Food Review March 2022 by New Media B2B

www.foodreview.co.za

MARCH 2022 Vol. 49 • No. 3

SOUTH AFRICAN JOURNAL FOR FOOD AND BEVERAGE MANUFACTURERS

INNOVATION reduces

operational costs

Solutions to reduce food safety risks

The latest healthboosting ingredients

Custom CIP systems

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EDITOR’S COMMENT

Are you learning or are you teaching?

t was amazing to be back at Propak Africa,

time to look at my top reads in the magazine

walking around and talking to people IRL

this month.

(in real life). One of the most common

What does microbiology have to do with

views at the show this year, from both

food safety? More than you think. It is one

visitors and exhibitors, was that physical

of the main aspects of overall testing in

human interaction was certainly missed

South Africa. Failing to do the necessary

over the last two years, especially in the F&B

microbiology testing can result in a slew of

industry. Nothing quite compares to being

complications. But what should you test for?

able to stand face-to-face with a company,

How often should you have your products

tell them exactly what it is that you need

tested? What does the law say about

to make your business a success and then

microbiology testing? Find out on Page 14.

being able to watch as they demonstrate

Clean-in-place sanitation systems are

THE TEAM EDITORIAL Editor: Tennille Aron +27 (0)73 995 5599 tennille.aron@newmedia.co.za Layout & Design: Kirsty Thomas ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Càndida Giambò-Kruger +27 (0) 71 438 1918 càndida.giambò-kruger@newmedia.co.za 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

their latest technology on the market, which

becoming more popular in the F&B industry,

could potentially solve your problem and

offering a modern method for automated

make your business a huge success.

cleaning. These systems consist of stationary

CIRCULATION

skids with cleaning circuits installed

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

Psychiatrist and author M. Scott Peck said it best when he said, “All human interactions

throughout. Read all about them on Page 22.

are opportunities either to learn or to teach.”

The food industry is arguably the sector

And I certainly learnt a lot by interacting

most susceptible to damages caused by a

with the exhibitors and customers alike

breach in hygiene protocols and the costs

at this exhibition. Here are a couple of key

reach far beyond damage to stock. Rentokil

learnings from the expo. While the pandemic

Initial explains the real cost of poor hygiene

has catapulted the global F&B industry

practices in manufacturing facilities on

towards increasing automation in their

Page 30.

manufacturing plants to increase efficiency,

Beauty from within is emerging as one of

PUBLISHING TEAM General Manager: Dev Naidoo Production Controller: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE Ground Floor 272 Pretoria Avenue Randburg, 2194 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146

locally we have just started on the road to

the fastest-growing product segments today

automating our factories. Therefore, there is

across all age demographics and across a

an increased need for entry-level machinery

broad range of consumer product types.

to help South African companies start on

The addition of certain healthboosting

their automation journeys.

ingredients to beverages can have a fantastic

MANAGING DIRECTOR: Aileen Lamb

effect on the overall health of individuals

COMMERCIAL DIRECTOR: Maria Tiganis

and hygiene are still a top priority for all the

and boost their beauty from

BRAND STRATEGY DIRECTOR: Andrew Nunneley

players in this industry with manufacturers

within. Discover more about this trend on Page 34.

CHIEF FINANCIAL OFFICER: Venette Malone

always on the lookout for new equipment

The expo also highlighted that food safety

Enjoy the read!

more environmentally-friendly products

Tennille Aron

and packaging. These are just a few key learnings; if you

MANAGEMENT TEAM

HEAD OF HR: Ruth Shogoe

to help improve the hygiene in their plants, while also increasing efficiency and creating

Published by New Media, a division of Media24 (Pty) Ltd

CEO: MEDIA24: Ishmet Davidson HEAD OFFICE New Media, a division of Media24 (Pty) Ltd 8th floor, Media24 Centre, 40 Heerengracht Cape Town, 8001

want to find out what else is trending in the F&B industry, then don’t forget to take some

@foodreview13

@SA_FoodReview

SA_FoodReview

EDITORIAL ADVISORY BOARD

Food Review is published by New Media Publishing (Pty) Ltd 11 times a year

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 Symrise 2001 to 2020 . Chairperson of SAAFFI Business Consultant

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

Rudy McLean

and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher. The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost. Food Review is printed and bound by CTP Printers. Copyright: all rights reserved. ISSN 0257-8867 Readers are prohibited from using the contact details displayed in any advertisement or editorial within the pages of this publication to generate and/or distribute unsolicited bulk emails or other forms of mass marketing correspondence.

Gail Angela Macleod

March 2022 | FOOD RE VIEW

CONTENTS MARCH 2022 Vol. 49 • No. 3

Advanced processing

NEWS

INDUSTRY TALK

particle sizes

BEVERAGE INNOVATIONS

Endress+Hauser sets up shop in Ireland

Digitalising process plants with IO-link

The best source of sensor-

The best ingredient to create beauty from within

SAB & Corona strengthen the plastic recycling chain

Microbiological testing and its benefits

F&B industry

tna celebrates 40 years

Jumping onboard the alternative protein train

PepsiCo launches the Kgodiso Development Fund

technologies to reduce

based sorters for the

Kemin Industries’ “61 Since ’61”– themed anniversary celebration

MEAT, FISH & POULTRY

PROPAK REVIEW

What to expect at IFFA 2022

Didget Printing showcases local talent Ishida’s Propak experience

March 2022 | FOOD RE VIEW

28 18

FOOD SAFETY & COMPLIANCE

FOOD PROCESSING TECHNOLOGY

An industry leader in

Raising the bar on water savings in food processing

equipment for quality

The advantages of air-frying technology

The real cost of poor

The increasing popularity of clean-in-place systems

Processing stainless steel of

supplying laboratory assurance

food hygiene

the highest quality

37 SUSTAINABLE & RECYCLABLE PACKAGING Holistic concepts to achieve sustainable packaging Response to SA Plastics Pact

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Promag H 100: The ﬂow measurement specialist with an ultra-compact transmitter is designed for hygienic applications.

Liquiphant FTL33: The compact point level switch saves your resources with a reliable overﬁll protection.

Smartec and Indumax CLS54D: The toroidal conductivity systems optimize cleaning and reduce product loss.

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March 2022 | FOOD RE VIEW

April FRUIT LOGISTICA BERLIN, GERMANY 5 - 7 April www.fruitlogistica.com

May VITAFOODS EUROPE GENEVA 10 -12 May ONLINE 2 – 13 May www.vitafoods.eu.com/en/home.html PROPAK EAST AFRICA THE SARIT EXHIBITION CENTRE, NAIROBI, KENYA 10 – 12 May www.propakeastafrica.com IFFA 2022 FRANKFURT AM MAIN 14 – 19 May https://iffa.messefrankfurt.com/frankfurt/en.html SIAL SHANGHAI SHANGHAI NEW INTERNATIONAL EXPO CENTRE 18 – 20 May www.sialchina.com

June FOOD & KITCHEN AFRICA 2022 NAIROBI, KENYA 9 – 11 June https://www.expogr.com/kenyafood/ AFRICA’S BIG 7 GALLAGHER CONVENTION CENTRE 19 – 21 June https://www.africabig7.com/ PROPAK CHINA NATIONAL EXHIBITION & CONVENTION CENTER, SHANGHAI 22 – 24 June https://www.propakchina.com/en

NEWS

employees were welcomed in December of last year. The centre started operations with a team of 15 specialists in March 2022. “With this step we want to improve transparency and customer satisfaction,” emphasises Wilkening. Blum expects the change to lead to faster innovation cycles. “By managing the global logistics network

ENDRESS+HAUSER SETS UP SHOP IN IRELAND

ourselves, we can be more agile and make more stringent decisions. We can increase the service level and strengthen our focus on sustainability, for example by always using the most suitable carrier,” explains Blum.

The Endress+Hauser Group will soon be

expanded. “Global supply and sales networks

managing its worldwide logistics network

require making expeditious decisions in the

CONTINUOUS EXPANSION

from a single operations centre in Ireland. A

same room,” emphasises Thorsten Wilkening,

The new centre will operate from the

small team of logistics specialists is tasked

head of Corporate Logistics. Oliver Blum,

premises of the Irish Sales Center in Kildare,

with managing the day-to-day operation

corporate director Supply Chain, adds, “Our

south of Dublin. Founded in 1979, the Sales

and enabling the smooth and sustainable

utmost concern is satisfying all customers,

Center currently has a team of 30 employees

movement of goods.

and that includes the areas of logistics

who assist customers primarily in the life-

and transport.”

sciences and food industries. A Regional

RESPONSIBILITY IN ONE PLACE

Support Center established at the same

The responsibility of the Global Logistics

FOCUS ON CUSTOMER SATISFACTION

location in 2016 provides operative and

Operations Center is to ensure smooth

With the creation of the Global

business process support to a large number

operation of the Endress+Hauser worldwide

Logistics Operations Center in Ireland,

of sales centres. The Human Resources

logistics chain. The group’s global

Endress+Hauser is bringing operative

Shared Services Center team joined the

transport network has become increasingly

control of the logistics processes back into

Ireland location in 2020, where it manages

regionalised in recent years and the portfolio

the company. To date this has been the

learning activities in the worldwide

of carriers and forwarding companies has

responsibility of a service partner. The first

Endress+Hauser network. •

BUILDING A SUSTAINABLE FUTURE ONE BRICK AT A TIME In 2021, Corona became the first beverage

this partnership. SAB Sustainability agenda

possible without the aid of our partners,”

brand in the world to achieve a Net Zero

aims to strengthen and support the local

says Thomas Lawrence, South African

Plastic Footprint. In 2022, and in honour

recycling chain, recognising the importance

Corona marketing manager. For Lawrence,

of Global Recycling Day that took place on

of local recyclers on the plastic waste fight,

supporting a business in the recycling value

18 March, South African Breweries (SAB)

maintain resources in usage and away from

chain is exactly how SAB and Corona are

and Corona are launching a partnership with

our environment - preserving it for future

contributing to creating a circular economy

Ramtsilo, strengthening the local plastic

generations,” says Josh Hammann, SAB

and taking action to keep plastic out of our

recycling chain and assuring a Net Zero

sustainability director.

communities and environment. •

Plastic Footprint in South Africa. The achievement of a Net Zero Plastic

Ramtsilo, a 100% black female-owned company, provides an incredibly sustainable

Footprint means that Corona recovers

solution to the global plastic pollution

more plastic from the environment than it

pandemic. Not only will Ramtsilo facilitate

releases into the world and it focuses on

the plastic collection programme, provide

redesign efforts to progressively eliminate

specialised sensitisation and training among

plastic. This initiative falls in line with SAB’s

waste pickers, but will also repurpose these

sustainability goal, which is to have 100%

plastics into environmentally-friendly, fire

of its products in primary packaging that is

tested bricks that can be used in households,

returnable or made from majority recycled

buildings and roads.

content by 2025.

