Food Review September 2020

SOUTH AFRICAN

www.foodreview.co.za

Journal for food and beverage manufacturers

SEPTEMBER 2020 Vol. 47 • No. 09

“We’re small enough to care and big enough to make it happen” Bakery

Permissible indulgence with clean-label appeal

Water processing technology

Up your game with radical new solutions

Carton & Board

Creative & sustainable packaging at your fingertips

Sugar Reduction in Baked Goods: Mission Impossible?

The solution from Symrise: Our research shows that consumers like a 30 % sugar-reduced biscuit with symlifeÂŽ Sweet Optimizer Baking MFC as much as they like the full sugar version. www.symrise.com

SCan Me

CONTENTS SEPTEMBER 2020 | Vol. 47 • No. 09

PAGE

34

PAGE

14

Success depends on a lean and flexible facility 10

NEWS

Entrepreneurs embrace business growth

Innovative mask sports airtight fit

Another gold for quality SA meat

Barentz acquires Royal Polak and De Weerd

Soft drinks industry steps up to the plate

12

INDUSTRY TALK

Why you must strategise to go digital

“As a global innovator of taste, scent and nutrition, the newly-launched Tastepoint by IFF focuses on serving the local needs of dynamic customers in Southern Africa and capturing expansion opportunities in these fast-growing markets”

33

SAFETY, HYGIENE & QUALITY CONTROL

Put a stop to COVID spread now

Choose the right pump for a highly regulated industry

All you need to know about disinfection and microbial air monitoring

Food – too good to waste

40

WATER PROCESSING TECHNOLOGY

Perfect conditioning for perfect water quality

16

MARKET TRENDS

Six changes that power innovation

The age of the carbon-neutral processing plant has arrived

17

PROFILE

Optimal water use impacts the bottom line

Integrity and originality moves Ishida

44

CARTON & BOARD

20

BAKERY

Adaptive processes drive baked goods

Tetra Pak meets demand for growing sustainability

Discover the wonderful world of baking

H.P. Fuller commits to creative solutions

Spread happiness with new yellow colouring

Clean label forges ahead

47

INTELLIGENT PACKAGING

Permissible indulgence draws consumers

The changing world of pick-and-place technology

A new era dawns at Iberchem

Breathe new life into PP lidding

27

DAIRY FOOD

Slice, dice and all things nice

More than a gut feel

Stevia’s incredible formulation benefits

Building a culture of fermentation

A first in micellar casein isolate

PAGE

20

Make your confectionery production shine September 2020 | Food Review

3

EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: Andipha Nkoloti +27 (0)11 877 6168 andipha.nkoloti@newmedia.co.za Contributors: Melika Seiderer & Stefan Fageräng

Why we must continue to dream of a world without waste

I

was incredibly moved when I watched Craig Foster’s documentary My Octopus Teacher, which follows the incredible and unlikely relationship that developed between the filmmaker and a young female octopus in the cold Atlantic waters near Cape Town.

Foster was, like so many of us, burnt out physically and emotionally – and in the process lost his way a bit. One reviewer called the film ‘The love story we all need now’ and I couldn’t agree more.

The cinematography is powerful and offers an exquisite glimpse into one of the planet’s most fragile eco-systems. Recyclable packaging is just one of the many challenges facing the food and beverage industry but one that the Food Review team will continue to highlight in the magazine and our various online platforms. Issues surrounding sustainability, clean and smart manufacturing, water and resource optimisation, ingredient and plant-based NPD are important, and here to stay.

With that in mind, we applaud the initiative

by Coca-Cola Beverages South Africa as it continues the roll-out of its 2L returnable polyethylene terephthalate (PET) plastic bottle into more regions across South Africa.

Returnable PET is part of The Coca-Cola Company’s World Without Waste vision, which focuses on the entire packaging value chain from how bottles and cans are designed and made to how they’re collected, recycled and reused later. The hope is, of course, that these items won’t end up in landfill or polluting our oceans and water resources.

In this edition we highlight the stunning launch of Tastepoint by IFF. You can read how leveraging the global power of IFF with a unique local focus, will allow Tastepoint to work at any scale and grow with its customers.

Turn to page 14 for the full story. We also

spoke to Melika Seiderer, the newly-appointed general manager of Ishida SA (page 17) about her vision for the local arm of this international packaging powerhouse.

While there is no global regulatory definition or understanding of clean label, Innova research shows consumers are willing to pay more for natural products with a simple ingredient list. On page 24 we look at how you can tap into consumer willingness to pay more for natural.

Water is essential and used in various ways during food and beverage processing. Radical Waters’ ECA solutions can impact the quality of water used in the F&B industry (page 40) while growing demand for sustainable carton packs continues the drive for renewable content of packs.

Please remember that entries are now open for our 2020/2021 New Product Competition.

Please let me know if we can send you an information pack – there are some surprises in store for competition entrants next year with a completely revamped event!

Happy reading and keep on recycling!

ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 càndida.giambò-kruger@newmedia.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Production Controller: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media, a division of Media24 (Pty) Ltd MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis BRAND STRATEGY DIRECTOR: Andrew Nunneley

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

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

Dr Heidi Grimmer

4

Food Review | September 2020

Managing director of Symrise South Africa; chairman of SAAFFI.

Rudy McLean

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

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

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

Gail Angela Macleod

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

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Food Review | September 2020

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From one

brave team to another‌

Thank Thankyoyou u to toeveryone everyone in manufacturing and an essential d essential services serv ices for keepithe machines ng t he machines for keeping running run and heves sto cked, durin shelves stocked, duringthe the V I shutdown. th e COVID-19

You are the unsung heroes!

Our #PurplePeople salute you!

New Media, a division of Media24 (PTY) Ltd.

Sugar packs gets a sweet revamp

Huletts Sugar has introduced a refreshed and modernised look for its white and brown sugar packs (250g to 12.5kg) to create greater onshelf appeal for this legacy brand. A prime consideration of the modernisation project was to retain the brand's recognisable iconography while underscoring its 128year heritage of growing, farming, milling, refining and selling fine quality sugar products.

Reformatting a SA staple

South Africa's ubiquitously consumed mealie/maize meal porridge/pap/putu has entered the ready-to-eat food market in the innovative form of Papstix, pre-packaged rolls filled with a tasty relish centre. The on-the-go meal comes in a 250g serving, with 70% pap and 30% relish, and is available in three flavours: carrot chakalaka, tomato and onion, and chilli soy beef.

