary widely, writes Giles Wilcox.
each have their own regulations. Standards
minimise machine downtime and wasted
related to hygiene are strictest in the food
energy. From leak detection to pressure and
zone where food product directly contacts
consumption monitoring, smart pneumatics
machinery. In the splash zone, food product
solutions can be seamlessly integrated into
may come into contact with parts of
systems. Edge computing solution, like
equipment but is cleaned off and doesn’t
Emerson’s RXi2-LP Edge Computing Device,
move into the handling process. In the
provides real-time operations control that
non-food zone, food product doesn’t touch
delivers key insights into equipment and
machinery or components.
systems that help end users increase uptime and overall efficiency.
3. Understand hygienic requirements According to regulations, food and beverage
7. Talk to pneumatics experts
equipment must be designed and built
Working with a proven pneumatics supplier
achine designers are expected to
to avoid any contamination risk. It’s also
in the food and beverage industry makes the
commission pneumatic systems with
essential that it’s built to withstand the rigors
design process quicker and easier. An expert
excellent compressed air quality and
of industry demands. To make them durable
supplier will have a complete pneumatics
hygienic designs quickly and efficiently. Here
and easy to clean, pneumatic components
portfolio, often with preassembled actuator
are seven tips that make pneumatic selection
must be made of corrosion-resistant, non-
control systems, freeing engineering
faster and easier.
toxic, non-absorbent materials.
resources and streamlining procurement. For
1. Ensure pneumatic system efficiency
4. Consider compliance requirements
can provide resources for the design and
When precisely designed, pneumatic systems
National and international regulations shape
implementation of pneumatic positioning
save a significant amount of energy. To
the way equipment used to produce food
systems that use IIoT and advanced feedback
properly size actuators, it’s important to
and beverage products is designed. These
control, like the Aventics Series AES fieldbus
consider the required force, pressure and
regulations vary from region to region, so
module. These systems can be easily
mechanical limitations of an application. Find
it’s important to know which apply in your
designed to monitor the correct position of
appropriate components in a few clicks and
manufacturing location as well as where the
a cylinder and load while transferring critical
save engineering time by using online sizing
machine will be used. Compliance has extra
machine data to a PLC for analytics and
software and cylinder configuration tools.
advantages too. It often extends equipment
predictive maintenance. •
When the appropriate pneumatic valve is fit
service life and reduces maintenance.
M
instance, Emerson’s pneumatic specialists
near an actuator, it provides just the right flow requirements needed for the cylinder to
5. Recognise operational demands
move the load and can reduce cycle times by
From high-pressure cleaning to chemical
improving overall machine performance.
agents, food and beverage washdown
In addition, mechanical or electro-
processes can be harsh. It’s important to
pneumatic pressure regulators ensure that
know where components will be located
processes only use the energy they need by
and which processes, they’ll be subject to.
giving users precise pressure control, and
Pneumatic components should be built to
some even offer customised pressure control.
endure frequent cleaning, like Emerson’s
Integrating vacuum sensors into machines
Aventics Clean Line Air Valves Series CL03.
with vacuum components can save energy,
With an ingress protection rating of 1P-69K,
too, since sensors automatically switch
these valves are robust enough to not require
pressure on and off when vacuum levels
a protective cabinet in washdown areas.
About the author: Giles Wilcox is the subSahara African Manager, fluid control and pneumatics at Emerson
have been met. 6. Incorporate smart pneumatics 2. Know the food zones
The diagnostic and preventive maintenance
There are three zones typically recognised
data that smart pneumatic solutions provide
in the food and beverage industry, and
can help anticipate wear and significantly,
22
MARCH 2021 | FOOD REVIEW
Emerson – www.emerson.com
GRAMEC MIXER
The features of the Gramec Twin Shaft Paddle Mixer are as follows: MIXED IN 60 SECONDS
In many cases, mixing times are as low as 10 seconds, with an average mixing time of less than one minute!
SMALL OR LARGE BATCHES
GENTLE PRODUCT HANDLING
COMPLETE HOMOGENEITY
Gramec mixers offer high-precision blending with a coefficient of variation regularly below 5%.
Gramec mixers provide such gentle product handling that they can even mix breakfast cereals without breakage.
VERSATILE FOR LIQUID ADDITION
ELECTRICITY SAVINGS
Our mixers are manufactured in 12 sizes from 28 to 5000 litre batch capacity. Batch levels range from 30% to 100% of nominal.
Because of low power input and extremely short mixing times, Gramec mixers save up to 60% of your electricity costs.
Liquids of varying viscosities can be added to powders, granules or pellets.
G0028 Batches from 6kg to 22kg
G2100 Batches from 500kg to 1400kg Other products that we manufacture include industrial dryers, vacuum coaters and grinding/pin mills
ONLY MIX WITH THE BEST GRAMEC (PTY) LTD Contact: Niels Ellefsen Tel (011) 882 1914 Fax 086 615 1547 Cell 082 653 6069 niels@gramec.com www.gramec.com
MEAT, FISH & POULTRY
Powerful solutions for full line integration
The plucker and scalder unit
Marel’s poultry processing systems are known for high yields, reliable performance, ease of operation, low cost of ownership and excellent maintenance models. Maryke Foulds digs into how the company can assist in retrofitting existing plants, turning them into state-of-the-art processing facilities.
R
egardless of the desired production
highly-dynamic industry and it would be very
packing. Using these software solutions,
capacity and the type of end products,
difficult for food processing companies to
food processors can take complete control of
Marel has effective, reliable, profitable
operate without the support of an intelligent
their value chain: they can maximise yields,
and quality solutions. Whether processing
software platform. In such a complex
throughput and uptime while reducing costs,
500 or 15 000 broilers per hour. Poultry
environment, Marel’s plant-wide Innova
stock and give-away.
companies can always find tailor-made
solution makes it possible to think smart and
automation for each process step – from
act quickly. Data-driven processing is critical
extended with modules such as traceability,
live bird supply, anaesthetising, plucking,
to make informed decisions that can be
order management, quality control and
evisceration, cooling, cut-up, deboning,
implemented with very little notice.
IMPAQT that offer even more control of plant-
sorting, packing and labeling to convenience food processes.
Marel offers all the tools required for the resilience and speed-to-market processors to
The company invests 6% of its revenues
be competitive in the industry. Across all the
in innovation and research and development
departments in the poultry processing plant,
every year. This translated to €82m in 2019.
modular Innova software solutions connect
Innovation projects are often conducted
and serve the needs of the staff on the
in collaboration with renowned research
factory floor or in the control room.
and scientific institutes, resulting in
Marel’s Innova software system is fully
groundbreaking advances. Many of these
prepared to be integrated into existing lines.
solutions have set new standards in the
Innova offers a highly-flexible and fully-
industry, allowing processors to maximise
scalable production control software suite
yield, quality and throughput.
that empowers processors to efficiently
Marel pays also considerable attention to
control, monitor and improve every aspect
This software package can be
wide processes.
“The modular system can grow from straightforward production of chicken parts to a powerful inline cut-up solution” Optimised traceability through the whole
important themes such as animal well-being,
of the production process, from live bird
production chain is at the forefront of food
traceability, food safety, sustainability and
handling up to the dispatching orders
safety. The traceability functionality links
CO2 footprint.
and QC processes. It’s a completely modular
every process step of the production chain
platform to which modules can be added
to ensure that products can be traced back
INTEGRATION INTO EXISTING LINES
according to the processors’ needs and
to their source. Quick action can be taken to
requirements. It’s possible to start controlling
minimise the impact of recalls.
Adding ‘intelligence’, in terms of software, is
the weighing, packing, labeling, pricing
the best way to integrate new options into
and palletising processes with end-of-
module (Intelligent Monitoring of
an existing processing line without having to
lines modules such as final goods manager,
Performance, Availability and Quality Trends)
make big investments. Food processing is a
inventory, weighing and labelling and
will unleash the full potential of a Marel
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MARCH 2021 | FOOD REVIEW
Implementation of the Innova IMPAQT
MEAT, FISH & POULTRY
The CoreTech infeed line
The inventory department at a major chicken supplier
(yellow product). While being able to meet the
production line. Innova IMPAQT measures
MODULAR INTEGRATION
the trends in losses in the process over time;
When making the switch from manual
changed customer demand, the new machine
it’s the perfect analysing, signalling and
operations to automated processes, or when
setup will blend perfectly with the existing
optimising tool which starts in the primary
an upgrade to a higher capacity is needed,
automated or manual processes.
process. Optimally-improved production
Marel’s modular solutions can integrate into
processes and highest added value will be
the process at any required level. With its
grow along with the processors, without
the result.
modular setup, Marel systems can seamlessly
needing big investments every time. In
combine with other equipment and with
this way, it’s possible to integrate new
factory, from quality control manager to
manual processes. They can also be flexibly
features into existing lines without incurring
production planner and technical manager,
adapted to available space and budget,
prohibitive costs.
offering real-time dashboards for paperless
ensuring tailor-made integration.