Corona’s vision is to be a sustainability

Achieving a Net Zero Plastic Footprint is

leader in consumer-packaged goods, taking

part of a long sustainability journey and this

significant steps to help protect the world’s

Global Recycling Day marks the beginning

oceans and beaches from marine plastic

of a long-term partnership with Ramtsilo.

pollution. “We have a duty to decrease

With this partnership, they aim to collect and

our impact on this world and I am proud

recycle hard-to-recycle plastics in Gauteng

to work for a brand that takes this duty

and the Free State. “We are really proud of

seriously. Of course, none of this would be

FOOD RE VIEW | March 2022

NEWS

CELEBRATING FOUR DECADES OF FOOD PROCESSING AND PACKAGING SOLUTIONS WITH TNA Global food processing and packaging

navigate the shifting food processing

specialist tna solutions is celebrating

and packaging landscape. “With the

40 years of revolutionary innovations

wealth of 40 years’ industry-leading

by reaffirming its commitment to

experience behind us, we’re forging

people, the planet and the prosperity

ahead into a new chapter,” adds

of the local communities and regions

Taylor. “We will continue to embrace

in which it operates. As the company

a digitally-forward future, while

enters a new era, its global team of

breaking down the complexities of

experts is looking ahead to build

smart systems, consumer trends

a fresh, innovative and digitally-

and regulatory changes with

forward future.

straight-forward, tailored advice.

Established in 1982 by two

It’s this approach that has made tna

ambitious entrepreneurs, Nadia and

the no. 1 choice for thousands of

Alf Taylor, today tna’s more than 500

operators and engineers worldwide.”

employees have installed more than packaging systems worldwide. The

GOOD FOR BUSINESS, BETTER FOR PEOPLE

company changed the face of food

In parallel to its technical

packaging in 1985 with the launch of

breakthroughs, tna’s sustained

its flagship solution – the tna robag

success can be attributed to a

vertical form fill and seal (VFFS)

people-first approach. “Giving

packaging system.

back – to the larger international

14 000 advanced processing and

Alf Taylor, CEO and managing

community – has always been non-

director of tna solutions, comments,

negotiable for us,” comments Nadia

“A lot has changed over the last

Taylor, co-founder and director

four decades. We’ve expanded our

of tna solutions. “This dedication

family of brands with the acquisition

ultimately led to the creation of our

of leading processing names like

humanitarian organisation, the Nadia

FOODesign, Florigo and NID, and

and Alf Taylor Foundation. Over

added a fully-integrated snack and

the last 20 years, the Foundation

confectionery processing line to our

has helped to transform the lives

list of industry-firsts. One thing that

of more than 20 000 people across

hasn’t changed though, is our positive

39 countries through more than 150

outlook and dedication to serving the

grassroots organisations. We actively

needs of our customers.”

work towards bettering the lives of

As part of its commitment to

the most vulnerable population in

customer-focused progress, tna is

society, supporting children through

pleased to announce the launch

initiatives around education, social

of “tna rethinks” – a new series of

enterprise, healthcare, human rights

blogs and web articles giving tna’s

and social welfare.” •

experts a platform to share their unique perspective on today’s top industry trends and help food brands

Nadia and Alf Taylor, founders of tna solutions

PEPSICO HELPS BUILD A SUSTAINABLE FOOD SYSTEM IN SOUTH AFRICA Food and beverage company PepsiCo recently launched the Kgodiso Development Fund, a fiveyear, R600m investment to help transform the food system in South Africa. It will look to create “shared value” solutions that ultimately help build a sustainable food

Diale Tilo, executive director of the Kgodiso Development Fund

system by creating local employment opportunities and increasing local procurement, and supplier diversity. “PepsiCo aims to play a bigger role in supporting activities that contribute to the long-term sustainability and resilience of South Africa’s food system,” says Tertius Carstens, CEO of PepsiCo Sub-Saharan Africa (SSA). “The Kgodiso Development Fund will act as a catalyst to create local jobs, increase local procurement, build small businesses, support education and holistically contribute to black economic empowerment in South Africa.” The fund has hopes of delivering a meaningful impact through its commitment to creating shared value solutions and transformation of supply and value chains. Although founded by PepsiCo, it will be run as an independent fund with an executive director and a Board of Trustees. “The Kgodiso Development Fund will prioritise activities that support the growth and scaling of black-owned emerging farming enterprises and SMME businesses, promote regenerative agriculture practices and encourage the adoption of innovation to revitalise local production within South Africa’s agriculture sector,” explains executive director of the fund Diale Tilo. The fund will allocate R300m to agricultural development to assist black-owned emerging farming enterprises to upscale their businesses and ensure that they are provided with opportunities to integrate into the value chain. “This will help transform the country’s agricultural landscape by developing a new generation of sustainable farming enterprises,” says Tilo. Additionally, R200m will support education to enable initiatives that provide appropriate training and upskilling – thereby enhancing the skills pipeline in the country. Carstens says, “This will assist in unlocking the immense potential of South Africa’s human capital by addressing key skills and knowledge gaps in the food system.” Within this pillar, PepsiCo launched a Graduate and Future Leaders programme in 2021. Finally, the fund will allocate R100m to SMMEs to provide incubation and technological support to those small businesses which can provide their goods or services to PepsiCo or its partners. “This investment looks to encourage unique innovation, increase competitiveness and drive economic inclusion by building a pipeline of suppliers and entrepreneur networks, and by providing them with a route to market, business development support, funding and mentoring,” says Carstens. •

March 2022 | FOOD RE VIEW

NEWS

CELEBRATING 61 YEARS OF TRANSFORMING LIVES Kemin Industries, a global ingredient

a variety of industries to offer products

co-founder, R.W. Nelson, created the

manufacturer that strives to sustainably

with functional benefits that enhance

company’s first products. The site is now

transform the quality of life every day for

the health and safety of people, pets,

part of a 70-acre campus that is home

80% of the world with its products and

production animals, plants, and the

to Kemin’s $30m global headquarters,

services, is launching its global “61 Since

planet. Six decades later, Kemin remains

built for future expansion and additional

’61”-themed anniversary celebration to

focused on transforming the quality

research facilities.

commemorate 61 years since its founding

of life.

in 1961.

“For six decades, Kemin has continued

With more than $1bn in annual sales,

to grow our global footprint with the

the multinational, family-owned-and-

foundational philosophy of serving others

globe interact with any number of Kemin’s

operated company is headquartered

– from our customers to our communities –

over 500 specialty ingredients. Tortillas

in Des Moines, Iowa – on the site

to improve the quality of life. This basis has

that stay fresher for longer; dog kibble

of the old wool barn where Kemin’s

driven Kemin’s product innovation and new

Every day, billions of people around the

market entry around the world,” said Dr

that is more palatable and nutritious; supplements that protect eye health; meat raised without antibiotics; apples free of pests and pesticides – Kemin

From left to right: Libby Nelson, vice president and general counsel, R.W. Nelson, Mary Nelson, and Chris Nelson

Chris Nelson, president and CEO of Kemin Industries and second-generation Nelson family member. “As an essential business

science and solutions can be found in any

serving the global food supply chain, our

of these everyday items.

work became even more critical during the

Initially created to provide feed

pandemic, and our employees, customers,

flavours, crop preservatives and

and partners remained deeply committed

antioxidants to Midwest farmers, Kemin’s

as we all faced the crisis. In 2022, with a

business has greatly expanded since 1961.

deeper recognition and appreciation of

Today, Kemin operates in more than 90

all we’ve accomplished together, we’re

countries and applies its technologies

commemorating 61 years of innovation and

and expertise in molecular science across

celebrating our history.” •

It’s more than supply chain management…

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FOOD RE VIEW | March 2022

PROPAK REVIEW

Growing little fish into big whales One of the bigger focuses of Propak Africa this year was the importance of supporting local in the industry with the overall theme of the final day of the expo even being ‘local is lekker.’ No company believes in this more than Didget Printing, who used their expertise together with the talent of a local artist to create a stand dedicated to showcasing the true potential of local talent. Marketing manager Gabriella Finke spoke to Tennille Aron about their stand.

Tumisang Khalipha at the Didget stand at Propak Africa

were also the first company to be a part of the Did.It entrepreneur initiative, which is an initiative that was started by Didget Printing just before the pandemic began to help entrepreneurs that they have identified to grow and develop their businesses. “The idea behind the concept was to have a curated café at the expo and so they decided to take a local artist’s artwork and turn it into art that could be shared with a wider community by replicating the artwork on coffee bags and assembling it into a 4m high installation at the Didget

"I remember suddenly having the idea of turning coffee into art and art into coffee."

stand. This would in turn provide more exposure for both the artist and the coffee brand. Each individual bag has a piece of the original artwork, a unique number as well as the Sonwaro story on it. All of these

items were printed onto the bags using Didget’s digital printing capabilities and was put together manually. “Tumisang didn’t even know what his artwork was being used

for when he agreed to let us use it. When he n amongst the sea of the latest packaging

about showing how big companies can help

arrived here and saw his art, he was actually

machinery and equipment on display

grow little fish around them into big whales.

very emotional,” says Finke.

at Propak Africa, stood a structure

This was an opportunity for Didget to pay it

“The next step in the process would be to

consisting of over 273 coffee bags that

forward by helping fellow entrepreneurs gain

auction of the installation either as a whole

had been digitally printed and assembled

more exposure for their businesses.

or as separate bags and all the proceeds

together to replicate a beautiful art piece

Interestingly, the idea for the installation

would go towards an art scholarship, paying

painted by talented local artist Tumisang

came about while we were sitting and

it forward to another artist. So, we want to

Khalipha. This amazing artwork stood in the

having a coffee,” explains Finke. I remember

use this to support another up-and-coming

middle of the Didget Printing stand at the

suddenly having the idea of what if we

local artist,” said Finke. At the end of the day,

expo and as marketing manager Gabriella

turned coffee into art and art into coffee,”

these initiatives help us to be the best of

Finke explains was about more than just

says Finke. And that is exactly what they

ourselves by helping those around us. The

displaying the outstanding digital printing

did. Sonwaro Coffee is a local coffee brand

installation was well received at the expo

capabilities of the company, but it was rather

with their coffee house in Maboneng. They

and was already receiving great interest. •

March 2022 | FOOD RE VIEW

PROPAK REVIEW

Ishida attends Propak Africa 2022 After two years of uncertainty from the pandemic, Ishida was extremely excited to be back at the Propak Africa expo, which took place at the Expo Center Nasrec in Johannesburg. If there’s anything the last two years has taught them and the industry as a whole, it is that brands need to spend more quality time listening to their customer’s needs, and the show afforded them the perfect opportunity to do just that.