Premium wine in a can

South Africa’s favourite wines, Sauvignon Blanc, rosé and Merlot are now available from Spier in 250ml cans, each crafted by acclaimed Cellar Master Frans Smit and his team. These cans are where convenience and quality converge and they’re terrific for on-the-go adventures and make for fantastic everyday fridge-fillers.

Nestlé enters the market for plant-based seafood alternatives

Nestlé has announced the launch of a plant-based alternative to tuna, its first move into the growing market for plant-based seafood alternatives. The plantbased tuna alternative can be used in a wide range of dishes such as salads, sandwiches and pizzas. It has the flaky texture and rich flavour that makes tuna a favourite in many meals.

8

Food Review | September August 2020 2020

Lourensford unveils new demi-sec Cap Classique The new Demi-sec Nectar 2018 Cap Classique, a bottle-fermented 100% Chardonnay from Lourensford Estate in Somerset West, is a tantalising sparkling wine with colourful, delicate citrus notes and white peach and lemon peel. The flavours are complemented with a rich biscuity allure and velvety mouthfeel.

Are you ready for #StimorolRetro?

SA’s #1 chewing gum brand, Stimorol launched its limited-edition Stimorol Retro gum. It’s a refreshing bubblegum flavour that treats your taste buds to a throwback. Stimorol Retro goes beyond just a flavour, it’s all about the nostalgia of the ’80s, '90s and '00s.

And if you weren’t there for all that, don’t worry, you'll feel like you were!

Are you READY? 2020/2021 Food Review/ Symrise

New Product Competition Since its inception, the competition’s primary

platforms. The grand prize also includes a trip

goal is to provide local and international brands,

to SIAL Paris 2022, one of the world’s most

featured on local shelves, the opportunity to

exciting trade shows where future trends are

showcase their innovative new products.

set. Don’t miss this opportunity for your first-

Entrants and winners will receive extensive exposure throughout the magazine’s various

row view of the latest developments in global food and beverages.

Entries are now open,

and close on 1 June 2021!

For more information, please contact Maryke Foulds at maryke.foulds@newmedia.co.za or give me a ring on 082 569 2330 to discuss.

NEWS iTRAK 5730 small-frame intelligent track system improves throughput in multi-product applications

Tray-sealing opportunities abound

W

ith the rise in online food and confectionery sales, Proseal maintains that the variety of tray designs in terms of shape, depth and the availability of multi-cavity formats is a solution to safely package most types of products while preserving food further after opening.

The majority of trays are fully recyclable, unlike some alternatives such as pouches

and bags. Some trays are now manufactured from new materials made from renewable or recycled board, and this offers an added sustainability benefit. Proseal can design and install fully-integrated turnkey production lines for mass customisation solutions, allowing businesses to maximise opportunities in the growing online sector while tailoring products to individual customer requirements. For food items, in particular, the wide choice of seal formats, including gas flush, vacuum and skin pack, will help to deliver the required levels of product preservation to maintain freshness and quality throughout the distribution process. •

A sealed tray of salmon and vegetables

Young entrepreneurs aim for business growth

A

s South Africa’s unemployment rate increases to 30.1%, the far-reaching impact of COVID-19 on businesses is concerning.

While access to funding and the skills transfer needed for business resilience remains the biggest challenge for many young entrepreneurs, support from larger enterprises such as Mondelēz South Africa’s Enterprise Development programme Kasivators 2.0 has helped uplift the sector.

The programme currently empowers four black-owned brand activation businesses through business training, mentorship, tools of the trade and business grants. This investment, in turn, on average more than doubled their staff constituent.

10

Food Review | September 2020

“Entrepreneurship is often a very lonely path. There are many challenges to navigate. Having that additional support system in the form of mentorship and coaching made a real impact for me – from guidance on the day-today running of my business, to the grant which meant I was able to upscale our distribution systems.

The programme helped us increase our overall profitability and, in turn, our capacity to create more jobs,” says Edwin Sebilwane, a 33-year-old at brand experience company SirBillionaire.

Global brands such as Mondelēz International have the skills and experience that typically place them at the forefront of the innovation and thinking needed for success. •

iTRAK 5730 offers improved flexibility

F

ood and beverage manufacturers are constantly under pressure to package a wide variety of products in more types of packaging without compromising productivity.

Now they can answer these trends while increasing throughput using the new iTRAK 5730 small-frame intelligent track system from Rockwell Automation.

Independent cart technology offers many benefits over traditional gear, chain and belt conveyors, including unlimited machine flexibility, better traceability and increased uptime. By using magnetic propulsion, the individuallycontrolled carts can quickly start and stop with high precision, which reduces

machine wear and is energy efficient. The technology quickly manages changeovers using pre-configured move profiles that can be implemented with the push of a button from an HMI. “The iTRAK 5730 system extends the flexibility and productivity benefits of iTRAK to meet growing demand for customised food and beverage products,” explains Michaela Kaufmann, product manager at Rockwell Automation.

In addition to delivering a smarter form of motion control, the iTRAK 5730 also offers integrated safety.

Safety zones can increase safety without compromising productivity by allowing the motion to continue outside of the safety zone, even after a trip inside the safety zone. •

Acceleration of expansion into Africa underway

H

udaco is aiming to create a growing awareness of its broad portfolio of technologies, products, operational infrastructure, logistic capabilities and technical skills. Bearings International (BI), one of the group of companies within the Hudaco stable, plays an important role in its value Emile Joubert proposition.

This is due to its wide product offering and extensive branch footprint to support and service its installed base on end-user

sites. “Such a capability positions BI and the other Hudaco companies as a partner for project houses, taking overall accountability for the design and seamless integration of our multi-disciplinary technical offering, as opposed to being sourced from multiple vendors,” comments Emile Joubert, group business development leader for Hudaco’s projects division.