There are modules for every role in the
control of every production process.
Let’s take the defeathering department
Marel machines also offer the option to
The Nuova CoreTech, for example, is an eviscerator that can grow in line with its
as an example. To make the defeathering
user’s needs without the need to invest
machine shows a drop in performance, if
process fit for new products, it is possible
in a completely new machine. The first
customers suddenly change their order, or if
to reuse existing scalders and pluckers and
investment in a Nuova CoreTech means the
a recipe needs to be changed, Innova gives
add a second or third plucker with its own
direct availability of all basic features and
real-time insight into how processes can be
specialty. An existing plucker can become a
technical characteristics of a full-scale Nuova
adjusted to solve the issue. Processors who
dedicated attack plucker, while the new one
system. Later on, when capacity grows, the
decide to integrate Innova into their daily
will function as a finisher. Combined with new
number of units can be doubled without a
operations will from then on know exactly
scalding settings, it’s now possible to produce
big investment and finally, the drawn viscera
what’s happening in the factory in real-time.
the specific end products that customers
pack can be transferred automatically to a
They’ll have a stable digital component on
ask for, such as skin-on poultry meat with
separate pack shackle, so that the eviscerator
which everybody can rely.
epidermis removed (white product) or not
has evolved into a top-class machine, without
If an incoming flock varies in weight, if a
having to buy new machines. In the same way, a first investment in an ACM-NT Compact cut-up system – custom-designed to match every budget – will immediately give access to first-class automated cut-up, making use of the same modules as a full-blown ACM-NT solution. If customer demand increases even more, upgrading is easy with gradual investments over time. The modular system can grow from straightforward production of chicken parts to a powerful inline cut-up solution, achieving multiple cuts intelligently and simultaneously without manual interference. •
The traceability scanner
Marel – www.marel.com
FOOD REVIEW | MARCH 2021
25
MEAT, FISH & POULTRY
Clean label:
The fil-rouge driving innovation in processed & meat alternatives Even though it’s a non-scientific consumer term, ‘clean label’ has nonetheless been accepted by the food industry, consumers, academics and even regulatory agencies. Maryke Foulds looks at why this trend is now considered the new normal in F&B manufacturing.
I
n its simplest form, clean label means
considered to cause health issues, such
developing and manufacturing a
as phosphates - whether scientifically
consumers. In France, a third of people
food or beverage product using as
proven or not.
interviewed by Mintel specialists agreed
few ingredients as possible and ensuring
Clean label represents a big
The same feeling is shared by French
that processed plant protein food (e.g.
that those ingredients are recognised
opportunity for food manufacturers
soy burgers) are just as bad for health as
by consumers. It also includes products
to increase market share and value
processed meat.
that feature no artificial ingredients or
proposition. According to a survey
synthetic chemicals, or that substitute
2017 Food Manufacture survey of 1 300
food additives (identified in Europe as
consumers across Europe, North America
E-numbers) with natural items.
and Asia-Pacific, 76% of respondents
HOW TO CHOOSE THE RIGHT INGREDIENTS AND PURSUE THE CLEAN LABEL OPPORTUNITY
Although it has no legal or commonly
said they would be more likely to buy a
The bio-ingredients division of Lallemand,
accepted definition, clean label pushes
product that contained ingredients they
and savoury segment specifically, focuses
the industry to re-evaluate ingredients,
recognised and trusted. In the same
on high-value yeast products from
formulations and processes. It can be
survey, 52% of respondents said they
Saccharomyces cerevisiae and Torula
interpreted as “all natural”, “minimally
would spend over 10% more on a food
yeast. It includes whole cell nutritional
processed” and “non-GMO.”
or beverage product that contained
yeast, yeast extracts and yeast
ingredients they recognised and trusted.
derivatives. Yeast and yeast derivatives
In a Mintel study, A year of innovation
in meat poultry 2020, analyst Stefania Apostol highlighted the three main areas of opportunities in processed meat: To satisfy customer’s needs with clean label and sustainability, animal welfare issues, and paying more attention to consumers’ dietary needs. The processed image of meat and poultry products can be a purchase barrier for many consumers. As a result, brands are committing to cleaner labels by removing additives and preservatives, artificial ingredients, hormones and antibiotics, amongst others. A point that consumers are not willing to compromise on is great taste and food safety. The past few years have seen movements aimed at avoiding ingredients
DOES THE CLEAN LABEL TREND IMPACT ON MEAT ALTERNATIVES? Producers of meat alternatives should pay attention to their ingredient selection. Mintel’s report presented during FIE 2019 What’s next for plant-based diets? indicates that plant-based products must deliver on consumer expectation for transparency and naturalness. Up to 44% of UK consumers agree that it is unclear what ingredients are used in meat-free foods, 41% of them consider meat-free food with a short ingredient list more appealing than a long one, and 31% maintain that meat-free food is too processed to be healthier than meat.
have been used for thousands of years in the production of bread, beer and wine. It is well-known and appreciated globally for its functionality. One of the drivers for Lallemand’s applied research is to find applications where the original properties of inactive yeast and yeast fraction are not yet tapped, with the target of playing an active role in the development of clean label solutions for customers.
PHOSPHATE REPLACEMENT IN PROCESSED MEAT The mineral used in meat and meat products has several functions, such as pH adjustment, buffer properties, sequestration of selected cations, changing ionic charge distributions and/ or bacteriostatic effects. Sequestration of metal ions which are present in meat, such as Ca2+, Mg2+, Fe2+, Fe3+ etc., will enhance the water holding capacity of meat and meat products, improving the degree of tenderness and the meat’s colour. Whole cell yeast has emulsifying, flavour enhancing, water and oil binding properties that can be useful
26
MARCH 2021 | FOOD REVIEW
MEAT, FISH & POULTRY
in processed meat products.
flavour of a meat or meat alternative
is Savor-Lyfe FB (fish, boiled). The
Combining the characteristics of
preparation without adding allergens.
allergen-free light beige powder with a
selected inactive yeast and specific
Imagine delicious oriental-style
characteristic umami and sweet base
process suggestions, Lallemand has
marinated skewers without the presence
note of boiled fish is the perfect building
reached very interesting results.
of soy or gluten. This is possible thanks
block for fish taste foundation. It is
to Savor-Lyfe SSC, a yeast extract-based
suitable for fish fingers, crab soups,
ingredient with increased water holding
natural flavour that can donate the
surimi and veg-surimi, and many more
capacity. The inclusion in the meat matrix
authentic soy sauce taste without the
delicious preparations.
contributes to the colour stability and
headache of allergens.
Toravita 033 is a yeast-based specialty
If you are looking for a clean label
From the same product portfolio,
smoked touch in your meals, Bakon is
produce cleaner label emulsified sausages
Savor-Lyfe BEC is a great ingredient to
the equivalent of traditionally smoked
and deli hams, as well as fish fingers,
substitute beef extract. This allergen-
torula yeast. Manufactured using a
surimi and others.
free light brown powder provides
unique process, this range of ingredients
characteristic beefy notes. It is useful
adds umami and smoky flavour notes
repeated purchase and other product
to enhance and add savoury, meaty
to different food applications. Bakon
attributes. It can be targeted for
notes to vegan and vegetarian soups,
Memphis style, with its robust hickory
innovation, keeping clean label in mind. A
sauces, snacks, meat analogues, meat
essence profile, evokes the traditional
key concept that goes together with clean
preparations and stews. Thanks to its
BBQ cooking style of the Memphis area.
label, is ‘free from’. Emma Schofield, in the
taste and flavour profile, Savor-Lyfe BEC
previously mentioned Mintel report, also
helps to lower the salt content without
about these products? In South Africa,
cites consumers’ interest in free-from
compromising the savoury experience.
Lallemand Bio-Ingredients Savory
flavour release - a big opportunity to
Taste is one of the main drivers for
dieting. Free from and cleaner labels are
Savor-Lyfe CB (chicken, boiled) is
mentioned as drivers for the 'new' plant
characterised by a long-lasting boiled
protein ingredients.
chicken flavour, ideal for nuggets as
Lallemand Bio-Ingredients yeast extracts, inactive yeast and yeast-based flavours can play a role in defining the
Are you interested in knowing more
products are successfully distributed by Savannah Fine Chemicals. •
well as for plant-based meals, soups, sauces, etc. The most recent product launch
Savannah Fine Chemicals – www.savannah.co.za
PROFESSIONAL
INNOVATIVE SOFTWARE SOLUTION FOR THE MEAT, FOOD AND BEVERAGE INDUSTRY
INFO@MATRIXSOFTWARE.CO.ZA | +27 16 423 5537 | WWW.MATRIXSOFTWARE.CO.ZA
On premise ERP factory floor solutions | Time driven stock control | Multiple warehouses Industry specialists | Unique serial numbers | Accurate stock aging Hardware integration (Scales, Printers, Probes etc) | Forward and backwards traceability Manufacturing technologies used (Mobile Solutions included)
FOOD REVIEW | MARCH 2021
27
MEAT, FISH & POULTRY
Thermo Scientific Salmonella Precis Method simplifies workflows and encompasses challenging food matrices
Salmonella testing drives efficiencies,
enables flexibility and solves problems A quick and easy culture-based method for the enrichment, detection, and confirmation of Salmonella species has been validated for the broadest range of food, animal feed, and environmental samples, and is ready to slot into standard laboratory workflows.