ead generation is always a top

Africa is the only accredited service

students develop their skills in the food

priority for brands who exhibit

provider of packaging qualifications. At

packaging industry.”

at Propak Africa and this year

the moment we are offering marketing

While manufacturing equipment is Ishida

certainly didn’t disappoint. In fact,

and business development. The Ishida

business, David Tiso, managing director of

according to Ishida’s general sales

learnership programme is targeted at

Ishida Europe, explains that the drive behind

manager Melika Seiderer, unlike previous

underprivileged young people who haven’t

the company is so much more than that. The

years where people came to browse,

completed school, but who have a strong

company is focused on growing their local

the client base that attended this year’s

desire to learn. We intend to take them

communities and most importantly, helping

event were there with a dedicated focus

out of their current situation and help

their customers achieve their goals. “Our

to make purchasing decisions. While this

them gain the qualifications necessary

approach to our customer is not necessarily

was great for the brand, one of the other

to either take up a position at Ishida or

around the machinery, it is about the

important opportunities that the show

with our affiliated customers, ” explains

customer. What’s important to them, what

presented was the chance for the Ishida

Seiderer. “The goal is that in the next ten

they seek to achieve and how to implement

team to see first-hand the changes in the

years, we would have helped at least 40

it, says Tiso. •

market drivers that the pandemic has brought about as well as the challenges that their customers are currently facing. “As we speak to clients at the show, we are seeing a greater demand for automation,” explains Mike Cairns, sales director at Ishida. Ishida South Africa certainly intends to meet this demand with more entry-level automation systems set to enter the South African market in the upcoming months.“ Later on in the year, we will be bringing in entry-level machines that suit a market that is just entering automation,” says Seiderer. Apart from providing high-quality machinery, Ishida is also dedicated to integrating themselves into the local communities through their new learnership programmes. “Ishida South

Team Ishida at Propak Africa

FOOD RE VIEW | March 2022

INDUSTRY TALK More and more plants in the F&B industry are being digitalised with fieldbus- independent IO-Link technology.

IO-Link accelerates digitalisation of process plants IO-Link is enjoying increasing popularity, with demand for the communications standard growing rapidly, especially in the F&B industry. The fieldbus-independent technology for point-to-point communication is easy to use and provides a cost-effective way to digitalise industrial plants. Endress+Hauser, a leading provider in the industry, offers a wide range of IO-Link products for a large selection of process parameters.

O-Link is regarded as an established

be optionally operated in analog mode

standard for measurement devices with

(4–20mA) with simple configuration changes

NEW ADDITIONS TO THE IOLINK PORTFOLIO

basic functionality, offering advantages

to the instrument, thus allowing production

Endress+Hauser offers a comprehensive

such as data transparency and additional

workflows to remain in place. If extra

product portfolio of IO-Link-capable

control through digital technology.

information such as diagnostic and service

instruments for all relevant process

Integrating IO-Link-capable sensors and

data is required, in addition to the actual

parameters. The company recently

actuators is especially popular with suppliers

process parameters, an installed IO-Link-

introduced the Smartec CLD18 compact

of machines or skids for the F&B industry.

capable instrument can be simply switched

conductivity sensor, IO-Link versions of

Particularly for utilities, devices with basic

to a digital signal.

the PMP51, PMP55 and PMC51 pressure transmitters, and the Deltapilot FMB50

functionality are well suited; instruments with

A SIMPLE AVENUE TOWARDS INDUSTRY 4.0

level transmitter. With these new additions

“Although IO-Link is not the most powerful

exploit the benefits of digitalisation in a

BROAD OFFERING FOR THE F&B INDUSTRY

communications standard for process

cost-efficient manner. •

Endress+Hauser is a leading global supplier of

and harbours tremendous potential for

process instrumentation for the F&B industry.

the digitalisation of process plants,” says

“No other manufacturer offers such a broad

Naidoo. Endress+Hauser instruments with

and deep range of products and services.

IO-Link interfaces support the transmission

Our comprehensive IO-Link portfolio clearly

of helpful metadata to ensure stable and

illustrates this position. As a strong partner

efficient production. Furthermore, the

for process automation, we support our

smart sensor profile is designed for simple

customers with IO-Link sensors in numerous

engineering, which reduces the effort

fields of application,” says Dhiren Naidoo,

required by plant operators to integrate

industry manager: Food and Beverage.

sensors into their systems.

ANALOG SIGNALS AND DIGITAL COMMUNICATION

Endress+Hauser offers a wide range of process instrumentation with IO-Link technology for digital communication.

a rich set of different functionalities would unnecessarily increase complexity and costs.

The majority of the IO-Link sensors can

March 2022 | FOOD RE VIEW

to the IO-Link portfolio, customers can

engineering, the technology is cost-effective

Endress+Hauser – www.endress.com

Complete Prepared Food Solutions designed for your business •

Preparation & Processing

•

Frying & Oil Management

•

Batter & Breading

•

Branding & Searing

•

Cooking, Roasting & Drying

•

Coating & Seasoning

•

Product Handling

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

info@heatandcontrol.com

heatandcontrol.com

INDUSTRY TALK

The importance of microbiological testing What does microbiology have to do with food safety? More than you think. It is one of the main aspects of overall testing in South Africa, in fact. Failing to do the necessary microbiology testing can result in a slew of complications. But what should you test for? How often should you have your products tested? What does the law say about microbiology testing?

s a manufacturer, it is your responsibility to ensure that your food products comply with

standards and regulations. That’s why you need to clarify your testing strategy. To do that, you need an understanding of microbiology testing. So, let’s get into it.

What is microbiology testing? Microbiology testing is the process of analysing your products to detect and quantify pathogenic microorganisms. The purpose of it is to ensure that the food is safe for consumption. These labs can test your products for a variety of microorganisms.

How does this fit into overall food safety?

"Microbiology testing is the process of analysing your products to detect and quantify pathogenic microorganisms."

The frequency of microbiological testing depends on the type of product you are producing. Moist foods need to be tested more often than dry foods. This is because

Foodstuffs can carry hazards that are not visible to the human eye. These could be

How often should you do microbiology testing?

Partly cooked or uncooked seawater or

dry environments are not hospitable to

microbiological or chemical risks. Common

freshwater foods like mussels should have

bacteria. However, despite the technicalities

hazards, in terms of microbiology, include

a limited amount of Vibrio and Shigella. In

of how often you should test, it is still a good

bacteria like salmonella. Food products can

25g of these products, the microorganisms

idea to test frequently.

also contain parasites and pathogens. If

should be absent.

ingested by people, these can cause illnesses

These are just two examples to show

In 2017 -2018, a pathogen called Listeria monocytogenes went undetected in certain

and disease, and could have a detrimental

you that you are required by the law to

meat products. This led to a listeriosis

effect on public health. Microbiology testing

ensure that your products are safe. The

outbreak in South Africa, which caused the

helps you to prevent harm being caused

laws are in place to keep people safe. So, if

death of more than 180 people. If pathogens

through your products.

you don’t follow them, you are endangering

go undetected in your products, you face

people’s lives.

severe reputational risks, unnecessary costs (the sum of recalls, legal fees, damages and

What does the law say?

more), and you are putting people in harm’s

The Department of Health has made

What should you test for?

regulations for microbiological standards,

There are two sectors of microorganisms

way. It’s better to test frequently to avoid a

in terms of the Foodstuffs, Cosmetics and

that you should be aware of. The first group

situation like this.

Disinfectants Act, 1972 (Act no. 54 of 1972).

are microorganisms that result in spoilage.

Anything that results in food poisoning or

They detail various organisms that are not

These will not cause people to get sick, but

spoiled foods, is a risk to food safety. That’s

allowed to be present in food products.

will cause food to go off. In general, for this

why microbiology testing is so important.

Also, they specify which tests you should

category you would test for bacteria, moulds

Undetected harmful substances can cause

use to find organisms in food. For instance,

and yeast.

your business and your customer’s harm.

they explain that: All food products are

Second, you should test for pathogens

To avoid this, you should get in contact

prone to spoilage by microorganisms.

that cause food poisoning. For example,

with accredited providers of food and

Certain microorganisms like Escherichia

E.coli or Salmonella. It is important

occupational health and safety testing, to

coli, Listeria monocytogenes as well as

to remember that there are limits for

analyse your products. •

Salmonella should be absent in ready to eat

the presence of all microorganisms in

food products.

March 2022 | FOOD RE VIEW

Assurecloud – www.assurecloud.co.za

From farm to fork. Southern Africa’s Leader in Food Safety

Testing We provide a broad range of Chemistry, Microbiological, Diagnostic and Molecular Testing in our custom-built, state of the art laboratories country wide.

Professional Lab Testing Services www.assurecloud.co.za

INDUSTRY TALK – PLANT-BASED ALTERNATIVES

Companies scramble to develop egg-citing new plant-based products South African companies across several sectors have jumped onboard the alternative protein movement, with many making great strides in plant-based meat, milk and cheese. However, the next opportunity seems to be winking from the horizon, and it is something that companies might not have egg-spected.

ompanies have been producing

or ethical reasons, there is one product

soy and almond milk for as long

whose replacement is not freely available,

as we can remember, with newer

and that has created potentially huge

Donovan Will, Director of ProVeg SA

options like pea and potato milk emerging

opportunities for local food manufacturers.

improves shelf-life and

only recently. On the meat side, many

That product is the egg.

reduces input costs.

would argue that at least some options,

For baking applications, there are

When consumers think of eggs though,

like Beyond Meat’s beef-style burger or On

already many well-known alternatives

they think of fried, poached, scrambled

The Greenside’s chicken-style fillets, are

like banana, flax seeds, chickpea flour

eggs or omelettes. Like milk, cheese and

indifferentiable from the products they

and packaged egg replacers like NoEgg.

meat, there is a growing demand for plant-

replace (and some have gone as far as to

Using these replacements not only allows

based alternatives that mimic these foods

say that they are improvements).

food companies to appeal to health,

at a reasonable or equal cost. This creates

environmental and ethical considerations,

a potentially huge opportunity for local

but also removes an allergen, and often

food manufacturers.