BI has the necessary product offering and technical competencies to develop clientspecified engineered solutions as part of integrated turnkey projects locally and into Africa. •

NEWS

Local brand creates Sola MR2 mask

W

hile the world has

99.99% anti-viral efficacy.

adapted to the new

Respirators and masks are

normal of everyday

particularly vulnerable to

mask wearing, INEX has

high humidity conditions. The

created the Sola MR2. With a

sealed fit of a respirator or

soft TPE face seal, the INEX

mask creates an environment

Sola MR2 provides an airtight

that increases humidity with

fit, preventing air leakage.

every breath.

Alternative masks allow

INEX RFT filters are

air to escape and enter at

made from electrospun

the top and on the sides,

polyvinylidene-fluoride,

reducing protection. With

which repels water and

the use of a sophisticated

oil, maintaining maximum

filtration system, the mask

filtration efficiency. •

Acquisition of spice specialists Royal Polak and De Weerd announced

B

arentz International, a global distributor of life science ingredients, has expanded its activities in taste and nutrition with the acquisition of two Dutch-based spice specialists: Royal Polak Spices - a B2B cinnamon specialist, and De Weerd Spices - a specialist in natural taste development and innovation for the European food industry.

The acquisition of both companies is aligned with Barentz’ strategy to become a global leader in the life science industries and to further develop taste and nutrition knowledge, products and services within the human nutrition sector.

The completion of the transaction is subject to customary closing conditions, including regulatory approval. •

uses an elaborate flow path that prevents moisture droplets from passing through the filter casing.

Using inexpensive disposable filters, made from high-tech nanofiber material which outperforms the filtration textiles found in FFP2 or KN95 masks, the INEX mask offers

Quality Cured Meats awarded gold at the Aurora International Taste Challenge

R

ichard Bosman’s Quality Cured Meats has been awarded Double Gold for its popular Smoked Streaky Bacon and traditional Pepper Fuet. It also received Gold for its Prosciutto at the Aurora International Taste Challenge 2020.

“I am extremely proud of this achievement and it is great to be acknowledged for the work that my amazing team and I have put in. It has taken many dedicated years to get to this point,” says Bosman, who started his business in 2009 to create world-class charcuterie using the best pork in South Africa.

The top-selling Smoked Streaky Bacon awarded Double Gold is smoked for 24 hours with oak wood chips during the dry-curing process. “This provides a special and delicate smokiness and ensures the bacon crisps up very quickly when cooking,” explains Bosman. Awarded Double Gold, the Pepper Fuet is a classic plain salami with whole peppercorns.

Bosman says the salami is cured the traditional way with a 48-hour ferment followed by two months of ageing. The Gold-winning Prosciutto is made Richard Bosman using pork legs, which are trimmed and salted scoops gold at the Aurora International for a month before being washed with red wine Taste Challenge and then dry-cured for up to two years. •

CCBSA continues rollout of new 2L returnable PET plastic bottles

C

oca-Cola Beverages South Africa (CCBSA) continues the roll-out of its 2L returnable Polyethylene Terephthalate (PET) plastic bottle into more regions across South Africa.

Returnable PET is part of The Coca-Cola Company’s World Without Waste vision, which focuses on the entire packaging value chain from how bottles and cans are designed and made to how they’re collected, recycled and reused later.

“As a user of packaging we have a responsibility to not only recycle packaging through our various initiatives, but also to continue to invest in infrastructure that can help us develop innovative packaging to achieve our World Without Waste ambitions,” says CCBSA managing director, Velaphi Ratshefola. “By offering a returnable PET bottle, we are creating greater value for money, as well as an incentive for consumers to collect packaging, rather than disposing of it into the environment.This initiative strengthens our PET collection efforts through our various partnerships such as our membership in the PET Recycling Company (PETCO) and several buy-back centres we have established in communities around the country,” adds Ratshefola. “Last year, 62% of PET bottles were collected for recycling.

Through this new returnable PET packaging and other innovations, we are set to continue improving our collection and recycling rates, until we reach our ambitious targets.”

During 2019 more than 92 000 tonnes of postconsumer PET bottles were collected through the PET Recycling Company (PETCO). These bottles were diverted from landfills in South Africa, saving 612 000m² of landfill space. •

September 2020 | Food Review

11

I N D U S T RY TA L K

Transforming your business digitally New technologies like cloud computing, artificial intelligence (AI), machine learning, and predictive analytics continue to disrupt industries.

R

ecognising this potential,

through collaborations with leaders and

society and a vibrant knowledge economy

government strategies emphasise

entrepreneurs committed to building a

that is more inclusive and prosperous.

the role of digital in accelerating

better future, governments on the African

Similarly, the Moroccan government

economic diversification, promoting

continent are leading the way in securing a

introduced the Morocco Digital 2020 strategy.

sustainability and ensuring citizen

viable future for their citizens. It also raises

This set of policies and reforms promote the

happiness. Digitalisation has been

their national competitiveness profile at a

effective use of and access to technology

identified as a pillar that will support the

global level.

in various sectors to position the country

future digital economies on the continent.

By placing new digital and ICT

In South Africa, the National Development

as a digital economy. Nigeria has also

Plan 2030 (NDP), published in 2012,

taken significant steps to drive economic

transformation programmes at the

emphasises how ICT will underpin the

transformation, sustainability and future

heart of their national plans and

development of a connected information

skills development through technology.

12

Food Review | September 2020

I N D U S T RY TA L K

While businesses can gain massive

BUSINESSES REAPING THE BENEFITS OF 4IR

value opportunities in these areas,

KNOWLEDGE BUILDING AND FUTURE-READY CURRICULA

Digitisation spurs the development of new

companies undertaking these efforts

Apart from access to affordable

industries, as in the case of e-commerce, mobile financial services, IoT, and cloud computing. These contribute to national GDP in multiple ways, while promoting growth of allied industries such as logistics, infrastructure and payments. These opportunities are not only limited to the ICT industry, but also disrupt traditional industries to unlock speed, lower costs, and ensure higher quality.

While many businesses are fuelled by competition and adopting new and disrupted forms of technology, many organisations are still using legacy IT and have shied away from digital transformation. Digital transformation essentially involves a fundamental change in how an enterprise uses its technology, its workforce and business processes to improve its performance and value to customers.

“A major obstacle to the development of internet infrastructure within Africa is a lack of experienced network engineers” PPK023-21.pdf

1

2019/10/15

10:13

quickly learn that the technology in digital transformation is often the easiest part of change. Development gains from digital transformation are not automatic and can result in new divides and widen inequalities.