E
Bernd Hofmann, VP Thermo Fisher
xtension of the validation scope for
including challenging samples such
the Thermo Scientific Salmonella
as cocoa and chocolate (up to 375g),
explains, “Our customers work in a pressured
Precis Method according to
infant formula (with and without
environment, handling many different types
ISO 16140-2 brings the opportunity for
probiotics), infant cereals, and related
of samples, with varying timelines and
increased efficiency by eliminating the need
ingredients (up to 375g), and animal feed
demands. We want to help them do all they
for multiple broths, plates, supplementation,
(up to 150g).
can to streamline processes, become more
and incubation temperatures. Historically, alternative, more rapid,
Confirmation is available in just two minutes using the Thermo Scientific
efficient, and reduce the likelihood of costly errors. “The extended validation scope for the
Salmonella testing methods have required
Salmonella Latex Test, meaning laboratories
specialised enrichment broths and
can act quickly and decisively on behalf
Salmonella Precis Method means laboratories
supplements, and incubation temperatures
of their clients.
can run multiple Salmonella testing methods, including PCR, using the same enrichment
have differed from those for other forms of
procedure. When compared to the ISO
the difficulties of testing larger samples of
THE SALMONELLA PRECIS METHOD:
substances like chocolate, infant formula, and
• Uses a single, overnight enrichment
broths needed from three to one, the number
bacterial screening. This, combined with
animal feed, have presented laboratories with something of an efficiency challenge. By incorporating Buffered Peptone Water as the enrichment medium for the Salmonella Precis Method, laboratories can reduce handling and increase workflow efficiency. The same sample preparation can now be used for other procedures such as quality indicator enumeration and detection of other bacterial targets that also use BPW for enrichment. Crucially, the method has been validated for the broadest range of food matrices,
28
MARCH 2021 | FOOD REVIEW
step for fast time to result • Uses a BPW enrichment enabling
reference method it cuts the number of of plates from two to one, and uses a single, widely available culture-medium supplement.
quality indicators enumeration
It frees up incubator space, is validated for
from the same broth reducing costs
a broad range of foods together with large
• Uses liquid supplementation for higher throughput at a lower cost • Uses fewer consumables, compared to traditional methods • Is effective at between 34°C and 38°C,
sample sizes for challenging food matrices, and uses a quick, reliable confirmatory step. It slots seamlessly into standard working practices to provide greater flexibility and increased efficiency.” •
reducing the need for alternativetemperature incubators • Uses widely available broths and supplements for increased confidence in supply.
Thermo Fisher www.thermofisher.com/ salmonella-testing-food
MEAT, FISH & POULTRY
F&B safety solutions reduce food risk
Biotecon’s foodproof STEC Screening LyoKit and STEC Identification LyoKit in combination with the StarPrep Three extraction kit received AOAC-RI Performance Tested MethodsSM (PTM) Certification (Certificate No. 102004).
AOAC Certification for foodproof STEC Screening and Identification LyoKits awarded
T
he rigorous evaluation, which was
Its foodproof STEC Screening and
conducted with raw ground beef and
Identification LyoKits were validated in
raw beef trim, was found to meet the
comparison to the reference method USDA-
appropriate standard for its intended use.
fast, demonstrating its compatibility and versatility. “We are proud that our assays continue to
FSIS MLG 5C.00. The foodproof STEC method
be recognised by this globally acknowledged
successfully detected STEC in fresh raw
agency. AOAC approvals have a reputation
beverage safety solutions to reduce the risk
ground beef and fresh raw beef trim after
for the highest standards of excellence
of individuals becoming sick from foodborne
eight and 22 ± 2 h incubation time for 25g test
and thorough analysis. Such independent
illnesses. Shiga toxin-producing Escherichia
portions; and after 12 and 22 ± 2h incubation
assessments give us the assurance we need
coli (STEC or VTEC), such as E. coli O157, E.
time for 375g test portions.
to continue safeguarding our customers’
“Our core business is to provide food and
coli O145 or E. coli O104 are known to cause
Furthermore, when using the mTSB
businesses and protecting end consumers by
diseases such as diarrhea, hemorrhagic
enrichment medium there was no need for
providing trusted, reliable testing products to
colitis (HC) and the potentially fatal hemolytic
additional antibiotics. This rapid workflow with
the food and beverage industry. Furthermore,
uremic syndrome (HUS).
only two PCR tests ultimately leads to cost-
this new certification also demonstrates our
“This is something we take very seriously
savings and opens up good opportunities for
commitment to producing easy-to-use, rapid,
and we have made it our mission to help our
the food sector, especially the meat industry,
molecular biological solutions that improve
customers in any way we can to build brand
to generate new sales.
lab productivity while achieving outstanding
trust and loyalty. With this AOAC approval,
Finally, the STEC screening and
we highlight the reliability and high level
identification method, with its open
performance of our STEC screening and
platform, is AOAC-RI PTM validated on
identification methods,” said Dr Kornelia
the following cyclers: LightCycler 480,
Berghof-Jäger, CEO of Biotecon Diagnostics.
LightCycler 96, AriaMx, CFX96 and ABI 7500
results,” concludes Berghof-Jäger. •
Biotecon – www.biotecon.com
FOOD REVIEW | MARCH 2021
29
MEAT, FISH & POULTRY
New belt design
The full Flex-Grader unit
enhances grader performance Ishida Europe has enhanced its market-leading Flex-Grader for fresh poultry and meat with the introduction of a new high accuracy weighing platform which allows for more accurate grading and improved overall equipment effectiveness (OEE).
T
he Slack Belt weigh bed incorporates
The Flex-Grader bin arms
a single belt mechanism which eliminates product transfer issues
to and from the weigh bed. This creates a more stable weighing environment for even greater accuracy. Besides, the weigh bed features a scraper that removes any product debris, which ensures a more consistent and accurate auto zeroing of the load cell. The Slack Belt’s hygienic construction to IP68 certification is fully protected against water ingress, making it ideal for harsh, high care environments; the belt can also be easily removed for cleaning. A windshield is
Expert service advice, from a distance
provided as standard to ensure protection against environmental factors during the weighing process, wastage, while maintaining
DID YOU KNOW? The company’s aftersales service has continued to support customers across the EMEA region throughout the current pandemic using the latest in support technology, such as augmented reality for the delivery of remote training and servicing.
hygiene standards.” The Ishida Flex-Grader offers a high-speed and accurate solution for the grading of fresh specifications, including specified weight, minimum weight or number per pack. It can also deliver target batching with tolerances and priorities, including product overlapping. An intuitive touch screen remote control ensures ease of set up and changeovers. The Flex-Grader features a modular
The Slack Belt
The full Flex-Grader unit
poultry and meat to a variety of different
design that is easily integrated into existing processing and packing lines which can be modified and adapted for changing requirements. It can incorporate between four and 32 collection bins in a variety of
“… the Slack Belt’s hygienic construction to IP68 certification is fully protected against water ingress, making it ideal for harsh, high care environments; the belt can also be easily removed for cleaning"
configurations including single, double and twin line layouts, handling pieces from
Ishida’s global network provides full local
100mm to 400mm in length at speeds from
support for every Flex-Grader installation
175 to 500 per minute.
to ensure optimum performance. The
As part of Ishida’s ability to supply
company’s aftersales service has continued
complete turnkey lines tailored to individual
to support customers across the EMEA region
customer requirements, the company
throughout the current pandemic using
understanding their specific challenges, in
also offers a full range of complementary
the latest in support technology, such as
particular tackling areas of inefficiencies,”
machines. The portfolio includes multi
augmented reality for the delivery of remote
explains Ciaran Murphy, Ishida Europe’s
head-weighers, tray sealers, leak detectors,
training and servicing. •
business manager EMEA – quality inspection
checkweighers and X-ray inspection systems
control. “For the FLEX-Grader, our focus was
and the IX-G2 model specially designed for
to develop a solution that helped to minimise
the detection of low-density contaminants
the impact of product giveaway and food
such as bone fragments in chicken fillets.