For those who are looking to avoid animal products, for health, environmental

March 2022 | FOOD RE VIEW

INDUSTRY TALK – PLANT-BASED ALTERNATIVES

"Some of the main ingredients being investigated as base ingredients to manufacture plant-based eggs include mung beans, chickpeas and fava beans." There are international leaders, like Just,

are created. New formats of legumes and

who has a liquid egg that claims to make

other proteins can be developed to use as

the perfect scramble, and whose Just Egg

base ingredients, plant-based materials to

folded egg is available in South Africa. While

manufacture realistic “eggshells”, omelette

reviews are quite positive, these products

mixes, and even plant-based ready-meals

have limited applications - like not being

that appeal to the vegan, vegetarian and

African firms cannot take a big share of this

able to be served ‘sunny side up’.

flexitarian market.

international market, and help to grow the

A few small local firms are proving that

Currently, South Africans consume

local demand too.

South Africans are extremely innovative

between 150 and 159 eggs per person with

and are demonstrating what is already

a national population of about 60 million

needed to perfect the plant-based egg,

possible with modern food science. Urban

people. This is in stark contrast with the

and even then more work is needed to get

Vegan launched a new egg that can be

plant-based egg market, which is virtually

the price point to a place where they can

used to make scrambled ‘egg’ or omelettes.

open for the taking.

compete with chicken eggs. Considering

Perhaps the most innovative ‘egg’ we have

According to Factmr.com, the global

More research and development is still

the ingredients and the rapid overall

seen locally is Vegan Streetfood’s crack-

vegan egg market experienced year-on-

growth, this presents a huge opportunity

able egg. This egg alternative product looks

year growth of 6.9%, which accounted for

for SA food manufacturers to be a world

just like a fried egg and even comes in a

US$1.5 billion in 2021. Growth is expected to

leader in one of the fastest-growing global

plastic egg casing for the added enjoyment

continue to rise. There is no reason South

food segments. •

of being able to ‘crack’ an eggshell. This product also sports a realistic poppable yolk allowing consumers to finally enjoy a sunnyside-up plant-based fried egg. Some of the main ingredients being investigated as base ingredients to manufacture these plant-based eggs include mung beans, chickpeas and fava beans. Flavourants may include Kala namak (a volcanic salt with a taste that resembles boiled egg) and more well-known spices like turmeric. These ingredients often have less saturated fat, contain fibre and can have increased health benefits. These firms are priming the scene for product development by even bigger companies with more resources and expertise, and as these products are improved, multiple layers of opportunities

FOOD RE VIEW | March 2022

FOOD PROCESSING TECHNOLOGY

Save up to 95% in CIP liquid Drain valves comprise up to 20% of all valves in a typical processing plant. However, cleaning them is costly, difficult and time-consuming due to long cleaning cycles and the risk of pressure shocks. The new Alfa Laval ThinkTop pulse seat clean addresses all these issues, quickly and effectively making drain valves spotless, while delivering savings of up to 95% in Cleaning-in-Place (CIP) liquid.

savings yet again. The new pulse

FASTER, MORE EFFECTIVE PULSE CLEANING

seat clean feature cuts drain valve

Short bursts or pulses drive the valve

hinkTop is raising the bar on water

The Alfa Laval ThinkTop pulse seat clean

CIP liquid consumption by up to 95%.

cleaning process, activating the valve when

Imagine the savings made possible by using

shear forces peak. Each position-based pulse

this standard automated valve-position

takes less than a second, preventing pressure

feature, triggered by a rising programmable

shocks in the system. The pulse creates high

logic controller (PLC) signal and controlled

turbulent flow as the liquid passes through

by the Alfa Laval ThinkTop V50 and V70

the narrow gap between the valve house and

sensing and control units. “The ThinkTop

valve seat, effectively removing all residuals

pulse seat clean brings unheard-of savings

for spotless drain valves.

and close the seat quickly ensures faster, more rigorous cleaning and hygiene than timer-controlled cleaning. The ThinkTop also verifies that valve cleaning has been seat valves or butterfly valves used as drain

valves and automation, Alfa Laval. “Alfa

100% CLEANING VALIDATION OF DRAIN VALVES

Laval is the first and only valve automation

The pulse seat clean makes control and

solutions provider to deliver significant

validation of valve cleaning cycles easy.

savings in CIP liquid for drain valves,”

The valve position is not controlled by the

says Stietz.

PLC timer, but by the Alfa Laval ThinkTop.

FIND

used, programming the sensor to open

completed. Intended for use with single-

in CIP liquid to process plant owners,” says René Stietz, product portfolio manager,

Besides reducing the volume of CIP liquid

valves, pulse seat clean is a standard feature of ThinkTop V50 and V70 sensing and control units with one solenoid valve. •

Alfa Laval – www.alfalaval.com

US A T

Hall 10.1 Stand G071

DC Norris is committed to helping customers reduce their carbon footprint using cutting-edge systems to reduce water and energy usage. We can stream-line your processes with faster cooking and cooling times whilst achieving optimum performance.

Food Processing Innovation

“Production times are much quicker, whilst giving excellent ﬁnished product quality.” Nigel McGinn, Kettle Cuisine, USA DC Norris & Company Ltd www.dcnorris.com www.jetcook.dcnorris.com

March 2022 | FOOD RE VIEW

Courlanders Agencies (Pty) Ltd T: +27 43 722 5513 E: c.tucker@courlanders.co.za

A COMPLETE RANGE OF PUMPS FROM ONE MANUFACTURER

VERDER

The perfect pumps for food and beverage manufacturing Verder is the pump manufacturing specialist with a wide range of hygienic pumps. These range from the PACKO® centrifugal, rotary lobe and twin screw pumps, to hygienic versions of VERDERAIR® and VERDERFLEX® pumps. With this complete range we can answer all your hygienic pump questions!

This PACKO ZL series for example is designed for a wide range of hygienic applications in dairies, breweries, the pharma and cosmetics industry and bakeries etc. The ZL is the ideal solution for gentle pumping of low to high viscous liquids. Max. flow

100 m³/h

Max. viscosity

1.000.000 cP

Max. pressure

20 bar

Max. temperature

150 °C

Certifications

OTHER HYGIENIC VERDER PRODUCTS

+27 (0)11 704 7500 VERDER PUMPS SOUTH AFRICA (PTY) LTD

TEL +27 (0)11 704 7500

MAIL info@verder.co.za

WEB www.verder.co.za

VERDER is manufacturer of VERDERFLEX®, VERDERAIR® and PACKO® pumps

FOOD PROCESSING TECHNOLOGY

Taking advantage of the growing air fried foods market Heat and Control, a world-leading equipment manufacturer and long-term partner with process prepared foods industry, brings together technologies to introduce the AirFry System to create lower oil content food products. The popularity of air frying has continued to grow over the last decade and brands are looking to take advantage of new product opportunities in the market.

he AirFry System creates air oven fried products with taste, texture and appearance like fried foods

without using traditional (submersion) frying methods. The AirFry System provides a continuous means to produce a ‘fried-like’ product by applying a controlled volume of topical oil, followed by pressurised high velocity cooking atmosphere from an impingement oven. The system utilises highly accurate spray dynamics oil application equipment that ensures complete and uniform coverage of the product while keeping oil use to a minimum. Paired with Heat and Control’s AirForce Impingement Oven with its highly uniform airflow and high levels of process parameter adjustment, ensures the most uniform and fastest air fry time in the industry. The AirFry System works with standard batter and breading application systems. Customers have the option for a complete, new system installed, or existing impingement oven owners can retrofit a spray applicator system with minimal investment.

March 2022 | FOOD RE VIEW

FOOD PROCESSING TECHNOLOGY

CEIA Inspection Solutions designed for your business ABOUT HEAT AND CONTROL Established in 1950, Heat and Control is a privatelyowned company with a global team that has built an extensive knowledge bank and developed a wealth of experience and expertise. Access to production and technical support from a network of engineers, food technicians, field service technicians, skilled tradespeople, and support teams provide food manufacturers with confidence to achieve production goals. • Eleven manufacturing facilities, 12 test centres, more than 30 offices globally • Testing, design, engineering, manufacturing, installation commissioning, user-training, spare parts and provision of after sales service.

“Heat and Control wanted to assist our customers in producing a high-quality product with fried characteristics without using the traditional submersion frying system,” said Doug Kozenski, Processing industry manager at Heat and Control. “We have been working closely with the industry to develop innovative ways to adapt to consumer trends demanding low oil content.” With 1600+ employees worldwide in more than 30 offices, Heat and Control brings science, imagination and unmatched commitment to every project. Striving to do more, they help customers bring their products to market. •

Heat and control – www.heatandcontrol.com

Top inspection performance for total product quality confidence. Deliver unparalled inspection with extremely high detection sensitivity for metals - whether ferrous, non-ferrous, or stainless steel - for all manner of food and pharmaceutical products. Whatever your product needs, we can meet it with precision and passion.

info@heatandcontrol.com

HP_V_CEIA_2022_SAFoodReview_88.5w x 262h.indd 1

heatandcontrol.com

17/01/2022 FOOD RE VIEW | March 2022 2:29:02 PM

FOOD PROCESSING TECHNOLOGY

Custom clean-in-place systems offer economic and environmental benefits With the rising costs of raw materials and labour, the need to make food processing more efficient and cost-effective is on the rise. Besides the cost of materials, there are also hidden costs in the amount of downtime and the cost of water and chemicals required to keep food processing systems properly sanitised and operating at full capacity. Manufacturers are now looking at ways to integrate more sustainable food processing solutions, providing economical and innovative options.

lean-in-Place (CIP) sanitation

chemical savings. Running an automated

Automatic CIP systems feature

systems are becoming more popular

CIP system allows for the maintenance of

automatic valves that will introduce

in the F&B industry, offering a

your cleaning schedule and decreases the

the CIP flow at the proper time to the

modern method for automated cleaning.

wear and tear on your machine. Operators

process line. The valves allow the flow of

These systems consist of stationary skids

will have a safer work environment as they

product to pause, introduce the cleaning

with cleaning circuits installed throughout.

will have less exposure to chemicals and

solution and then reintroduce product

Highly customisable mechanical

can avoid situations with confined space

back to the system after sanitisation is

arrangements and controls lead to an

entry. While it is difficult to calculate the

complete. Tanks can be incorporated for

efficient process, minimising downtime.

exact amount of savings that comes with

caustic wash, acid wash and freshwater

CIP systems provide a valuable return

a safer work environment, preventing

rinsing. The automation sequences include

on investment when considering how

workplace injuries allows for more

regulating duration, amount of chemicals

many hours will be saved from minimising

productive workers, less downtime and

and temperature. Electronic data records

unscheduled downtime and implementing

increased performance. With a focus on

and digitally saved files streamline the

faster cleaning cycles. Systems can also

safer conditions for employees and safer

record-keeping process to stay compliant

fit in tight and congested spaces when

products, quality will naturally be passed to

with the industry.

planned properly.