BUILDING INTERNET INFRASTRUCTURE AND DIGITAL SKILLS A major obstacle to the development of internet infrastructure within Africa is a lack of experienced network engineers.

Without these engineers, national internet investment, policy and regulatory decisions may lack the technical foundation that will ensure an open, affordable, scalable internet.

If South Africa had the required mass of network engineers who were able to shape the future of network infrastructure at both a local and national level, businesses and organisations would be able to unlock their full potential and fully utilise Fourth

connectivity and devices, there is also a need to digitally upskill people to operate or work with the advanced and/or emerging technology in 4IR. Investments in human development and digital skills are necessary to build a pipeline of future talent that can embrace this dynamic and increasingly digitised environment. This will require a massive educational overhaul that addresses basic education backlogs at all levels, from basic to tertiary education.

The World Economic Forum has highlighted the importance of African educators to design future-ready curricula that accelerate the acquisition of digital and STEM skills to match the way people will work. African governments, with the help of private sector stakeholders, have an opportunity to develop tailored approaches to understanding the region’s evolving skills base and emerging jobs scenarios. •

Industrial Revolution (4IR) technologies, like Internet of Things (IoT), artificial intelligence, blockchain technology and big data.

Syspro – www.za.syspro.co

C O M PA N Y F O C U S

Tastepoint serves dynamic local markets

As a global innovator of taste, scent and nutrition, the newly launched Tastepoint

by IFF focuses on serving the local needs of dynamic customers in Southern Africa and capturing expansion opportunities in these fast-growing markets. is empowering to know what Tastepoint is capable of doing when we combine local passion and expertise with the insights and innovation of a global powerhouse like IFF. We believe this combination will truly differentiate us and will help our customers to create products that stand out in the market.”

Tastepoint is dedicated to deliver on the needs of fast-moving regional, national,

DID YOU KNOW?

local, private label and entrepreneurial start-up customers. By leveraging the global power of IFF with a unique local focus,

In addition to traditional flavours and total solutions, the offerings will leverage an expanded naturals portfolio that includes colours, food protection and health ingredients.

Tastepoint can work at any scale, allowing it to grow with its customers. Its purpose? “To be the spark that advances our customers by being the perfect blend of heart and science.” This will be delivered through its structure and approach.

Tastepoint’s focus is on servicing customers with the can-do approach of a smaller company, but backed by expertise traditionally reserved for companies with more global reach. Like the original Tastepoint by IFF established in North America, South Africa’s Tastepoint will offer customers an increased product portfolio through IFF’s Taste Design.

In addition to traditional flavours and total solutions, the offerings will leverage an expanded naturals portfolio that includes colours, food protection and health ingredients.

Darrell Gray believes that the Tastepoint difference comes to life through local expertise and optimisation, global reach and a unique business model. “We have access to the latest industry insights and technology which drive our custom

“ By leveraging the global power of IFF with a unique local focus, Tastepoint can work at any scale, allowing it to grow with its customers”

14

Food Review | September 2020

I

solutions. Our team comprises some of the n December 2019, IFF announced its intention to roll out new Tastepoint by IFF companies in multiple geographies,

following the blueprint established in the

most creative minds in the industry, backed by over 130 years of IFF flavour leadership.

Our team can’t wait to show our customers how this can help them win,” he concludes. •

US in 2017.

Darrell Gray, general manager for Tastepoint by IFF, South Africa explains, “It

Tastepoint – www.Tastepoint.com

MARKET TRENDS

F&B innovation evolves in the case of COVID-19 ADM has identified six emerging behavioural changes that will power innovation and growth in the months ahead.

C

onsumer’s attitudes, priorities and

probiotics, prebiotics and postbiotics

of anxiety and stress as 35% of

behaviours are shifting significantly

can benefit the microbiome and are

consumers report being concerned

and this evolution is providing a

gaining momentum in the marketplace.

about mental health2. People are

unique opportunity for forward-looking

2. Plant-based becomes mainstream

looking for new ways to improve their

food and beverage companies to bring a

In the U.S., 18% of alternative protein

mental wellness during these stressful

suite of trailblazing new products to market.

buyers purchased their first plant-based

times, including permitting themselves

protein during COVID-19 and 92% of those

to consume indulgent, comforting

marketing, ADM. “ADM OutsideVoice

first-time buyers report they are likely to

food and beverages. They are however

research indicates that 77% of consumers

continue purchasing meat alternatives2.

tempering this desire with weight

intend to make more attempts to stay

In Germany, the U.K. and the Netherlands,

management needs and seek a careful

healthy in the future. Food and beverage

80% of consumers state they are likely

manufacturers who successfully balance

to continue eating plant-based meat

good nutrition.

consumer health concerns with affordability

alternatives beyond COVID-192. With

Food and beverages designed to elevate

are most likely to win,” she explains.

health, safety and convenience as top

mood, sustain energy and reduce stress

purchase motivators, products that

will grow in popularity in the months

This is the view of Ana Ferrell, VP of

ADM has identified six behavioural shifts that will create opportunities for

deliver exceptional nutrition and a high-

food and beverage manufacturers to gain

quality sensory experience will be poised

market share in an increasingly uncertain business environment.

1. Focus on gut health and immune function connection Globally, 57% of consumers report being

overall balance of indulgence and

and years to come.

ADM also projects new opportunities for

for success.

comfort food, snacks and baked goods

3. New perspectives on weight

offering nutrient-rich ingredients and

management and metabolic health The pandemic’s consequences for individuals with hypertension,

functional health benefits.

5. Personal nutrition As COVID-19 increases consumer

more concerned about their immunity

diabetes and cardiovascular disease

awareness of individual health risk

as a result of COVID-191. As consumers

have consumers viewing weight

factors, demand for products offering

strive to enhance their immunity, they

management and metabolic health

tailored, highly personalised health

are becoming more knowledgeable

in a new light, with 51% of consumers

and wellness solutions will take off.

about how the human microbiome

indicating they are concerned about

ADM research shows that 49% of

supports the immune system and

being less active or gaining weight

consumers feel every individual is

overall wellbeing. Products containing

during the pandemic. That worry

unique and requires a customised

is likely to increase demand for

approach to diet and exercise, and 31%

functional solutions supportive of

of consumers are already purchasing

metabolic wellness and healthy

more items tailored for health and

“Food and beverages designed to elevate mood, sustain energy and reduce stress will grow in popularity in the months and years to come”

weight management.

nutrition. Products that focus on

4. S elf-care, emotional wellbeing

improving nutrition, self-care and

and nutrition

general wellness will increasingly

The difficult circumstances stemming

attract consumers’ attention2.

from COVID-19 have increased feelings

6. A Shift in Shopping Values An increased focus on health is triggering a windfall in consumer health and wellness spending. 48% of consumers plan to purchase more items related to health and wellness 2.