“Working closely with customers is key to
30
MARCH 2021 | FOOD REVIEW
Ishida – www.ishida.com
MEAT, FISH & POULTRY
Global benchmarks for local pork producer
Eskort is a well-established farmers’ cooperative that supplies a comprehensive range of pork products to local consumers. Since 2000, the company’s focus on consistently investing in product development and technology has paid off, discovers Maryke Foulds.
I
t was in the early 1990s that Eskort decided to improve its throughput with the acquisition of a series of optimising and
automated high-speed lines. This allowed the company to become competitive and volume driven. The move to include fresh value-added meat products in 2000, from the factory in Heidelberg, was also a major move for the company. The line included products such as marinated ribs, fresh pork and spiced and marinated products that are near-ubiquitous at South African braais. Smoking rooms were installed by Schroter with oak woodchips imported from Germany through local supplier PHT. “We blend our flavour profiles and don’t depend on batch packs. We also found that our authentic woodsmoke flavour profile really sets us apart from our competitors,” enthuses Eskort’s group technical manager, Melindi Wyma. “Most raw ingredients are sourced locally, in line with PUR standards.” The listeria scare in 2018 changed the meat industry significantly. “While Eskort was not affected, it was a very bad situation for all of us. We broadened our investment in our laboratory and testing services, PPE and cleaning schedules,” says Wyma. This has benefitted protocols during the COVID-19 pandemic. “SMT is our accredited
NEW BADGE ACKNOWLEDGES PRODUCT QUALITY Eskort’s new quality assurance badge – SAFE – acknowledges the company’s commitment to pork product quality in South Africa. The new look was introduced in the second half of 2020. The globe aims to communicate the global benchmarks that Eskort’s quality assurance practices meet while the acronym neatly summarises the four cornerstones of its quality assurance programme: • Sustainable & Accountable This addresses Eskort’s superior farm practices, including food safety and traceability systems, pig welfare and sow-friendly practices, and biosecurity and environmental sustainability programmes. • Farm-to-fork Quality control programmes address the entire value chain, including processing and manufacturing. This means that Eskort grades and enforces compliance concerning how manufacturers and processors maintain their facilities, and how they look after the pigs’ welfare once they
are delivered into those facilities. These are just two critical links in the post-farm supply chain. • Excellence The fourth cornerstone is evident in the company’s 103 years of uncompromised quality, its rigid commitment to quality and hygiene practices, and its many safety principles in place. “We place our customers’ health and well-being above all else. It is, therefore, crucial for us to take ownership of every element of the supply chain,” says Eskort’s CEO, Arnold Prinsloo. “The critical difference between our quality assurance approach and the farm assurance mark most other producers adhere to is that Eskort addresses every link in the supply chain. The adoption of the SAFE badge conveys our holistic approach to quality assurance. “We think this approach is worth acknowledging and celebrating with the SAFE badge, and are certain our customers will agree with us,” he says.
partner and we subject our facilities to weekly verification tests and monthly hygiene checks. Ecowise is our contract cleaning partner at both our sites and both factories are HACCP certified and obtained FSSC certification through SABS.” Eskort is busy with a concerted campaign to educate consumers about the benefits and ease of eating pork, as well as its focus on Pork 360, herd health and its state-of-the-art food safety management system. “Since the pandemic, we have seen an upswing in the volume of value-added pork products as being a component of a main meal, as opposed to merely processed meats. This is great news for the future of the pork industry in South Africa," Wyma concludes. •
FOOD REVIEW | MARCH 2021
31
FOOD SAFETY & COMPLIANCE Analysing grated cheese on the integrating sphere of the MPA II
Food analysis and quality control with FT-NIR spectroscopy
Food quality requirements are steadily growing and the need for rapid, but user-friendly methods to monitor and ensure food integrity is on the rise worldwide.
F
• In-line process control
T-NIR has proven to be a powerful
APPLICATIONS
technology for the control of raw
Modern multi-purpose spectrometers
With fibre optic probes, the point of analysis
materials as well as intermediate and
combine different measurement
can be inserted directly into the reactor or
techniques in one system and thus cover
container. Specific quality parameters
a wide range of applications in food
can be controlled in real-time directly in
usually takes less than 30 seconds, can
analysis, including not only dairy, oil and
the process, leading to shorter cycle
simultaneously answer several analytical
meat applications but also flour and milling,
times, better product quality and less
questions. It offers a practical alternative to
confectionary, condiments and beverages.
out-of-spec batches.
the time-consuming, wet chemical methods
Dedicated sampling accessories can be
and chromatographic techniques. FT-NIR
adapted for any type of liquid, powdered,
is non-destructive and requires no sample
semi-solid or solid sample.
finished products along the production chain. Only one measurement, which
preparation or chemical reagents.
This opens an array of applications, making
FAST & EASY ANALYSIS AT LOW COST Especially in comparison to wet chemical
FT-NIR a valuable tool for raw materials
analysis, NIR offers practical as well as
HOW DOES IT WORK?
inspections in the warehouse, in process-
economic advantages:
FT-NIR spectroscopy simply measures
control and final quality testing.
• no sample preparation required, no waste • simple sample presentation and handling
the absorption of near-infrared light of the sample at different wavelengths. The
• Raw materials identification
recorded NIR spectrum is characterised
Every organic material has a unique NIR
by overtones and combinations of the
spectrum – like a fingerprint. Therefore,
fundamental molecular vibrations of
NIR is widely used to test if a raw material
molecules containing C-H, N-H or O-H
is identical with the expected substance
groups. This is why NIR spectroscopy is first
(identification) and if it meets its dedicated
choice for the analysis of organic materials in
specifications (authentication).
classic methods • analysis of several components in less than a minute • suitable for solid, semi-solid and liquid samples. FT-NIR spectroscopy is a powerful
the food and beverage industry. Sample pretreatment is eliminated, which
• no typical user errors as with
• Multi component quantitative
tool for the food industry. The fast and
saves a lot of work and eliminates a common
analysis
reliable analysis results help to optimally
source of error. From the high information
The amount of light absorbed by the
control raw materials, production
content of the spectra, several parameters
sample depends on the concentrations
processes and finished products. It is the
can be determined simultaneously. In the
of its ingredients. Since the NIR spectrum
tool of the future and already replaces
food sector, the most important parameters
contains the analytical information of
many of the slower, especially wet-chemical
such as fat, protein, moisture / dry matter,
every component simultaneously,
analytical methods. •
lactose and even inorganic parameters
the operator receives all quantitative
like salt and the ash content can be analysed
information by collecting just
as well as many more specialised parameters.
one spectrum.
32
MARCH 2021 | FOOD REVIEW
Bruker – www.bruker.co.za
Quality Control of
Feed & Ingredients
with FT-NIR Spectroscopy
MPA II: Unrivalled flexibility for your daily QA/QC work as well as for sophisticated method development. TANGO: The next generation FT-NIR spectrometer with touch screen operation and intuitive user interface. MATRIX-F: On-line FT-NIR for direct measurements in continuous or batch processes, enabling a close production control. FT-NIR is a powerful and effective technology for control of raw materials, intermediates and finished products. The major application areas of NIR spectroscopy include feed and feed ingredients as well as forages, silages, amino acids and other additives. In contrast to most wet-chemical and other reference methods, FT-NIR technology is quick, cost-effective, non-destructive and safe, since it does not use chemicals, solvents or gases. Bruker Optics has the industry‘s most comprehensive FT-NIR product-line; from the very intuitive FT-NIR spectrometer TANGO to the versatile Multi Purpose Analyzer MPA II and award-winning MATRIX systems for online measurements.
Contact us for more details: info.za@bruker.com | www.feed-analysis-nir.com
Innovation with Integrity
F T-NIR
FOOD SAFETY & COMPLIANCE
Pass your audit in nine easy steps Audits are an operational requirement in the food and beverage manufacturing industry, but they can make even the most seasoned professional sweat a little.
E
ven the smallest infraction can result
assessment is conducted across the
in low or failing scores, which in turn
entire site and that your contract
could see your factory having to
stipulates specifics, including which
5. Notify your pest control provider of your audit date so that they can be on standby or on-site for the audit. 6. Review on-site documentation and
halt operations for an extended period of
pests will be treated for and the
time - severely impacting your bottom line.
frequency of visits per pest. Not all pests
organise it according to your audit
In addition, this time-consuming process
have the same breeding cycle so you
requirements (if you are a Rentokil
requires multiple departments to work
might need more scheduled visits for
customer, myRentokil will have this
together, as auditors often look at processes
particular pests. Other areas that need
that stretch across the entire operation.
to be assessed are pest history, building
To assist customers, Rentokil has put together a basic guideline of common audit actions to help you prepare, although it
information ready for you). 7. Walk the interior of your factory or
integrity, surrounding environment and
warehouse and confirm that all interior
audit requirements.
pest control devices are indicated on the
2. Clearly communicate which
floor plan, identified correctly, and labelled
pays to remember that audit standards
audit standards your organisation
with the correct pest control service
are constantly evolving as processes and
follows - along with any internal
information. Confirm that these devices
technology develop.
auditrequirements - to your pest
are serviced as per the service schedule
control provider at the start of the
indicated on your contract, and are
contract period.
placed correctly in accordance with
The following steps will help you with basic compliance and food safety but need to be supplemented with your specific auditing requirements.