the customers. Preventing contaminations

Food grade panels are integrated into

between batches leads to consistent

our custom systems that are rated for

allow for increased traceability and are

product and decreases the opportunity for

complete washdown. Hygienic enclosures

environmentally friendly with water and

foodborne illnesses.

protect electrical equipment in the

By increasing efficiency, these systems

most extreme washdown and sanitary conditions. FDA compliant gaskets protect against cleaning agents and are safe for high-pressure washes. Sanitary door latches can also be added to save time during the cleaning process. The Spec Engineering team has prior experience with customising a CIP system to fit in a congested space. In a project for a leading food manufacturer, Spec transitioned a 20-year-old CIP system to a modern, automated system. Old and new lines were run simultaneously for approximately four weeks before completely transitioning to the new system. With a skid system of 6m long x 2m wide x 5m tall, the engineering team needed to be strategic with transporting

CIP sanitation systems are becoming more popular in the F&B industry, offering a modern method for automated cleaning

March 2022 | FOOD RE VIEW

FOOD PROCESSING TECHNOLOGY

"CIP systems provide a valuable return on investment when considering how many hours will be saved from minimising unscheduled downtime." The CIP system in a food manufacturing plant

space with over 600m of sanitary tubing

Automated CIP sanitation systems

installed. There was a large effort from

make food processing solutions more

the automation team as new safety

efficient while reducing the amount of

the system into the facility, while also

features were introduced to the system

water and chemicals used and increasing

finding the proper space for the system.

and PLC/HMI controls were Ethernet-

operator safety. Whether integrating a

This modular CIP skid was pre-assembled

connected throughout. While plant

new CIP system into your food processing

in Spec’s manufacturing facility and

capacity increased, the integration of the

line or updating an old system, the

an in-house factory acceptance test

CIP system also decreased downtime for

economic and environmental benefits are

was completed. The skid was then

cleaning shutdowns. At the same time,

well-received. •

disassembled and prepared for shipment.

there is increased cleanability and hygienic

Pipe routing plans were developed to fit the system into the congested

design while the amount of operator interaction has decreased.

Spec Engineering – www.spec.engineering

• Vacuum Cook/Cool • Pressure Cooking • Bratt Pans

FOOD RE VIEW | March 2022

FOOD PROCESSING TECHNOLOGY

Particle size reduction technologies for selected foods and food additives In the food, luxury food or food additive sector, micronisation is one of the most important processing steps. For that unit operation, Netzsch Food & Confectionery offers advanced processing technologies to reduce particle sizes. Examples are natural food colourants, diverse hydrocolloids, fibres, sugar and sweeteners, but also nut and oil seed pastes, cocoa and chocolate related products.

n the field of dry milling and classifying, a wide range of machines are available, including flexible fine

impact mills as well classifier and jet mills for fineness below 20µm. For fibrous products like cellulose or carob, fine-cutting mills are installed. The machines and systems must meet the highest requirements regarding safety and hygienic design, which makes Netzsch a proven and reliable partner for the processing of high-quality food and food additives by dry-milling. In addition to this, one can also depend on Netzsch’s experience and expertise as a worldwide leading company in the area of wet-grinding and dispersing. With innovative dry and wet processing technology, an economical solution that suits your requirements is always found.

PROTEIN SHIFTING AND ENRICHMENT WITH THE USE OF DRY GRINDING AND CLASSIFYING The worldwide nutritional demand for plant-based proteins is increasing enormously. The main sources are soybeans, wheat or peas. More often, regional crops such as faba beans are being taken into consideration. Semi manufactured products are among others protein-enriched flours or highprotein containing isolates using wet processes. The use of large amounts of water, chemicals and energy for drying makes isolate production

March 2022 | FOOD RE VIEW

"Netzsch Food & Confectionery offers advanced processing technologies to reduce particle sizes."

The Netzsch CFS/HD-S achieves the highest yields with a minimal loss of protein in the highstarch fraction

a laborious, complex and resource consuming process. Netzsch focuses itself on protein shifting by dry grinding. This process, taken from classical flour production, is being used successfully to process legumes such as yellow peas, faba beans, mung beans or chickpeas. The aim of the process is to gain a protein-rich fraction

FOOD PROCESSING TECHNOLOGY

by fine-grinding and classifying, in which the amount of protein is considerably higher than in the original product.

PROCESSING STEP 2 – EFFICIENT SEPARATION USING A HIGHEFFICIENCY CLASSIFIER, MODEL CFS/HD-S

PROCESSING STEP 1 – PRODUCTION OF REFINED FLOUR

The resulting refined flour, which has

Ideally, the cleaned legumes are dehulled

low-protein fraction, has a particle size

prior to the protein shifting process to

between 40 and 70µm. This is a range that

a residual portion of < 1%. The refining

brings conventional sifting to its limits. For

serves to break the cell structure and

this reason, fractionation with dynamic air

to isolate the relatively large starch

classifiers has become widely accepted.

granules from the smaller protein

to be separated into a high-protein and

The Netzsch High-Efficiency Fine

granules. Depending on the product, the

Classifier, model CFS/HD-S achieves

proteins have a particle size of < 3µm,

the highest yields with a minimal loss

whereas the starch granules range from

of protein in the high-starch fraction.

3 to 40µm.

In contrast to conventional classifiers,

Most important for the subsequent

this classifier is highly compact and is

separation is that during grinding, the

equipped with a guide vane cage for

difference in size between the protein

most efficient dispersion and separation

and starch granules remains as large

– the decisive advantages when viewing

as possible. Care must be taken not

the economics of protein enrichment.

to damage the starch granules in the

Dependent on raw materials, protein

process. The most effective and gentle

values > 60% in the protein rich fraction

way to achieve this is through impact

are obtainable! •

grinding in a Netzsch Classifier Mill, model CSM.

Netzsch – www.netzsch.com

ABOUT NETZSCH GRINDING & DISPERSING The Grinding & Dispersing Business Unit, one of three business units of the global Netzsch Group, offers a comprehensive program for the many challenges in mechanical process engineering. The Business Unit is primarily involved in the areas of wet and dry grinding, mixing, dispersing, de-aeration and classifying. The laboratory- and production-scale machines as well as complete production lines, are used in almost all areas of industry, such as the forward-looking nanotechnology, the production of ink, minerals or foods. The bundling of processing knowhow, their extensive machine program, solutions for customerspecific problems and their global presence are unique. Hence, the strength of the business unit. Their performance standards are high. They promise customers proven excellence – exceptional performance in everything they do, proven time and again since 1873.

The perfect mixture

of safety and efficiency!

NEW! Available as ATEX version

and with Special Alloy materials

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 • https://www.vdm-awh.com

made by

FOOD RE VIEW | March 2022

FOOD PROCESSING TECHNOLOGY

Maximising protein’s profitability from meat, poultry, rendering and pet food There’s money in protein. Whether it’s meat or poultry, and whether it’s processed for human consumption or rendered for pet food, it’s worth making the effort to extract every possible kilogram of saleable raw materials. However, this is a business with risks.

or one thing, derived meat

Increasing meat production is good news

the right fat percentage for any grinder/

for rendering delivered by

for processors and renderers, but there is

mixer set-up for minced meat, burgers

slaughterhouses typically contains

a downside: meat and dairy production are

and sausages as well as making real-time

foreign materials and these can be so

responsible for a whopping 14% of global

measurements of protein and moisture

difficult to detect that they get all the

greenhouse gas emissions. This means

levels. The QV-P in-line detection machine

way down the processing line into the

it’s imperative to minimise food waste by

for chicken fillets helps ensure that fillets

final product. For another, when rendered

making more efficient use of the potentially

with ‘wooden breast’ don’t end up in the

meat and poultry are turned into dry

usable food in livestock. For these reasons,

final packaging.

pet food, one type of kibble can easily

rendering is an environmentally-friendly way

get cross-contaminated with another,

to recycle material that would otherwise be

sausages shouldn’t be compromised by

so that packages mistakenly contain

wasted - and it also reduces the greenhouse

having casing residues still attached to

unlisted ingredients.

gas emissions.

the final product. The Tomra 5B detects

These threats mean it is crucial for

Producing and selling tasty, protein-rich

even the smallest casing fragments. The Tomra 5B also controls for sausage length,

safeguards in place to protect food safety

SORTING MACHINES SOLVE THE PROBLEMS

and product quality, while also minimising

Tomra Food, the leading manufacturer of

There’s the option to sort out the rejects in

food waste to improve sustainability

sensor-based sorters for the food industry,

two streams - one for foreign materials and

and profitability.

offers machines that safeguard brand

casing remains, and one for products that

reputations and enhance sustainability

don’t match the set scope but can be reused,

RISKS, YES - BUT POTENTIALLY BIG REWARDS

by reducing food waste, protecting food

minimising food waste.

The risks and rewards of meat processing

product standards.

processors and renderers to have effective

safety and consistently maintaining high

and rendering are increasing for two big

dimensions, discolouration and breakages.

For IQF products such as chicken nuggets or stripes, bacon bits or other breaded or un-breaded products, the best sorter is the

reasons. One is that consumers have become

SOLUTIONS FOR MEAT AND POULTRY

Tomra 5C. This unit sets the benchmark

far less tolerant of imperfections in the food

Tomra offers sorting solutions for a wide

in product safety at the same time as

they buy for themselves or their pets. The

variety of meat and poultry applications.

minimising false rejects and food waste. By

other is that the demand for high-quality,

These are for frozen products such as

using new, best-in-class laser technology

protein-rich foods for people and pets is

ground meat, nuggets, patties and bacon

combined with Tomra’s unique biometric

growing fast.The United Nations’ Food and

bits, and for fresh raw products such

signature identification (BSI+) scanner, the

Agriculture Division predicts that by 2050

as sausages.

unseen becomes visible, making foreign

global meat production will double as the world’s population increases to 9.8 billion.