Concurrently, manifesting concerns around widespread economic decline has prompted a shift to value-based shopping, including growing demand for basic pantry staples, stimulating trade-downs to private labels and increasing traffic to value retailers. • FMCG GURUS: Twelve-Step Guide for Addressing COVID-19 in 2020 and Beyond, April 2020 2 ADM OutsideVoiceSM 1

ADM – www.adm.com

16

Food Review | September 2020

P R O FI L E

Automated solutions that meet the needs of the South African market Food security and value for money will support business growth and help feed the nation, explains Melika Seiderer, newly-appointed general sales manager, Ishida South Africa.

W

hen times are tough, being in

Today’s models can handle a much

the food industry is generally

wider variety of products and at higher

to identify the best-performing machines

For food manufacturers, the priority is

regarded as something of a

speeds than earlier versions. Design and

to help meet their production needs and

safe haven. The argument being that

technical enhancements have included

value proposition. At Ishida, a key benefit

even in straitened times, people still

the use of special contact surface

of its tray sealers is that all models

have to eat.

materials for sticky products and reduced

have the flexibility to cope with and

angles for fragile items.

switch easily between pack types and

When budgets are tight, cost becomes a critical factor in any purchase. Food

Equally important, software advances

materials, while being able to run at very

manufacturers must aim to deliver

have allowed the introduction of more

quality products while achieving

responsive hoppers and improved

Similarly, snacks bagmakers feature

maximum efficiencies and throughput

loadcells that deliver even greater

servo motors and software-controlled

on their production lines. The resultant

accuracy levels. In the early days of

variable seal time, jaw temperature

competitive pricing will allow these

multihead weighing, a reduction of

and pressure to deliver a high level of

companies to succeed – whatever the

giveaway to 0.1g was achievable; now

precision. Strippers plates clear the

state of the economy.

this can be as low as 0.01g. Aside from

seal area before sealing, which ensures

additional cost savings and efficiencies,

good pack quality, and servo-driven and

even deeper in South Africa. According

one of the most important benefits of

vacuum-assisted pulldown belts enable

to Stats SA, 6.8 million South Africans

the improvements in standard deviation

accurate and consistent bag lengths to

experienced hunger in 2017. Although

is that it can further increase pack

optimise film use and enhance

this number has halved since 2002,

consistency whilst minimising

pack presentation.

The need to deliver value for money goes

hunger still affects 1.7 million households across the country.

Affordability therefore becomes a critical factor in having enough to eat.

product giveaway.

high efficiency.

Confirming the quality of the sealing

If accurate weighing is

process is equally important to prevent

essential to delivering

any sub-standard packs causing early

value for money,

food deterioration. Seal testers check

this cannot be at the expense of product safety.

the integrity of snack pillow packs and top-sealed, thermoformed, flow-wrapped or lidded trays in different materials and

It is important

sizes by applying controlled pressure

to maintain

to each pack going across a conveyor in

commercial

product quality

order to detect any unwanted ‘give’.

issues are

and freshness

driving the

and to ensure

of in-line leak detection is the Airs can

development

that it is

system that uses laser technology to

of automated

freefrom

Moral and

solutions on the production

any unwanted foreign bodies.

and packing line

to deliver products which

detect CO2 leaks from holes as small as 0.25mm in MAP packs, without stopping production and at a top speed of 180 packs per minute.

that can enable food manufacturers

A recent Ishida innovation in the field

As the testing process is very gentle, The multihead-weigher delivers pinpoint accuracy

both of these technologies further minimise food waste, so that product

are manufactured and packed safely

can be saved

and minimise waste, while maximising

and repacked.

speed and throughput to ensure the best economies of scale.

This is not a new phenomenon.

The multihead weigher, for example, invented by Ishida back in the 1970s, has been delivering pinpoint accuracy in the weighing of a huge variety of food products for well over 40 years. There have been many developments in the weigher’s capabilities during that time.

“Such moral and commercial issues are driving the development of automated solutions on the production and packing line that can enable food manufacturers to deliver products which are manufactured and packed safely and minimise waste”

One of the most vital areas of food quality is ensuring that packed product is free of foreign bodies. This is

Melika Seiderer

September 2020 | Food Review

17

P R O FI L E

output, together with the long-term reliability of the equipment, can result in low cost of ownership and a very fast return on investment. Equally important, the best suppliers combine the offer of advanced equipment with strong aftersales support to ensure machines continue to perform at their optimum.

The breadth of equipment available is also critical, with a choice of machines to meet different requirements and budgets. At Ishida, the wide variety of models in all the equipment ranges includes entry-level variants that are competitively priced while still offering the advanced technology for which Ishida is renowned. This enables smaller and start-up companies to begin their automation journey.

Embracing automation is the first important step to growth, and an especially significant focus for South Africa where the government’s National Development Plan 2030 is looking to SMEs to be major sources of employment and drivers of growth for the economy.

The plan recognises that the potential for job creation increases as a small business matures and that it is important that SMEs receive relevant support early on, especially as over 50% say they Product transfer between various processes takes place quickly and effectively

especially critical as lines become more automated, meaning there are fewer personnel available to spot any problems.

This has led to the development of X-ray inspection technology which has the ability to spot many unwanted items, including metal, stone, glass and dense plastic, as well as other quality issues such as broken, deformed or

need assistance in being able to access

“Seal testers check the integrity of snack pillow packs and top-sealed, thermoformed, flow-wrapped or lidded trays in different materials and sizes by applying controlled pressure to each pack going across a conveyor in order to detect any unwanted ‘give’” This is where the benefit of having

incorporate the company’s patented

a single supplier really comes to the

intelligent genetic algorithm (GA)

fore. Such a company will be able to

technology. For many products, the

take full responsibility for the design

contaminants found are generally similar.

and installation of the line, selecting

By analysing image data over multiple

the most appropriate models to create

generations, the machines achieve an

a bespoke solution that is best able to

extremely high level of precision and

meet the customer’s production targets

this in particular provides greater

and quality standards.

sensitivity in the detection of lowdensity foreign bodies.