9 ESSENTIAL STEPS THAT CAN ASSIST YOU IN PASSING YOUR PEST CONTROL AUDIT 1. Ensure that a thorough pest risk
34
MARCH 2021 | FOOD REVIEW
3. A ction any pest control recommendations
your auditing standards. For example,
put forward by your provider as soon
Insect Light Traps ILT’s not above a food
as you receive them, to better manage
surface or at least 3m away from the
infestations. This proactive approach will contribute to positive audit findings. 4. Don't leave your audit planning for the last minute.
production lines. 8. Walk the exterior of the facility and confirm that all exterior pest control devices are indicated on the floor plan,
FOOD SAFETY & COMPLIANCE
via your online pest control reporting system (like myRentokil) or in a logbook binder that has been sorted into categories as per your audit requirements. Ensure that you are familiar with your pest control audit system or file as you will need to confidently talk your auditor through it and answer any questions. “Rentokil is here to help. As prominent leaders in the pest control industry, we form close partnerships with our customers as well as auditing and regulatory bodies, including the GFSI, AIB, identified correctly, and labelled with the
the ground;
YUM and BRC Global Standard
correct pest control service information.
- in good condition which means that they
to ensure that we are abreast of the latest
Confirm that these devices are serviced
should not be broken or heavily chewed
audit standard changes and internal audit
as per the service schedule indicated on
on and;
requirements,” concludes Nathalie Leblond
your contract and that devices are placed correctly in accordance with your auditing standards. For example, rodent bait
- clean and free of decomposed rodents
category manager at Rentokil. •
or other animals. 9. C onduct a final review of the interior and
stations have to be:
exterior of the facility and ensure that all
- t amper-resistant, locked and secured to
pest control documentation is accessible
Rentokil Initial – www.rentokil.co.za
When food is at the core of your business, nothing can be left to chance. Pest problems disrupt production, hit revenue and pose major threats to compliance in the food industry. These are significant risks for any business, but with Rentokil on your side, you’ll stay firmly in control. We are trusted by our customers to deliver ground breaking solutions and expert advice to advance food safety standards.
Contact the Experts in Pest Control, today.
Part of
t: 0800 77 77 88 w: www.rentokil.co.za
FOOD REVIEW | MARCH 2021
35
FOOD & SAFETY COMPLIANCE
Uninterrupted mobile calibration gets you up and running in record time
Calibration always results in an interruption of the process. On-site service and calibration from WIKA minimises the impact of these interruptions, and gets your processes back online in record time.
W
IKA South Africa operates
would otherwise have to
three mobile calibration vehicles
be replaced. For sensitive
that are equipped for pressure
instruments, there is always
and temperature calibration in Gauteng,
the risk that they would be
Eastern Cape and Western Cape provinces.
damaged in transit.
DID YOU KNOW? WIKA’s vehicles in Gauteng and Western Cape are also ISO 17 025 accredited for pressure and temperature. The Eastern Cape vehicle will be upgraded to SANAS status as the need for this type of certification increases in the region. All of the mobile calibration technicians are MetCert certified metrologists.
The WIKA vehicles in Gauteng and Western Cape are also ISO 17 025 accredited for pressure and temperature. The Eastern Cape vehicle will be upgraded to SANAS status as the need for this type of certification increases in the Eastern Cape. All of the mobile calibration technicians are MetCert certified metrologists.
MEASURING RANGES WIKA South Africa’s mobile calibration The company’s Namibia operation also
equipment covers pressure ranges from
operates a mobile calibration vehicle that
-1 bar to 700 bar, and temperature ranges
can offer a 3.1 certificate for pressure and
from -20°C to 550°C.
temperature calibration. The vehicles are all air-conditioned for
CALIBRATION CYCLES
temperature and humidity control, which is
The question often arises as to how often
recorded by a data-logger. The vehicles are
instruments should be recalibrated. Of
plumbed for external power connection, but
course the individual installations and
also have generators for back-up power.
applications have a great deal of influence
If there are more than 10 items to be
on this, but instrument manufacturers
calibrated, then on-site calibration becomes
recommend a calibration cycle of one year.
an attractive alternative and has several
WIKA is quite happy to assist customers in
advantages. Aside from the greatly reduced
developing a re-calibration protocol.
out-of- service time, there are also no With a technician on site, small repairs
WORLD-CLASS CALIBRATION EQUIPMENT
are also possible for instruments that
WIKA’s fixed and mobile calibration facilities
freight charges for the instrumentation.
36
MARCH 2021 | FOOD REVIEW
Janusz Luterek
ACCREDITATION
make use of the best-in-class calibration equipment. Mobile pressure calibration is facilitated by the Mensor CPG 2500 reference standard which has an accuracy of 0.01% of full scale. Pressure generation is handled by the CPP1200-X Hydraulic Comparison Test Pump. Temperature calibration is done using the CTB9100 oil bath or the CTD9100 dry-block calibrator. Temperature measurements are performed using the CTP2000 Standard Thermometer or the CTP5000 Reference Thermometer. Climate control is recorded using the CPU6000-W weather station. All of these items are available for purchase from WIKA. All WIKA metrologists are not only all experienced calibrators, they also have a lot of insight into best-practice methods for instrument installation and are ready to share this experience. •
WIK A Instruments - www.wika.co.za
FOOD SAFETY & COMPLIANCE
How manufacturers can
secure their digital future over the next 12 months Over the past year, manufacturers and distributors needed to contend with multiple supply chain disruptions, huge operational inefficiencies and a lack of integration between disparate systems, writes Paulo de Matos.
A
The question is, where do manufacturers
APPLYING THE CUSTOMER EXPERIENCE LENS TO INDUSTRY 4.0
smart manufacturer is already busy with
strike a balance between competitive
For any business planning an Industry 4.0
preparations to ensure future-readiness
advantage and unnecessary expenditure?
initiative, the plan should start with the
lthough these businesses are
indispensable in translating efficiency and
still in the midst of a short-
productivity gains back into the business.
term stabilisation process, the
for the long term. Many organisations have realised that a fundamental shift needs to take place by revising operational strategies and embracing digital technologies. The drive towards Industry 4.0 is truly underway. While the market has spoken about Industry 4.0 for quite some time, most midmarket manufacturers have limited
“During the pandemic, manufacturers realised the importance of connectedness to both suppliers and customers within their eco-system”
the digitalisation process due to perceived
requirements of the end customer in mind. During the pandemic, manufacturers realised the importance of connectedness to both suppliers and customers within their ecosystem. Any delays in customer delivery could have resulted in long term reputational damage and revenue loss. Here Industry 4.0 plays a vital role in real-time engagement. Careful application of Industry 4.0 can
capital commitments and a lengthy
also reinvent the customer experience
BUILDING A CASE FOR INDUSTRY 4.0
altogether. Over the last few months, supply
conversation regarding Industry 4.0 begins with enthusiasm at the endless possibilities
Ultimately, the drive towards Industry 4.0
needed to think ‘out of the box’ to secure
available, but the reality of the costs involved
needs to be a unique project addressing the
ongoing profit margins.
in setting up some of the more basic
requirements of the business. Manufacturers
requirements like Shop Floor Data Collection
need to think about which business pain
70% of businesses indicated that they would
(SFDC), Industry 4.0 is reconsidered.
points they need to resolve, what these pain
be exploring new revenue models with the
Additionally, there is trepidation when it
points are worth to them, and how their
aim for increased customer engagement
comes to investing in emerging technologies
digital strategy needs to maximise ROI.
through digital channels. B2B leaders started
implementation and payback process. Every
that will be replaced by newer technologies
When approaching industry 4.0 to become
in the near future, even before the current
future ready, manufacturers and distributors
investment has been recouped.
should consider digital changes to their
Despite the hesitations of the past, the
chain restrictions meant that manufacturers
According to our recent CFO 4.0 study,
adopting new digital selling models, resulting in accelerated adoption of eCommerce. Improving customer service has always
enterprise on two dimensions:
been a major priority for successful
disruptions of the pandemic have proven
• Customer experience
manufacturers, and with the continued
that the uptake of Industry 4.0 is now
• Operational efficiencies.