March 2022 | FOOD RE VIEW

Tomra also offers inline inspection systems. These help processors determine

materials a problem of the past. These technologies are also highly effective at

FOOD PROCESSING TECHNOLOGY

In dry pet food, foreign material isn’t

AN INVESTMENT THAT PAYS

the only threat - there’s also the problem

When processors and renderers first

of cross-contamination. As a solution, the

adopt Tomra’s sorting solutions, they

sorting-out discolouration, black spots,

Tomra Nimbus is unbeatable. This machine’s

are pleased to find that the once-steady

embedded plastic, doubles, thin coating

various sensors protect against foreign

trickle of customer complaints dries up.

and voids.

materials, loose and embedded, and cross-

One good example of this is JG Pears, a

contamination - and with Tomra’s new pet

leading processor of animal by-products

SORTERS FOR PET FOOD AND RENDERING

food software, the change over from one

and food waste in the UK, producing a

recipe to the next is like a snap of the fingers.

range of meals and fat for the pet food

The Tomra 5C prevents foreign materials

Tomra’s unique BSI+ technology checks the

industry. The company’s site manager, Craig

from reaching the pet food manufacturer.

inside of materials, ensuring that different

Harrison, said, “Non-conformances with our

This sorter often acts as the final control

types of kibble don’t get mixed even if they

customers have reduced dramatically, and

on the meal line: placed after the final

are near-identical in outward appearance.

we see very little waste or foreign bodies in

screen, it not only detects and rejects even

In wet pet food, the Tomra 5B is ideal for

our material. Our current customers have

the smallest particle of foreign material,

the inbound set-up, where incoming frozen

seen the difference in the finished product

but also sources out all the good product

blocks pass through either a breaker or a

and there’s lots of interest from additional

coming from the screen, feeding this into the

grinder before entering the mixer. Placed

customers enquiring about buying

good stream again. These capabilities, plus

between the breaker and mixer, it effectively

our material.” •

the ability to regulate the ash content to

detects and sorts various foreign materials

enhance the final quality, make the Tomra 5C

including stones, hard and soft plastics,

essential for every meal stream.

metal, wood, glass, rubber and bones.

Tomra Food – www.tomra.com/food

TOMRA 5A OPTICAL SORTING TO A HIGHER LEVEL The TOMRA 5A sorting machine guarantees optimal sorting of your food products. For more than 40 years, TOMRA Food designs and manufactures sensor-based sorting machines and integrated post-harvest solutions for the food industry, using the world’s most advanced grading, sorting, peeling and analytical technology. Better productivity, quality and efficiency for your industry. FOOD@TOMRA.COM

WWW.TOMRA.COM/FOOD

FOOD RE VIEW | March 2022

FOOD SAFETY & COMPLIANCE

Making the world a safer, healthier and better place

Due to our growing population, unsurprisingly comes an increase in the demand for food production. Meeting this urgency has become a significant challenge to the agricultural industry, especially having the pressure to decrease livestock production’s environmental, ethical and human health impacts.

ellular agriculture aims to produce

the other hand created

in more countries,

animal products that are typically

by the downflow air. The

in more languages,

obtained from live animals and

downflow air passes

than any

holds the possibility of producing a variety

through an ULPA filter

other product,

of cultured products from meat, milk,

and creates an ISO Class 3

demonstrating

egg whites and even leather. As these

work zone to protect

their commitment

processes, such as tissue engineering,

samples from the risk of

to the industry’s

stem cell biology and genetic engineering

cross-contamination. The

best safety

evolve, so does the importance of food

air exhausted also passes

and quality.

safety within these environments.

through an ULPA filter

Esco Technologies (PTY) Ltd is an industry leader in supplying laboratory equipment suitable for food QA/food

Quality

prior to release to protect

Assurance

the environment.

requires

Esco biosafety cabinets

many diverse

safety use, throughout South Africa and

have a wide range of

technical and

the African countries. With Esco, you are

options from work trays,

analytical skills.

assured of the highest quality product

side panel construction

It continuously

best suited for your sample preparation.

to accessories. Esco

monitors incoming

BSCs are designed with

raw and finished

Esco’s Biological Safety Cabinet is a

products to ensure

primary engineering control that provides

ergonomic and energy-

user protection against biohazards as

saving features. Aside from providing

compliance with compositional standards,

the inflow air creates airflow barrier,

protection for you and your environment,

microbiological standards and various

preventing accidental release of

Airstream Class II biological safety

government regulations. A typical food

biohazards from the cabinet’s working

cabinets provides protection for your

industry laboratory may have a chemistry

area and at the same time provides

microbiological samples.

lab, a raw materials inspection lab, a

product protection with the airflow barrier inside the work zone, which is on

March 2022 | FOOD RE VIEW

Esco’s biological safety cabinets have earned more independent certifications

sensory lab and a microbiology lab. All of these disciplines work together to

FOOD SAFETY & COMPLIANCE

"With Esco, you are assured of the highest quality product best suited for your sample preparation."

assure that the food we consume is of

customers of research accuracy. Cross

maintained for customer reference with all

the highest quality. After all, it is quality

functional teams from production,

the backup procedures.

that will bring a customer back again

R&D, quality assurance and senior

and again.

management are regularly assembled

offices based in Gauteng, Western Cape

to review and implement areas

and KwaZulu-Natal. The local team of

for improvement.

qualified technicians are equipped to

Esco Lifesciences Group is committed to deliver innovative solutions for the clinical, life sciences, research, industrial,

Esco Technologies also provides

Esco Technologies has three local

perform inspection, operational and

laboratory, pharmaceutical and IVF

After Sales Services – where minimising

community. With the most extensive

downtime is a critical objective. The

product line in the industry, Esco have

combination of predictive maintenance

respond to the world’s needs, they aim not

passed a number of international

and historical data assures customers

only to contribute to the advancement of

standards and certifications. Esco

that parts and labour are available

scientific discoveries, but also in making

represents innovation and forward-

whenever service is scheduled through

the world a safer, healthier, and better

thinking designs that are of the highest

the local sales organisation. All Esco

place to live in. •

standard quality since 1978.

products include unique serial numbers

Esco products are of high quality,

for identification. Documentation for

reliable and dependable, assuring

all performance tests is archived and

Airstream® Gen 3 Class II Biological Safety Cabinet

Key features include:

Compact and Efficient Biosafety Cabinets

AC2-4S8

Gauteng: Unit 2 Landsmark Park, 17 Landmarks Avenue, Kosmosdal Ext 11, Centurion 0157 Tel: +2711 314 3184

performance qualification on all products. As Esco takes the opportunity to

Esco Technologies – www.escolifesciences.com

• Energy-efficient

• Durable Metal Plenum

• Equipped with H14 filter

• Easy-to-clean

• Antimicrobial Coating

• Comfortable

CERTIFIED TO: Western Cape: Unit 2, 7 Edison Way, Century City, Cape Town, 7441 Tel: +2767 414 2986

EN 12469, Europe

KwaZulu-Natal: Office 009, 3rd Floor, Regus Business Centre, Westway Office Park, 18 The Boulevard, Westville, Durban, 3630 Tel: +2731 003 3225

FOOD RE VIEW | March 2022

FOOD SAFETY & COMPLIANCE

Can you afford to be non-compliant?

The real cost of poor hygiene practices in food manufacturing The food industry is arguably the sector most susceptible to damages caused by a breach in hygiene protocols and the costs reach far beyond damage to stock. Rentokil Initial explains the real cost of poor hygiene practices in manufacturing facilities.

THE COST OF PRODUCT RECALLS

the company’s chief executive put the total

water by a producer, personal hygiene

Product recalls are a major threat to any

costs of recalling the meat products at an

breaches and unsanitary food handling

food business. They disrupt operations and

additional R430 million.

practices, and pest infestations along the

cost the business time and money. Then

The effect on consumers is possibly the

there is also the indirect cost associated

most significant factor. A survey by Harris

supply chain.

with reputational damage: the loss of

Interactive found that 15% of consumers

that are potentially life threatening, such

consumer trust can result in significant

would never buy a recalled product again,

as Salmonella – outbreaks which usually

long-term financial losses. For example, one

and 21% of people at the centre of a recall

cause large food recalls. Stored product

of South Africa’s biggest food businesses

would not buy any product from the same

insects (such as weevils and beetles) are also

issued a recall of certain canned foods in

manufacturer again.

responsible for a number of recalls in grains,

Rats and other pests carry pathogens

cereal and dried food products.

July 2021, and the cost to transport, store, and dispose of the affected cans alone was

CAUSES OF FOOD PRODUCT RECALLS

estimated to cost them around R650 million.

The most common cause of food product

TYPES OF FOOD PRODUCTS RECALLED

This includes the cost of the recalled stock

recalls is biological contamination by

Raw foods are a major source of

being written off, but doesn’t even begin to

microorganisms and toxins (for example

contamination leading to product recalls

qualify the reputational damage done to the

Salmonella, Listeria and E.coli), which can

because they don’t go through the sterilising

brands concerned.

occur at any stage in the supply chain, and

phase of cooking. Consumers, therefore, rely

which mainly affect food which is supplied

on safe practices along the supply chain to

fresh or raw.

ensure food safety. Nuts, fruits, vegetables

The 2017 - 2018 listeriosis outbreak caused by contaminated cold-meat products cut the responsible food production group’s

Biological contamination can have many

operating income profit by R425 million, and

causes, including the use of contaminated

and dairy products are some of the major product types to be recalled. The direct costs of a food recall include: • A ssembling the crisis team • Removal of the product from market • Issuing notifications to regulatory bodies, affected businesses and consumers • Collecting the product from warehouses, retailers and consumers • Storage of the recalled product and destruction • Investigation of the root cause of the recall • Managing the PR to protect the business reputation.

"Rentokil Initial has a range of solutions to help reduce food safety risks at all stages of the supply chain." 30

March 2022 | FOOD RE VIEW

FOOD SAFETY & COMPLIANCE

INDIRECT COSTS OF A FOOD RECALL Indirect costs are often difficult to measure. For example, there may be no certainty that a reduction in sales or profits was caused by a recall. However, the effects of reputation damage and brand avoidance by consumers can last for years. In some cases a whole industry can be affected by a food recall by one supplier or manufacturer. Indirect costs of a food recall include • L itigation costs, prosecution or fines from government agencies • Lost sales • Decline in value on the stock market • The negative impact on brand reputation. Prevent product recalls The main way to prevent contamination is to implement strict hygienic protocols to

surfaces as well as the personnel

Rentokil Initial has a range of solutions

prevent cross contamination, such as:

handling food.

to help reduce food safety risks at all

• I mplementing strict pest control measures

• Preventing the growth of microorganisms

stages of the supply chain by preventing

to deny harbourage (nesting). Prevent

by temperature and moisture control

contamination through pest control and

entry to buildings (proofing) and prevent

through adequate ventilation

maintaining high levels of hygiene. •

access to food and water • Ensuring there are proper hygiene protocols in place for equipment and

• Implementing processes to prevent cross contamination between raw and cooked or fresh products.

Rentokil Initial – www.rentokil.co.za

When food is at the core of your business, impeccable hygiene is non-negotiable. Pests are a major risk to the hygiene standards of any food manufacturing business. Not only do they pose major threats to compliance, but they can disrupt production and hit revenue too. Rentokil is trusted by customers across the world to deliver ground breaking solutions and offer expert advice to enhance the food food safety standards of your business.

Contact the Experts in Pest Control, today.