With such an array of equipment

It must be recognised that, whether seeking a single machine for the first steps on the automation route or the

available throughout the packing line, the

installation of a complete packing line,

challenge is not just in selecting the right

both can involve a significant investment.

machine for each part of the operation

This is particularly true for SMEs.

but to ensure that product transfer

It is important that any investment

between the various processes can take

is considered more than simply in the

place quickly and effectively and that the

context of the initial purchase price.

entire line is fully-integrated and able to

Features such as high speeds, efficiency

operate at maximum efficiency.

and flexibility to deliver maximum

18

Food Review | September 2020

that the industries in which they operate are extremely competitive.

At Ishida, long-term customer partnerships have been fundamental to its success and growth worldwide, and the company remains focused on providing the high level of support and advice required. The range of equipment on offer, combined with longstanding knowledge of many end-markets and comprehensive after-sales and service

missing products.

All Ishida X-ray inspection systems

markets and around 40% acknowledge

support, mean Ishida can assist a business on its growth path.

In addition to ongoing economic challenges, the coronavirus pandemic has had serious implications for all economies worldwide. Effective automation will play a key role in the recovery and to enabling businesses to prosper in the future; and close customer and supplier partnerships will be best-placed to make the most of the opportunities.

In South Africa, this will help to provide the competitively-priced foods needed to counter the hunger crisis, and the means to enable forward-looking businesses to achieve success and growth. •

Ishida – www.ishida.com

B A K E RY

Make your confectionery production shine Consumers are demanding healthier options and choosing new types of products and flavours with a preference for sustainable manufacturing. To create these new products requires innovative ingredients and adapted processes.

Maryke Foulds spoke to James Outram to get the lowdown on the equipment and product concept that make this a reality.

C

onsumers of baked products are

using non-traditional ingredients

always looking for something new

will continue.

and different. If that new product

is also accessible in terms of price, and

The use of these popular ingredients also impacts on the design and

is healthy and tasty then you are

functionality of Bühler’s range

onto a winning formula.

of processing equipment.

In traditional markets there is established consumer demand for low-fat products – healthier alternatives to fried potato chips is one example. “Baked, not fried, snack products based on potato and

Traditional sheeting

DID YOU KNOW?

and laminating lines

Bühler has developed some concept products like gluten-free shortbread, vegan brownies, and rye and chocolate bars.

were initially designed for wheat-based products, using the elastic properties of gluten and a limited range of ingredients.

With new ingredients

other starches such

come new challenges in

as pulses are produced to

terms of dough properties.

perfection on our state-of-the-

“We have moved outside the

art cracker lines,” Outram enthuses.

comfort zone of wheat-based products

“Across our product range, we have

into a challenging space with new

worked with customers to make gluten-,

dough types. Stickiness, hardness

grain- and wheat-free products coupled

and elasticity are the new properties,

to low-fat and reduced-sugar products.

and these must be accounted for with

This is especially true in the area of

adapted and redesigned features,” he

cookies and cakes, which are essential

points out.

indulgent products. It is always good

IMPROVED PROPERTIES • Gauge rolls with independent drives to prevent the dough sticking • Improved hygienic design for quick allergen cleaning • High-specification gauge rolls can go to smaller gaps allowing for doughs with higher recovery rates for industry-leading dough piece weigh accuracy • Hybrid oven technology creates products with just the right texture.

Sustainability and global warming are growing challenges for society and the industry as consumers bring greater focus. The days of using fossil fuels to heat bakery ovens are numbered. “It can be anticipated that we will have to change to electric ovens, so we have launched our new Turbu E oven.

This has all the advanced features of even heat distribution; easy cleaning and efficiency of our Turbu 4 oven but powered by electricity. If you can source electricity from wind, solar or hydro

to take away a bit of the guilt and make them more permissible.”

When new products call for more better-for-you ingredients (anything

The Turbu E oven

from fibre or protein) and less of the bad-for-you ingredients (such as fat and sugar), then the trend of

sources, then it would be possible to bake products in a carbon-neutral way,” Outram concludes. •

Bühler – www.bühler.com

20

Food Review | September 2020

100 Years of baking and ingredient handling.

Bakery solutions from BĂźhler.

BĂźhler (Pty) Ltd Juice Street, 5 Star Business Park Honeydew, Johannesburg, South Africa.

Innovations for a better world.

B A K E RY

Explore the wonderful world of baked goods & confectionery In conjunction with its customers Zeelandia looks at finding and honing innovative products to turn your bakery into a success story.

T

cake mixes, fillings, coatings and chocolate. he supplier is constantly searching for new opportunities and ingredients to improve its products

and processes: all this is underpinned by vast technical knowledge.

“We inspire our customers with ingredients and better ways to bake, manage and sell.

Founded in 1900 Zeelandia has become a global player in the bakery ingredients business.

Zeelandia South Africa is based in Cape Town and from this base it serves South Africa, Namibia, Botswana, Zambia, Zimbabwe and Malawi,” MD Francois Eksteen points out.

Zeelandia SA manufactures and sells a complete range of ingredient solutions for small to very big bakeries. "We aim to deliver all you can need to create successful bread, cake, pastry, patisserie and viennoiserie; complete

To enable a good release from the pan is a critical part of a premium baked product and Zeelandia SA offers a full range of release agents and lubricants, including spray machines,” he says.

IN SEARCH OF GLUTEN-FREE The product range matches the latest knowledge about the impact of food products on consumer health such as its gluten-free range. It is produced in a certified gluten-free production facility, guaranteeing absolute product safety. “Our wide range of gluten-free mixes enables you to produce a complete assortment of great-tasting gluten-free bread and pastry products,’ Eksteen concludes. •

Zeelandia – www.zeelandia.com

SUPERIOR TASTE AWARD

Zeelandia Turkey entered its Burdenno Red Velvet Cake mix to the international Superior Taste Award contest, organised by the International Taste Institute in Brussels, Belgium and walked away with the highly regarded Superior Taste Award. The institute was founded in 2005 and evaluates and certifies the sensory attributes of food and beverages from all over the world. The jury is composed of over 200 renowned chefs and sommeliers from 15 European culinary or sommeliers associations. Over the years, more than 16 000 products have been certified by the Taste Institute’s jury.