integration of technology within
Special Offer GAP audits at 50% of normal costs plus discounted audit man-day rates on all other certification quotes until March 31 2021 Use code FR2021Q1
for the rest
Contact: Steven Lashmar Business Development Manager 079-634-5374 sales@ltlgroup.global
+27 79 634 5374
38
MARCH 2021 | FOOD REVIEW
FOOD SAFETY & COMPLIANCE manufacturing, should assist in improving it
of their deliveries. Over the last year,
automation, the recent Syspro-led CFO 4.0
even further.
manufacturers have realised that with
study also showed that 52% of businesses
supply chain disruptions, data was of value in
identified the investment in enterprise
APPLYING THE TECHNOLOGY LENS TO INDUSTRY 4.0 TO ENABLE OPERATIONAL EFFICIENCIES
understanding their businesses’ stable source
technology such as ERP, BI, and CRM as a key
of supply and ability to maintain healthy
strategic focus area to improve operational
inventory levels.
efficiencies. The goal being to achieve better
Most manufacturers are aware that Industry
totally new business models involving remote
across the whole business to enable
4.0 involves the implementation of revised
working and dark factories. As a result,
enhanced decision-making in real-time.
processes, redesigned operations and
there has been an increase in the uptake of
integrated automation to create the factory of
automation in almost every industry.
the future. At a basic level, the rollout of Shop
The last year also resulted in the rise of
IDC expects that by 2023, 75% of Global
clarity and transparency of information
With both operational and customer experience lenses in mind, Industry 4.0 needn’t be an unnecessarily expensive
Floor Data Collection, is regarded as one of
2000 IT organisations will adopt automated
investment, but rather an opportunity to
the cornerstones of the Industry 4.0 initiative.
operations practices transforming their IT
transform the business for enhanced growth
workforce to support it on an unprecedented
and long-term sustainability. Strategic and
against schedule, and identification of any
scale. Automation has been around for a
focused shifts in Industry 4.0 investments in
delays. Most integrated SFDC capabilities
while – so what has changed? With the
the company can help to ensure success in
require an ERP, the SFDC software, the
introduction of connected services and APIs,
the near future and beyond. •
appropriate adapters, and software drivers
systems have become far more integrated,
to get all the information to where it needs to
often using the cloud as the vehicle for this
go and assist the business with real
inter-connectedness and orchestration. The
About the author: Paulo De Matos is the
time decisions.
market is therefore seeing an evolution
chief product officer at Syspro.
It involves the real-time tracking of jobs
As the data collection and monitoring
of point-to-point systems talking to one
tools of Industry 4.0 become more
another, rapidly improving the effective
common in the factory and across the
execution of business processes for
supply chain, customers will have more
those that have adopted it.
visibility into production status and tracking
Beyond the application of SFDC and
Syspro – www.za.syzspro.com
FOOD REVIEW | MARCH 2021
39
HOT BEVERAGES
Influence of alpha-
Cyclodextrin on the foaming properties of dairy and plant-based systems Cappuccino (espresso with milk foam), latte macchiato (espresso with foamed milk and warm milk layers) and Asian bubble tea (tea with pearls and topping) are becoming more popular as new lifestyle products.
T
he resulting coffee and tea-based
2.5% almond content). Foam was produced
beverages use aerated/foamed
either by infusing steam through a coffee
toppings, which must develop a fine,
machine or through the use of a milk frother.
smooth foam with substantial volume and
Various properties of the resulting foam were
satisfactory stability over time. These food
then analysed.
products are made either fresh in food
Alpha-cyclodextrin is a ring-shaped
service restaurants, by the consumer at home
oligosaccharide based on six glucose units,
or in vending machines; nearly all types of
which is produced by Wacker Biosolutions
these applications involve the use of liquids or
in a patented fermentative process based
powder premixes.
on starch, a renewable raw material.
In addition to resistance to drainage,
Wacker markets ACD under the brand name
coarsening and foam collapse, another highly
CAVAMAX W6. Its unique molecular structure
valuable property in toppings such as these is
and three-dimensional interactions give the
a smooth, creamy mouthfeel. While research
molecule an internal lipophilic area (referred
aimed at understanding and optimising the
to as the “cavity”) and an external
corresponding mechanisms in dairy foams
hydrophilic area.
has a long history, increasing demand for
Due to this highly unique molecular
vegan diets requires the same properties for
structure, ACD has a huge variety of proper-
plant-based toppings as well.
ties that can be used in multiple food appli-
Dairy powder: powdered dairy and non-
cations. The hydrophobic inner cavity of ACD
dairy toppings varying in fat content; milk:
allows other lipophilic molecules to form host-
UHT milk varying in fat content; plant-based
guest inclusion complexes through non-co-
milk alternative:(in this case almond milk with
valent interactions.
Figure 2: Foaming capacity of different barista formulations: The foam volume of a reconstituted, medium-fat dairy powder system (4g powder in 100g water, fat content: 20 – 25%) was analysed either on its own, with 1.4% maltodextrin or with 1.4% alphacyclodextrin (ACD) (n = 3).
The spontaneous interaction of ACD with triglycerides at the oil-water interface of food systems gives ACD-TG complexes emulsifying properties (“emulsifier-in-situ”). Hydrogen ABG print press at S&N Labels Figure 1: The Technical Service Unit of the Nutrition Team at Wacker has explored the beneficial impact of alpha-cyclodextrin (ACD) on various foam properties in different model systems
40
MARCH 2021 | FOOD REVIEW
bonds between the exterior part of ACD and long-chain molecules, such as proteins or polysaccharides in food ingredients, make the system more viscous and therefore positively
HOT BEVERAGES
The milk containing ACD, on the other hand, was characterised as having more body, less bitterness, improved creaminess and better mouthfeel. Cyclodextrins are also known for their potential to mask undesired flavors in various matrices. As part of this study on the influence of ACD in barista toppings, this masking effect was demonstrated to either balance the cooking off-taste of dairy liquid systems and to cover/trap the rancid offnotes of the vegetable fat fraction of non-dairy powder systems. It also reduced the partial astringent or bitter note of almond milks – for other plant-based milk Figure 3: Foam stability and foam half-life-time in the presence of ACD Reconstituted, high-fat dairy powder (4g powder in 100g water, fat content: 50 – 60%) was analysed either on its own, with maltodextrin or with ACD (n = 3).
alternatives (those based on legumes such as soy or pea), the typical “beany”
influence the foaming/whipping properties
powders (fat content 50-60%) reconstituted
of the food matrix. As an additional beneficial
from 4g powder in 100 g water: the addition
consequence, the various interactions of ACD
of ACD increased foam stability even at low
also stabilize the desired food matrix.
dosage rates, extending the foam half-life-
Regarding the specific application of
time (the time it takes for the foam volume
barista toppings, an evaluation of various
to shrink by half) from three to 15 minutes
examples of the model systems in this study
– this will enable a longer serving time with
shows that ACD significantly improves
appropriate foam appearance.
foaming capacity, i.e., the amount of foam
Barista products are luxury lifestyle
achieved in such systems could be increased
products. This means that, in addition to
substantially, as shown in Figure 2.
the volume and stability of the foamed
The addition of 1.4% ACD nearly doubled
topping, consumers also place a great deal
the overrun. The same amount of an inert
of importance on the overall impression: the
linear oligosaccharide (maltodextrin) was
appearance of the foam should be nicely
used as a direct comparison. Maltodextrin
creamy and homogenous. 1% ACD in an
caused only a slight increase in the overrun,
almond milk foam has a positive effect. For
due to the increase of dry matter – not
the consumer, this homogenous, creamy pore
comparable to the significant increase in
structure correlates to a full-bodied beverage
foaming capacity achievable by the presence
and an improved mouthfeel – especially in
of ACD.
plant-based barista toppings, which often
Adding ACD to barista toppings not only improved foaming capacity – the stabilising
need an additional boost in that regard. a professional taste panel (n = 18 panelists)
retarded foam degradation reactions (Ostwald
confirmed in a blind triangle test (DIN ISO
ripening, drainage, coalescence, deformation
4120) that 12 out of 18 panelists prefer the
and bubble creaming) and therefore positively
almond milk with ACD. The pure almond milk
influenced foam stability in these toppings.
was described in the following terms: watery,
stability for the model dairy and non-dairy
consumer acceptance. Wacker responded to the challenges of food technologists by developing barista products with convincing foam properties for the consumer. This involved controlling for various parameters, such as the type of raw material (seasonal variations), the foam generation method and processing, and adapting accumulated expertise from dairy systems to plant-based (vegan) matrices. Three model systems were used (milk: UHT milk of varying fat content; dairy powder: different types of dairy and non-dairy powder systems of varying fat content; and plantbased milk alternative: UHT almond milk with 2.5% almond content). In variations of these systems, alpha-cyclodextrin (CAVAMAX W6) significantly improved the specific properties of barista foam toppings. •
The sensory evaluation of almond milks by
effect of CAVAMAX W6 in the foam also
Figure 3 shows the increase in foam
profile is a major concern and has to be balanced for
About the authors Dr. Ulrike FischerNägele and Yvonne Haslauer, technical service, nutrition, Wacker Chemie AG
no body, nutlike, bitter and astringent.