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

Part of

FOOD RE VIEW | March 2022

FOOD SAFETY & COMPLIANCE

Maximum Hygiene, Maximum Quality Hygiene Process Machinery (HPM) has grown in a short time since 1997 and has become one of the few well-known industrial companies in its sector in Turkey and worldwide. Since the first day they stepped into business life, their mission has been to meet the expectations and needs of their customers by processing stainless steel with the highest quality and efficiency.

ith more than 25 years of

sub-contracting projects as well

• Tanks and containers (customised)

experience in food and beverage

as manufacturing standard and

• Storage and process tanks

processing technology, HPM

customised equipment.

• Silo

has succeeded in reaching their customers

Their focus is stainless steel metal

• B unker

in more than 60 countries worldwide in

work. They can help their customers in

• Reactors

Europe, Africa, Middle East and Asia.

engineering design and manufacturing

• Syrup room

with a wide range of equipment. This

• Powder and solution mixers

equipment includes:

• CIP systems

HPM engineering and manufacturing teams are working hard to maintain the high quality of their products and to upgrade the efficiency of the manufacturing process. In this regard, they continuously invest in their machinery and technological structure to be more independent, which stabilises the quality of their work and decreases the delivery time of the final product. Hygienex, has entered into the market as a brand of HPM in 2001. Hygienex, has good experience in manufacturing hygiene equipment and machinery. Their goal is to target all hygiene equipment of the

• Water systems

"With more than 25 years of experience in food and beverage process technology, HPM has succeeded in reaching their customers in more than 60 countries worldwide."

• Spray dryer • Heat exchangers • L ifts • Circular sieves • Piping • Installation • Orbital welding services Up to now, HPM have successfully completed many projects in different areas. Besides engineering and manufacturing, they also offer automation and training of the staff

factories and to provide optimum hygiene

of their customers. As an international

conditions with respect to customer

company, they had the honour of working

needs. Today, Hygienex has become one the of leading companies to supply equipment for wet

To access video, check out the Food Review Digimag.

with many well- known brands worldwide including Krones, Spx, Coca Cola, Danone, Tuborg, Ülker and Fritolay. Technology has an important role in

field, machine, human and

this company as in all sectors of the

environmental hygiene.

world. Catching up with the advancing

They manufacture:

technology leads to an increase in

•H ygiene stations

work efficiency. It

• Sinks

also saves time, helps

•O pen plant cleaning (OPC

produce products of

system) • I ndustrial washing system •C rate washing machine •T urnstile control systems •S tainless steel furniture • A septic floor drains and ducts •S afety eye and body showers • A luminum pallets HPM as a mother brand offers a wide product range for the food and beverage

better quality and seriously reduces the number of mistakes made. In this regard, they use an ERP system in all departments, from procurement and manufacturing to sales and accounting. This helps them track and record every step in the company,

sector. They offer

which leads to more efficient and precise

turn-key projects,

evaluation and management. •

March 2022 | FOOD RE VIEW

I S T A N B U L T U R K E Y

60+ HYGIENEX was founded in 1997 as a HPM sub-brand in Turkey. As an experienced manufacturer in the hygiene machinery, HYGIENEX aims to respond instantly to customer requests to provide solutions with its standard and customized products, extensive spare parts and service network. We offer special designs according to the site layout and requested specification.

PRODUCT TYPES • Hygiene Stations • Turnstile Entry Systems • Stainless Steel furniture • Crate Washing Machines • Safety Eye and Body Showers • Industrial Washing Systems • Floor Drains and Channels

sales@hygienex.com.tr sales@hpm.com.tr

www.hygienex.com.tr +90 (216) 595-2203

BEVERAGE INNOVATIONS

The best ingredients to create beauty from within Beauty from within is emerging as one of the fastest-growing product segments today across all age demographics and across a broad range of consumer product types. The addition of certain healthboosting ingredients to beverages can have a fantastic effect on the overall health of individuals and boost their beauty from within. Ronè Luttig from Savannah discusses some of these new ingredients with Tennille Aron from Food Review.

eauty is not skin deep; it requires a

B- complex vitamins enriched yeast.

These ingredients help to protect skin

holistic approach in combination with

This ingredient can enhance physical

from oxidative stress and inflammation.

a healthy diet. Products promoting

appearance with nutricosmetics. The B-

They also boost skin health by improving

beauty from within are expected to reach

complex in it provides energy, red blood

skin hydration, elasticity and the

USD 4.4 billion by 2024 with an 11.9% CAGR

cell formation and a healthy glow. The

appearance of roughness and wrinkle

projected growth between 2019 and 2024.

zinc in Lalmin Beauty also maintains skin

depth, while decreasing age spots. Veri-

Traditionally, consumers focused on getting

health and provides antioxidant benefits

te- AquaResveratrol is a water-soluble

these types of ingredients from liquid tonics,

for anti-ageing and sun protection. The

capsules, tablets, gel formats and powder.

B-complex vitamins provide energy

However, at present more convenient

and aid in red blood cell formation, for

Ceratiq Phytoceramides is a natural,

delivery formats are growing in popularity,

optimal oxygen transport and a resulting

vegan source of ceramides – a class of

such as getting these ingredients from

healthy glow.

lipids known as ‘the skin’s natural sealant’

ready-to-drink beverages or even snacks. Savannah markets and sells key

• Verisol B Collagen

resveratrol from Evolva. • Ceratiq Phytoceramides

and they have been scientifically shown

Verisol B Collagen is a unique ingredient

to support fast-acting, long-lasting skin

ingredients that are used in products that

that is essential for the skin, nails, and hair,

hydration and wrinkle reduction. This

are formulated to have immune-boosting

and can boost overall skin health. A key

ingredient is perfect for beauty drink

and stress-relieving properties among other

benefit of this collagen brand is the low

formulations and soft gels as it is available

good health-promoting qualities. Here are

dosage (only 2.5g/day), which makes daily

in oil and powdered dosage forms. Ceratiq

some of the top ingredients:

consumption and delivery formats easy

Phytoceramides helps with wrinkle

• L almin Beauty

and effective.

reduction, increased hydration and plays a

Lalmin Beauty is a yeast-based health

• Veri-te-Resveratrol and Veri-te-

vital role in maintaining healthy skin.

ingredient. It contains standardised

Aqua Resveratrol

bioavailable minerals from selenium-

Veri-te-Resveratrol and Veri-te-Aqua

Haplex Plus (Hyaluronic acid) is a clinically

enriched yeast, zinc-enriched yeast and

Resveratrol is a powerful antioxidant.

proven beauty from within product that

March 2022 | FOOD RE VIEW

• Haplex Plus (Hyaluronic acid)

BEVERAGE INNOVATIONS

distinctly improves skin firmness and

Interesting concept ideas could include:

These innovative ingredient solutions

elasticity. It supports beautiful glowing

•R efreshing from the inside out! Revitalize

can be added to a range of other items,

skin and plays a role in joint care. Oral

your glow with a sugar-free G&T flavoured

including ready-to-drink beverages,

administration of Haplex plus can nourish

drink with Hyaluronic acid: Veri-te-

powders/drink mixes and even tonics and

skin from within and make it more elastic.

AquaResveratrol.

elixirs. The options are endless and with

•C reate a gorgeous get-up-and-go Mocha

POTENTIAL APPLICATION IDEAS FOR THESE INGREDIENTS The above-mentioned key elements can

consumers looking for the health benefits

with Verisol B Collagen to help boost your

surrounding beverages, adding these kinds

internal beauty.

of ingredients has become essential. •

•L almin Beauty and Ceratiq

be used in a series of finished applications

Phytoceramides can be added to bars for

to enhance food and beverage products.

added health benefits

Savannah Fine Chemicals – www.savannah.co.za

FOOD RE VIEW | March 2022

MEAT, FISH & POULTRY

Get all the latest meat industry news at IFFA The meat industry is set to meet at IFFA, Technology for Meat and Alternative Proteins in Frankfurt am Main from 14 – 19 May. Around 900 exhibitors from more than 40 countries will be showing their latest products and solutions for processing, packaging and selling meat and alternative sources of protein.

verything will be spread over some

of alternative sources of protein, IFFA

to travel to Frankfurt. The new digital

116 000m 2 of exhibition space

not only sets the trend, but also reflects

platform includes a variety of exciting

at Frankfurt Fair and Exhibition

current consumer behaviour.” IFFA has

options before, during and after the fair.

Centre. The traditionally high level of

expanded its product nomenclature and

For example, visitors can make contact

internationality of IFFA is also guaranteed

now includes solutions for vegetable-

with potential business partners and

this year with over 60% of registered

based meat substitutes and alternative

arrange mutually convenient appointments

companies coming from outside Germany.

proteins. At least 200 IFFA exhibitors

in advance via the matchmaking system.

Wolfgang Marzin, president and CEO of

offer products for the production of

Detailed product information and

Messe Frankfurt, says, “We are ready

meat alternatives.

corporate profiles of the exhibitors in word,

to welcome important players from the

photos and video offer a good impression

German and international meat and

IFFA Digital Extension

of the product ranges, while chat functions

protein industry to IFFA 2022. The breadth

For the first time, IFFA will be held with

and video calls mean making direct contact

and depth of the products and services

a digital extension and thus, opens up

is easy. •

to be seen is unrivalled and, this year,

new dimensions for visitors to make their

will once again generate a multitude of

trade-fair experience even more individual

innovative impulses. With the new theme

or to participate when it is impossible

March 2022 | FOOD RE VIEW

IFFA – www.iffa.com

SUSTAINABLE AND RECYCLABLE PACKAGING

Achieving sustainable packaging Sustainability in the packaging industry is one of the key aspects in fighting the plastic waste issue and ultimately climate change. The challenges that this presents, require flexible and powerful automation technology.

packaging, need to be accompanied with a collecting infrastructure that enables a waste-free or low-waste future along with an urgent behaviour change from consumers, industry, retailers, and the entire circular system. What is needed is future-proof manufacturing with automation and robotics technology that can work flexibly with different materials. The following examples show what companies should specifically look for.

CHALLENGE FILM JAMMING Thinner, recycled films are more sustainable, but can also tangle more quickly. Even slight changes in film thickness leads to uneven winding and unwinding, and increase the tension on the film. Uneven tension, in turn, causes defects during pouch forming or sealing, such as curling, ripping, folding or a sideways shifting or misalignment. Correct handling with maximum throughput and minimum film consumption is key to overall Original Equipment Effectiveness.