ZeroProblem Gluten Free

ZeroProblem Gluten Free

22

Food Review | September 2020

B A K E RY

Carrot-based powder delivers brilliant yellows with a long shelf life GNT Group has extended its range of yellow Exberry Coloring Foods with a new powder made from carrots.

A

vailable worldwide in addition to the existing liquid format, the Shade Yellow – Cloudy

Powder enables manufacturers to deliver a brilliant yellow colour shade in a wider range of applications. The powder is ideal for bakery applications as well as dry mixes including custard, brioches and biscuits.

“The Shade Yellow – Cloudy Powder is pH-independent and provides good light and heat stability, along with a 12-month shelf life at <25⁰C” Both the liquid and powder formats are made from carrots grown by GNT's farmers and are manufactured without chemical solvents. As such, they ensure high levels of consumer acceptance and can provide a perfect replacement for

The Exberry Shade Yellow – Cloudy Powder is ideal for bakery applications as well as dry mixes

colourants such as carotenes.

The Shade Yellow – Cloudy Powder is pH-independent and provides good light and heat stability, along with a 12-month shelf life at <25⁰C. fruit, vegetables and edible plants using

Sonja Scheffler, product manager at GNT says, "Building on the huge

extremely well across a wide range of

gentle, physical processes such as pressing,

popularity of our carrot-based liquid

applications, with great stability and

chopping, filtering and concentrating. •

yellows, this new powder opens up even

long shelf life."

more possibilities for manufacturers.

Extensive testing has shown it performs

Based on the principle of colouring food with food, products are made from

GNT – www.exberry.com

September 2020 | Food Review

23

B A K E RY

Are clean-label bakers the new agents of change?

One in two consumers check food labels for E-numbers, according to research by Innova Market Insights. This is a clear indication of the growing consumer demand for more transparency when it comes to how food is made and what it contains.

W

ithin the bakery industry, the rise in clean-label claims indicates that this is no passing trend. DuPont

Nutrition & Biosciences is assisting bakers to overcome the clean-label challenge in bakery innovation: Its new toolbox for clean-label bread production is one of the outcomes.

CONSUMER WILLINGNESS TO PAY A PREMIUM PRICE While there is no global regulatory definition or understanding of clean label, Innova research shows consumers are willing to pay more for natural products with a simple ingredient list.

Figures from Polaris Market Research show a strong increase in bread product launches with on-pack clean-label claims. This trend is forecast to continue until at least 2026.

“Although the interpretation of clean label is complex and varies from country to country, the common denominator is that the label lists ingredients which consumers recognise. They

Clean-label bread launches is a global growth market

want to know what their food is made from, how much water is used in production and any health benefits on-pack,” says Emeline Commun, bakery marketing specialist.

For manufacturers, the challenge is to understand consumer needs and which ingredients they will accept, while finding a balance between taste, texture, volume and cost.

The COVID-19 pandemic has added to the

“Reformulating to a cleaner-label recipe inevitably adds an extra layer of complexity to the bakery process”

complexity, causing consumers to reprioritise their purchasing criteria. In some cases, this has meant relaxing their focus on clean label for a while. “The current situation could lead to a substantial, long-term change in consumer perceptions of clean label. The bakery industry must be ready to adapt to new consumer needs,” Commun adds.

DuPont’s Label-friendly Bakery Toolbox addresses clean-label challenges in yeastraised baked goods and changes in consumer expectations, navigate these opportunities, and adopt the best solution for its formulation and processing methods.

Reformulating to a cleaner-label recipe inevitably adds an extra layer of complexity to the bakery process. Dough handling and

Food Review | September 2020

the transition to a clean-label formulation by meeting bakers’ most pressing need – to maintain product quality and a consistently stable process. As part of the toolbox, DuPont also presents the newest solutions to mitigate the challenges of clean-label formulations and

tolerance may be affected, along with sensory quality in terms of freshness, softness, volume, crumb colour and bread resilience.

To highlight the challenges, DuPont has identified five stages in the clean-label spectrum, starting with traditional bakery products made with emulsifiers, such as DATEM, SSL and monoglycerides, and mould inhibitors, such as calcium propionate.

At the other end of the scale are formulations based purely on kitchen cupboard ingredients, like flour, yeast and salt. The scale also indicates the impact of clean-label reformulation on product characteristics, highlighting the trade-off between a cleaner label on the one hand and process tolerance and product quality on the other.

24

The label-friendly Bakery Toolbox takes all these factors into consideration, smoothing

to ensure that bread quality is back up to the expected level.

Price continues to be a big driver for consumer food purchases, especially in the current context of COVID-19, where consumers are looking for more affordable products.

Bakery products have the multiple ability to provide value for money, as well as pleasure, comfort and, to some extent, protection via nourishment. The pandemic is also causing consumers to think about how their lifestyle impacts the planet. In that light, the clean-label trend is an opportunity for manufacturers to become agents of change. •

DuPont - www.dupontnutritionandbiosciences.com

B A K E RY

Sugar optimiser for permissible indulgence Imagine a world where you can have your cake and eat it. Symrise has developed a comprehensive product solution that allows one to balance the taste in biscuits with up to 50% sugar reduction. Sugar reduction is a key innovation that can assist your brand to leverage these opportunities as we move into a world where more and more consumers are looking for that permissible moment of indulgence.

A

s we move into a world where

CONSUMER

more consumers are looking

• Consumers actively seek sugar-reduced

for that permissible moment of

indulgence, the ability to reduce sugar is a key innovation that can assist your brand to leverage these opportunities.

Sugar reduction is on everyone’s lips with diverse implications from the different viewpoints mainly: environmental, consumer and product perspectives:

products in the bakery due to health reasons such as obesity, diabetes, tooth decay and calories • Lacking availability of sugar-reduced products, unpleasant taste or missing natural sweetener solutions are reasons not to use sugar-reduced products • There are four different consumer segments with different expectations

“Symrise’s Symlife Sweet Optimizer Baking multi-functional compound (MFC) allows up to 50% sugar reduction in biscuits”

regarding sugar-reduced products.