Wacker - www.wacker.com/food
FOOD REVIEW | MARCH 2021
41
RECYCLABLE PACKAGING & PRACTICES
Extrupet listens to the market Extrupet recently installed and commissioned its third food-grade line and is now supplying global brands from its premises in Johannesburg. Food Review spoke to Jiney Jutley about this exciting journey; what this installation means for recycling food-grade rPET in South Africa and the way forward.
The Phoenix PET Starlinger line
Q
: Tell us how the installation of your third food-grade line has been going.
A: Wow, what a journey. The start of lockdown, at the end of March 2020, brought with it the arrival of our new Starlinger and all installation plans had to be pushed back to the end of the year, while lockdowns around the world took their course. We thankfully justified the arrival of the engineers from Europe over December 2020 and have been running the new line since end MARCH 2021. Q: Much has been said about the flagship PhoenixPET® brand, which has grown into an rPET that we believe is now used commercially in 100% mineral water applications. Do all three of your food-
the driving force behind a rPET recycler
Q: Have you seen the recycling
grade lines use the same technology?
being so focused on quality?
space change much with the advent
A: We currently have one Vacurema line and
A: I think many of these requirements
of the pandemic?
two Starlingers, all making food-grade rPET.
have come directly from our multinational
A: We have seen pressure placed on the
Our total capacity now is just under 3 000 MT
partners that have global standards in place.
supply of raw materials, due to slower
per month.
We have been blessed to work with such
economic activity, but we did prepare for
wonderful partners over the last two decades
this in advance and thankfully are in a good
Q: The certification levels are remarkable,
and the quality standards are the output of
position to keep our three lines running well
from BRC to ISO, FDA, EFSA, GRS. What is
these collaborations.
into the future. However, the quality of the
42
MARCH 2021 | FOOD REVIEW
Three lines are better than one Extrupet’s additional Starlinger reco STAR PET 165 HC iV means we become part of an exclusive 3000 MT per month name plate capacity solution provider. Two Starlingers, one Vacurema and every ton globally certified.
Better for the environment and our economy. Putting the future in your hands.
Product of
Proudly associated with
extrupet
SAN BWA
Our accreditations
SOUTH AFRICAN NATIONAL BOTTLED WATER ASSOCIATION
Food Grade Plant
Contact: 011 865 8360 | Email: info@phoenixpet.co.za | Website: www.phoenixpet.co.za FOOD REVIEW | MARCH 2021
43
RECYCLABLE PACKAGING & PRACTICES
feedstock has become very important. We’ve noticed that it hurts the whole value chain when brand owners do not take a relevant position on how their packaging will be reused or recycled in a South African context. Q: What do you mean by relevant position?
Final product ready for despatch
A: There needs to be an understanding of what is relevant in the specific geography that you are doing business in. Our reality in South Africa is that most of the raw material we use originates from landfill. Therefore,
Q: Do you have an example of this?
economy and that’s something the entire
when designing packaging, brands need
A: There are many. For example, PVC and
value chain needs to be aware of. Ribena is a
to understand how their packaging will be
rPET shrink sleeve labels cannot be recycled
great example of a company making a change
collected from landfill and whether there is
in South Africa. They cause real problems on
and looking to improve recycling rates. They
value in the chain to make sure they
our line if they slip through our system. But it
have redesigned the sleeves on their plastic
are recycled.
is not just that - brands need to understand
bottles to prevent down cycling and ensure
the circular nature of their choices. Extrupet
that more bottles are collected.
Q: But surely anything can be recycled?
is constantly challenging the 'alleged' benefit
A: Unfortunately, that is not the case. From a
of recycling shrink sleeve labels.
Q: That’s just incredible. I am sure
'green washing' perspective, anything can be
It simply doesn’t exist in South Africa or
many more brands will be taking this
recycled yes, but from a practical repurposing
anywhere else in the world. Post-consumer
to heart and making sure their design
perspective, unless the packaging is designed
recycling faces huge issues when processing
choices have a circular view when
well enough in advance, the packs are
rPET bottles with rPET or PVC labels.
implementing changes.
doomed to an end of life end up on
Polyolefin wrap-around labels are the
A: I think that it’s important to have the
the landfill or in our oceans. For instance,
preferred option as there is less adhesive,
courage to talk about real solutions that are
Sprite bottles are now clear instead of
again reducing issues at the point of
relevant to your geography and economy.
green, as brand owners have taken the
recycling. In an ideal world, no label would
Standing up for what you believe in does not
correct steps to ensure that the bottles are
be preferred.
always make you popular, but it is still the
designed better for greater recyclability.
We are fighting hard to change this
Coloured bottles have limited use and are
perception and along with PETCO, we’re
harder to recycle. Although bottle design is
educating the industry - both converters and
progressing, the same cannot always be said
brand owners. However, it starts at the very
about the labels on the bottle - that’s
beginning with packaging and bottle design.
another challenge entirely.
The design is imperative to the whole circular
44
MARCH 2021 | FOOD REVIEW
right thing to do. •
Extrupet – www.extrupet.com
RECYCLABLE PACKAGING & PRACTICES
Labels for the health of the planet Sustainability is on the forefront of most packaging headlines, but it remains a complex and challenging topic for the industry, brand owners, and major retailers, writes Grant Watson of Rotolabel.
T
here is often a misconception around
labels can be recycled, but a critical factor
the various options available due to
is to ensure that the right label material is
a lack of knowledge or just being ill-
applied to the relevant package to provide
informed. While the industry is becoming more aware, there is still a disconnect
maximum benefit. It is critical to get the right advice
between the packaging industry, retailers
upfront from an informed person and a
and consumers.
reputable company.
Self-adhesive labels is a desirable option
Rotolabel is passionate about the
in the Western Cape for backing paper/liner (Soon to be rolled out nationally); • Using less label material for equivalent performance;
for a wide variety of products. This is partly
environment and implementing the right
due to the wide availability of different
processes and there is currently a focused
new project in conjunction with key
materials that can be used. When the option
approach on minimising any negative impact
stakeholders to be the first to bring in 100%
to separate the label from the primary
our product range may have on
PET recycling for food grade rPET.
packaging (e.g. a PET bottle) becomes
the environment.
part of the conversation, it means the
Rotolabel has been the driver and leader of
• Rotolabel is currently running an exciting
Our experienced account managers are trained and up to speed to advise customers
primary packaging can also be recycled,
innovation within the label printing space in
on what substrates will be best-suited for
all while ensuring the label solution stays
South Africa, with some notable initiatives:
their products and which ones will have the
commercially viable and competitive
• A ll paper labels are FSC ® (Forest
least impact on the environment. •
to others. Depending on the recycling process,
46
MARCH 2021 | FOOD REVIEW
Stewardship Council) certified; • Running the first-ever recycling programme
Rotolabel – www.rotolabel.co.za
RECYCLABLE PACKAGING & PRACTICES
How RFID can transform your business Food Review asked Marcel Coté, director of sales and market development for intelligent labels at Avery Dennison to share his insights about the rise of RFID and the unprecedented opportunities it offers for converters and end-users alike.
Q
: What are labels enabled with radio
RFID facilitates the wireless transfer of
label far exceeds the limits of a printed code,
frequency identification (RFID)?
data enabling a label to extend any physical
which opens up a world of possibilities.
A: It’s a pressure-sensitive label or
product to the digital world. Tagging an
non-adhesive tag with an RFID inlay attached
item with an RFID label creates the item’s
Q: Can you say more about those
behind it, which we call an Intelligent Label.
digital twin, with its very own unique ID,
possibilities?