Therefore, if creases are forming in the seal, n times of increasing sustainability efforts,

this issue start with increasing the use and

operators should check for machine errors

it is essential to find ways to develop

scaling of reusable and refillable systems,

that are contributing to the film not being fed

more environmentally friendly packaging,

redesigning the package with alternative

correctly. Examples include misaligned rollers,

conserve resources and rely on smart and

packaging materials that facilitate recycling

different feeding devices, or stuck rollers that

more efficient production lines. Holistic

are biodegradable, compostable or have

do not rotate freely. Omron‘s Film Tension

concepts are needed.

lower impact in the environment if they

Control System provides synchronised

end up in the landfill. Packaging made from

control of tension, feed and cut. This is

FIVE PILLARS OF SUSTAINABLE PACKAGING

mono-materials is another strategy attracting

complemented by (colour) mark detection for

increasing interest in the packaging industry.

film compensation through motion control

Key points to consider for a more sustainable

They have better recyclability, but migrating

to ensure optimal unwinding of the roll. The

packaging: First thing to address is, reducing

to them could be a challenging process that

Omron Packaging Library offers a wide range

packaging material – not only in terms of

requires strict process control as many times,

of function blocks for film processing in

virgin plastics content in primary packaging,

packaging equipment needs to be adapted

VFFS machines.

but also in the amount of protective

or customised to achieve an advanced

secondary and final packaging. Another point

form, fill and seal process that ensures the

CHALLENGE FILM SEALING

to work on, is to eliminate the need for single-

same package quality and performance. All

Thinner film materials offer lower costs

use packaging. Some strategies to tackle

these efforts to realise a more sustainable

and improved aesthetics. However, these

FOOD RE VIEW | March 2022

SUSTAINABLE AND RECYCLABLE PACKAGING

materials are more sensitive to heat

lead to irregularities in the shape and edges

application of adhesives. This requires a high

and susceptible to burn through when

during forming and cutting. More sustainable

level of precision and continuous quality

using traditional adhesives and sealing

materials such as non-laminated or mono

control. With its automated visual inspection

technologies. The actual sealing temperature

materials also change shape and can

system, Omron supports accurate detection

must therefore be constantly and precisely

reduce the fidelity or performance of label

of glue patterns. The high resolution and

controlled, and automatically adjusted to

printing. Reading, checking or verifying label

brightness settings allow low-contrast defects

avoid losing productivity or sealing defects

information on packaging is difficult when

to be detected, even in the toughest light

that will enate rejects and waste. Omron

the shape is inconsistent or the print quality

conditions or with difficult to detect materials.

addresses this challenge with an AI-based

changes. Omron addresses this with its High-

temperature control algorithm synchronised

Speed Inspection System: this simple and

with machine movement and sensor

scalable system is suitable for multiple lines

CHALLENGE OF MULTIMATERIAL HANDLING

technology that can be placed closer to the

and transparent integration with robotic

Cardboard boxes made of recycled fibers

sealing bar. Noise is compensated for by an

systems. It offers a multi-camera platform with

have higher porosity and are more flexible.

automatic filter adjustment function.

a single controller for multiple-image capture

Using traditional machines or unpacking

at high speed to reliably detect potential

and repacking manually, the handling of

CHALLENGE QUALITY CONTROL OF PACKAGING AND LABEL

defects. Advanced algorithms help to detect

boxes made of recycled cardboard without

difficult-to-read characters, in variable light

damaging them can be tricky. Traditional

Re-closable packaging or pouches with

conditions and high speeds.

palletising solutions are complicated to adapt

nozzles are increasingly replacing rigid

and program, they take up a lot of space, and cannot be relocated to other parts of the

Flexible packaging with new elements,

CHALLENGE OF NEW ADHESIVES AND GLUEING TECHNIQUES

such as resealable closures place different

Eliminating tapes and minimising adhesives

to have an integrated collaborative robot

demands on packaging integrity and quality

increases the recyclability of cartons.

(Cobot) solution with dedicated grippers to

testing. Thinner films, bio-based materials or

Removing the need for a silicone strip makes

safely handle a wide range of irregular shapes,

those with a higher recycled content have a

it 100% recyclable and biodegradable. To

porosity levels and delicate objects. •

different thermal, elongation and puncture

produce and seal cartons, companies are

resistance profile. These differences can

increasingly relying on a strategic and reduced

plastic containers.

C003-1.pdf

2021/10/04

12:19

plant when needed. It is therefore advisable

Omron – www.industrial.omron.co.za

extrupet

Joining forces So many things go well together - french fries and tomato sauce, movies and popcorn and the global plastics industry with recycling. The recent collaboration with the Beverage Company (BevCo), proud bottler of PepsiCo Beverages in South Africa and their combined use of PhoenixPET® has been an incredible journey to be a part of. The output of these joint efforts, demonstrates how large companies can form partnerships for the greater good of the environment. Each clear 2L PET Pepsi bottle now proudly boasts an inclusion rate of 20% rPET - an amount that is planned to be increased over time. Extrupet, as BevCo South Africa’s main rPET partner, would like to recognise this achievement and look forward to pioneering innovation in this space.

PhoenixPET® was established in 2009 and is a product of the Extrupet Food Grade Plant.

Contact: 011 865 8360 | Email: info@extrupet.com | Website: www.extrupet.com Extrupet is proudly associated with

SUSTAINABLE AND RECYCLABLE PACKAGING

Global and local PVC community rejects plastics pact’s list of “problematic plastics” The Southern African Vinyls Association (SAVA), supported by members of the Global Vinyls Council (GVC), has rejected the Phase 1 list of “problematic and unnecessary plastics” published recently by the SA Plastics Pact. This list advocates for these plastics in packaging to be phased out by members by the end of 2022 as part of ongoing work towards the fulfilment of its Roadmap to 2025.

food by guaranteeing a longer shelf-life, improving food safety, reducing bacterial proliferation and protecting against external contamination. For this reason, the global PVC community has also rejected the Plastics Pact’s list, which is influenced by the Ellen MacArthur Foundation, warning that it could pose risks to the public by eliminating certain types of packaging. Ned Monroe, President and CEO of the Vinyl Institute in America, said, “PVC packaging protects people’s food and medicine. Their list could lead legislators and regulators to deprive the public of life-enhancing applications. Implementing arbitrary restrictions on PVC packaging will not improve the recycling rate of other plastics because there is so little PVC in the curb side collection stream.” In the USA and Canada, more than 498 951 607kg of vinyl materials are recycled annually

mong this list of 12 items, the

difficult trading

Plastics Pact has listed PVC rigid

conditions, such

packaging (including bottles, except

as global raw

for medicine packaging), pallet shrink wrap

material shortages

and labels, stating that “PVC has a very low

and supply chain

recycling rate due to the small market size

issues, high material

and there are environmental concerns in

costs, interrupted

its production and end of life as well as the

electricity supply due to load shedding

additives included in PVC materials”.

and the ravaging effects of Covid-19. The

“Although we are a signatory of the SA

recent global shortage in raw materials and

Plastics Pact, SAVA rejects and opposes the

high polymer prices has driven the demand

inclusion of PVC packaging in the strongest

for recyclate even further,” says Monique

possible terms. Our latest recycling figures

Holtzhausen, CEO of SAVA.

clearly show that there is a strong demand

PVC is an intrinsically low-carbon plastic:

for PVC recyclate in South Africa. During

57% of its molecular weight is chlorine

the 2020 reporting period, a total amount of

derived from common salt; 5% is hydrogen;

21 433 tonnes of PVC were recycled in our

and 38% is carbon. It is extremely durable and

country, of which 13 440 tonnes were flexible

cost efficient, and it can be recycled several

(PVC-P) and 7 992 tonnes were rigid (PVC-U).

times at the end of its life without losing its

PVC was the only polymer to have recorded

essential properties. Using it as packaging

a year-on-year increase of 9.5% despite very

can help preserve and conserve

March 2022 | FOOD RE VIEW

- which includes 64 410 116kg of post-consumer vinyl materials. In Europe, 6.5 million tonnes of PVC have been recycled since 2000, saving 13 million tonnes of CO2 as a result during this time. Addressing the environmental, health and safety concerns highlighted by the Plastics Pact, SAVA reiterates that all of its members are signatories of its Product Stewardship Commitment (PSC), which addresses the PVC industry’s environmental issues. “Our PSC is based on international health and safety standards and

SUSTAINABLE AND RECYCLABLE PACKAGING

best practice models that specify sustainable

blister packs, clingfilm and other flexible

manufacturing, sustainable use of additives,

packaging, it is important to note that it

closed loop management and sustainability

has very specific and necessary application

awareness. In order to become a member

values that cannot be ignored”.

of SAVA, companies have to sign our PSC

In the final analysis, SAVA stresses that is

whereby they agree to limiting VCM emissions

important to remember that the SA Plastics

during production processes, commit

Pact does not have any legal right to ban

themselves to mercury-free production, and

packaging materials. They may voice opinions

the sustainable use of additives. Members

and could try to influence decisions, but

have to submit their completed PSC survey

the Department of Forestry, Fisheries and

annually in order to be awarded the Vinyl.

the Environment is the sole body in South

Product Label as proof that they comply and

Africa that has the jurisdiction to decide

meet our health, safety and sustainability

what can and cannot be used as packaging

standards,” Holtzhausen reiterates. She

material. Before any such decisions can be

added that local manufacturers of PVC

taken, careful consideration needs to be

packaging are also concerned that the

taken about the rights and livelihoods of

Plastic Pact’s statement will directly impact

workers. Much more consultation between

thousands of jobs during a time when most

Government and industry is required to

companies are fighting for survival.

ensure that the replacement materials

“The plastics industry contributed 20% to

" Our latest recycling figures clearly show that there is a strong demand for PVC recyclate in South Africa."

selected for PVC (or

our country’s manufacturing GDP in 2020.

other plastics) are

The industry is dominated by the packaging

as economical,

industry and any decision to ban a specific

recyclable, effective

stream will have dire consequences on

and fit-for purpose. •

thousands of people. Although only 9% of the locally consumed PVC goes into packaging such as bottles, thermoformed punnets,

SAVA – www.savinyls.co.za

MAKE PVC YOUR FIRST LINE OF DEFENCE Considering that hospitals rely on PVC (vinyl) to help protect against superbugs and infections – shouldn’t you use it for your packaging too? Using vinyl packaging can preserve and conserve food by guaranteeing a longer shelflife, improving food safety, reducing bacterial proliferation and protecting against external contamination.

Cling Film

Bottles & Labels

Other Packaging

www.savinyls.co.za Low Carbon: PVC is an intrinsically low-carbon plastic. 57% of its molecular weight is chlorine derived from common salt: 5% is hydrogen; and 38% is carbon.

SAVA Advert Artwork High Res Print Fle.indd 1

Recyclable and sustainable: It’s extremely durable, cost efficient and it can be recycled several times at the end of its life without losing its essential properties.

2022/03/05 14:12

FOOD RE VIEW | March 2022

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ANSWER

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Food Review March 2022

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