It comprises a tiny microchip which holds
visible across the supply chain and inventory
A: Intelligent Labels provide a multitude of
data, a very thin aluminium antenna which
management systems. RFID improves on
benefits, particularly in managing inventory
transmits and receives radio signals, and a
barcodes and QR codes in important ways,
and tracking and tracing items across
carrier material, typically paper or PET, which
not least of which is that the amount of data
logistics and supply chains. First, they offer
holds it all together.
that can be stored and protected in an RFID
a much higher level of visibility and accuracy
FOOD REVIEW | MARCH 2021
47
RECYCLABLE PACKAGING & PRACTICES
throughout the supply chain - from the
Also, inlays with our SmartFace™ top
whether your RFID application fully delivers
original raw material source locations
laminate use paper instead of PET. All of
a ROI and achieves the anticipated long-
through to the real time instore location -
our inlays with paper constructions use
term integration benefits. We’ve seen many
letting you see any tagged item, wherever
paper certified by the Forest Stewardship
problems occur because the quality was
it is across the globe, whenever you want
Council - we developed the industry’s first
overlooked by brand owners. We’ve even
to. Intelligent Labels also eliminate the need
FSC-certified tag. We’ve also developed
observed cases of RFID programmes being
for direct line-of-sight barcode scanning. A
a proprietary “strap attach” process that
discontinued after 12 months because of
box of 100 items with Intelligent Labels can
enables us to use 70% less plastic, and our
inconsistent performance results due to
instantly be identified with an RFID reader
antenna production process enables 100%
low quality RFID inlays used across the
without the need to even open the box.
recycling of waste aluminium. In terms of
supply chain. At Avery Dennison, we test
how our products advance sustainability in
every single inlay - 100% of them. We are
accuracy to 99.9% and allow for real-time
products and systems they’re part of, there
the only company globally to hold the
stock-checking and replenishment. They can
are many compelling benefits. At the top of
highly respected Auburn University Quality
prevent counterfeit products from entering
the list is the fact that they help reduce
Certification for manufacturing. A successful
legitimate distribution channels and make
waste, energy use, and transportation by
RFID deployment starts with the quality of
product recalls faster.
optimising inventories. One great example
your tag. If you compromise there, you’ve set
is food waste. It is proven that RFID tags
yourself up for failure. •
They improve inventory management
®
Q: Consumers and regulators are
can cut it by up to 20% which is a significant
increasingly demanding sustainable
sustainability benefit given the linkage to
packaging. How do RFID-enabled labels
global issues surrounding food shortages
fit the bill?
and climate change.
A: In terms of product design, we’ve taken many steps to reduce the
Q: What’s the one thing a converter or end-
environmental impact of our RFID inlays.
user should know before diving into RFID?
We’ve dramatically reduced their carbon
A: Consistent, dependable inlay quality
footprint relative to competing products.
is essential. It makes all the difference in
D011-3R.pdf
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2020/09/16
11:46
Avery Dennison - label.averydennison.com
RECYCLABLE PACKAGING & PRACTICES
Be proactive when
it comes to packaging waste South Africa is a rapidly growing and developing country. Growth in our country’s population has led to an increased waste generation rate. With 59 million people, there is enormous pressure to reduce the amount of packaging waste that is either sent to our country’s landfills or ending up as visible litter in the environment.
A
s a pro-active response to the
Through the updated Section 18
informal waste pickers, small and medium-
growing national concern around
regulations of the Waste Act, all producers
sized enterprises and large-scale mechanical
waste and its impact on society
are now called upon to demonstrate their
recyclers. In addition, there is a strong focus
Extended Producer Responsibility, or EPR.
on the development of new end-use markets
and the environment, South Africa recently published the Section 18 Regulations to the
EPR refers to the measures that extend a
to consume these recyclable materials,
National Environmental Management: Waste
producer’s financial or physical responsibility
as well as on the education of consumers
Act on 5 November 2020, which refers to the
for the product they make to the post-
to make them aware that used packaging
Extended Producer Responsibility aspect
consumer stage, when the consumer is done
materials have value and can be recycled into
of the National Environmental Management
with the product, and include, but is not
a whole range of new and useful products.
Waste Act (NEMWA). The regulations are now
limited to:
effective from 5 May 2021.
• supporting and initiating waste minimisation
South Africa recently published the Section 18 Regulations to the National Environmental Management: Waste Act on 5 November 2020, which refers to the Extended Producer Responsibility aspect of the National Environmental Management Waste Act (NEMWA). The regulations are now effective from 5 May 2021
and collection programmes, • financial arrangements for any fund that has
and industry. As an industry, we are committed to continue working closely with
re-use, recycling and recovery of waste;
government as this process unfolds.
• awareness programmes to inform the public of how to recycle, why to choose well-
These are some of the requirements
designed products, and what the potential
for producers:
impacts of product waste are on their health
• E xisting producers to register with the
and that of the environment; and
Department of Environment, Forestry and
• any other measures to mitigate the potential
Fisheries by 5 November 2021 (as per the
impact of the product on human health and
amended EPR regulations released on 15
that of the environment. Luckily, South Africa is well positioned for this next stage of environmental legislation as voluntary, EPR schemes for packaging have been running for many years now. There are several Producer Responsibility Organisations (or PROs) operating in South Africa who, between them, cover the different packaging streams, namely PETCO for PET, Polyco for multi-layer), the Polystyrene Association
January 2021). • Be part of an EPR scheme that includes the entire value chain. • Be accountable for the operation and performance of an EPR scheme. • Pay the appropriate levy to the EPR scheme – payments and contracting by end 2021. • Fulfil monitoring and reporting obligations – to begin Q1 2022. • Implement labelling of packaging to indicate disposal information. •
for polystyrene, Southern African Vinyls
approach of producing, using and discarding
Association for vinyl, The Glass Recycling
valuable materials such as plastics, paper,
Company for glass, Fibre Circle for paper and
glass and metals, our focus is now on
MetPac-SA for metal packaging.
developing circular economies within South
collaborative approach between government
been established to promote the reduction,
polyolefins (PP, HDPE, LDPE/LLDPE and Instead of supporting the outdated, linear
The new Section 18 regulations is a welcome step forward towards a more
Each of these PROs collect voluntary EPR
Africa. The value of should never be lost, but
fees from their members. However, this will
kept within the economy by ensuring that
become compulsory with implementation of
these materials are diverted from landfill to
the Section 18 EPR. The revenue generated,
be reused and recycled into many new and
will be used to support the collection, sorting
useful materials.
and recycling of recyclable materials by
Please take note of the following important dates and timeline: • End Q1 – Focus group to revise regulations for review (publication before 5 May) • 5 May 2021 – Effective date of regulations • 5 Nov 2021 – Revised date for final compliance with regulations.
Plastics|SA – www.plasticssa.co.za
FOOD REVIEW | MARCH 2021 202 1
49
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Carla Melless
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AD INDEX FOR SA FOOD REVIEW – MARCH 2021 Avery Dennison............................... 47..............www.label.averydennison.com
ISW Shrink......................................... IFC.............www.iswshrink.co.za
AWH Neumo Ehrenberg Group...... 21...............www.awh.eu
Matrix Software............................... 27..............www.matrixsoftware.co.za
Bruker SA ......................................... 33..............www.feed-analysis-nir.com
Plastics SA....................................... 45..............www.plasticsinfo.co.za
Capdan and Allied Equipment...... 13...............www.capdan.co.za
Polyoak Packaging........................ 48..............www.polyoakpackaging.co.za
Certification Partner Global........... 38..............www.cpg.global
Rentokil Initial................................. 35..............www.rentokil.co.za
Crown Food Group.......................... 15 ..............www.crownnational.co.za
Rotolabel.......................................... 46..............www.rotolabel.co.za
Extrupet........................................... 43..............www.phoenixpet.co.za
Syspro............................................... 39..............www.za.syspro.com
Gramec ............................................. 23..............www.gramec.com
TNA Packaging System SA............ 19...............www.tnasolutions.com
Heat & Control SA ........................... 9, OBC.......www.heatandcontrol.com
Wika Instruments .......................... 37..............www.wika.co.za
HG Molenaar..................................... 17...............www.hgmolenaar.com
Yamato Scale Dataweigh (UK)...... OFC...........www.yamatoscale.co.uk
50
MARCH 2021 | FOOD REVIEW
WEB REVIEW
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
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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 reputation for being efficient, cost-effective and professional. For over 50 years Formpak We import machines for our local clients across the whole of Africa, ensuring that they benefit from machines of the highest has supplied specialised quality at an excellent price. processing, packaging and Our staff have extensive knowledge of current Machines, Technologies printing machinery to the and Consumables and we also provide a modern Service and Maintenance Department to support our customers pharmaceutical, cosmetic, throughout the process. We service a diverse range of customers, from Large & Small plastic, glass, chemical, 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
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• Supplier to the hospitality trade and food factories • Service excellence, Your No. 1 industry leader for the most comprehensive ranges of both • Quality, portion controlled products synthetic and natural colours – used in food, pharmaceutical, cosmetic and (chilled/frozen /dried) industrial applications. Full demonstration of exclusive machines will be strategically positioned on the stands and this • Innovation & Flexibility Our technical team is available towill shade and receive a great deal of attention which colour match to specific requirements and / or • Meat & chicken products tailored for will be of great interest to you our customer. We look forward to seeing you at the show. special applications in the food industry THE BMPE TEAM Pantone references and to give legislative support on colours. • Dried meat products – real meat www.quantumcolours.com real flavour! Manufactured, marketed and distributed under Tel: +27 (0)11 032 8600 licence of SPECTRATEC INC. CANADA email: sales@dinnermates.co.ca Tel: +27(0)15 516 1514 email: factory@dinnermates.co.za/www.dinnermates.co.za
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FOOD REVIEW | MARCH 2021
51
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