This incredible technology brings multiple benefits to sweet baked goods manufacturers: • easily to apply in your recipe when reducing/removing up 50% of sugar as a compound of flavour and bulk ingredients •

ENVIRONMENT

texture, volume, mouthfeel,

• WHO has set goals for sugar reduction

browning, colour…)

• Government push via regulations/taxes for

• enables a consumer friendly

more sugar-reduced products • NGOs run campaigns against products with an above-average amount of sugar • The industry proactively works on solutions to get away from the unhealthy image of products with a high sugar content.

creates the complex properties

of sugar in baked goods (e. g.

PRODUCTS • The key challenges are not only to rebalance taste, but rather adapt the complete recipe, since sugar reduction impacts much more than sweetness perception. It also impacts on colour, texture and overall mouthfeel of products.

The symlife Sweet Optimizer Baking multi-functional compound (MFC) works with biscuits with up to 50% sugar reduction and rebalances sugarreduced product formulations in terms of sweetness perception, mouthfeel and flavour profile.

ingredient list according to EU legislation (soluble fibres, natural flavours) • Registered for patent, validated in application and commercially scalable.

Research has validated the consumer perception of sugar content in baked goods, with 28% of consumers weighing sugar reduction as more important than calories.

It goes without saying that innovation into sugar reduction will become a key feature when launching baked products. •

Symrise – www.symrise.co.za

September 2020 | Food Review

25

DA I RY F O O D

Growth and agility underpins activity in Africa Iberchem has announced that it will expand its presence in the South African market by joining Iberchem, Scentium and Versachem under a new name: Iberchem South Africa. Maryke Foulds looks at what this venture will bring to the industry.

T

he announcement comes two years after the group acquired 70% of Versachem, a company specialising in

food colourants and seasonings. The group recently bought the remaining 30%, thereby fully integrating Versachem’s activity into the group’s portfolio. All three divisions will be temporarily accommodated in Versachem’s current offices in Pretoria until a new location is found.

Scentium creates bespoke flavours for beverages as well as for sweet and savoury products while Versachem specialises in the production of food seasonings, dustings and colourants. With the expertise of all three combined, the group is well-positioned to service not only the local but also the export

QUOTE:

market, creating work opportunities and earning foreign currency for South Africa.

Iberchem South Africa is managed by Quentin Questiaux, who joined the company in May this year. Questiaux is well-known in the African market, with a proven track record in the flavour and fragrance industry.

In the coming months, Iberchem South Africa will gradually welcome new members to Iberchem and Scentium. “We are looking to expand our equipment to be even more

food and beverage market to reformulate

autonomous and agile with shorter delivery

with low and no-sugar variants and

times of projects. Our biggest strength

meet consumer health demands without

would be the laboratory that was developed

compromising on taste. This situation is

to perfectly respond to the needs of our

expected to keep going and even more so

local clients,” he enthuses.

as a result of the COVID-19 pandemic.

A key focus for the company this year is

“Every year, the Iberchem Group welcomes dozens of interns into its laboratories, allowing them to complement the academic training they have received in class. For some of them, their experience evolves into a full-time job. Year after year, the Iberchem Group exceeds the minimum percentage of employees with disabilities required by law.

We believe that every job has its learning process and that everyone deserves to be given the same chance” - Iberchem South Africa MD Quentin Questiaux

“Botanical ingredients like herbs

the expansion of its sensory library. It is an

and spices are innovations but are also

ongoing process as taste trends evolve and

highlighted for their health qualities,

change. “We rely on thousands

primarily less sugar and vitamin

Concerning growth on the African continent, he is optimistic. “Iberchem

of fragrance and flavour

and fibre additions. This can

South Africa is the result of substantial

references, all made available

help brands to capitalise on

investments that fall into an even larger

to our clients. If what we have is

growing consumer interest

expansion plan by the Iberchem Group on

not exactly what they’re looking

in natural and better-for-you

the African continent. Overall, it confirms

for, our teams of specialists are

products,” he notes.

the tremendous growth potential we see

at their disposal to fine-tune

The experience-seeking

in the market. We wish to support and

the selected reference until

consumer is looking for unique

be part of this growth, offering speed

we find the exact profile they

and quirky flavours, such as

to development, production, supply,

were looking for. In my opinion,

banana & chocolate or coffee

affordability, and the ability to supply both

having an extensive library is

& caramel. These flavours take

small and large volumes to service a broad

you into a sensory journey

spectrum of customers. I am confident

support that goes with it is

that can intrigue consumers

that this news is only the beginning and

even more important.”

in-store and encourage impulse

that shortly we will be making more

essential, but the technical

Quentin Ques tia

One of the biggest trends and areas

ux

purchase.“Substitute products must be

of growth Questiaux predicts is that of

equally qualified in taste to not lose the

reduced sugar products with a clean

consumer’s attention. Working in artificial

label – especially in beverages. “The sugar

sweeteners or natural flavours is a challenge

backlash continues to put pressure on the

for the sector.”

26

Food Review | September 2020

announcements,” he concludes. •

Iberchem – www.iberchem.co.za

DA I RY F O O D

Precise cutting with innovative solutions Cheese characteristics vary widely in terms of fat, moisture content and hardness. These issues must be considered when assessing the desired end-product.

P

rominent supplier of food cutting technology, Urschel, offers a range of premier cutting solutions for manufacturers working with difficult to cut cheese

products. Its dairy solutions provide quality size reduction for a variety of products.

The Affinity Dicer is the largest cheese dicer manufactured by the equipment supplier. It offers and delivers a sanitary

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design, optimal high-capacity output and precision cuts. The unit can process high-fat, cold-temperature products like cheese with additional feed assistance via the feed roll and feed drum delivered as the product transitions through the cutting zone.

The Urschel family of CC/CC-D series shredders deliver precise cuts at the high yields required by the cheese industry. Each model offers continuous operation for uninterrupted production and accepts an input product size up to 89mm. Models include the longstanding, production-proven CC and CC-D along with the newer CC-DL and CCX-D. High-capacity, versatile machines feature interchangeable quicklocking double-rings, singleadjustment cutting heads that enable processors to change the type of shred in just minutes.

Specially-designed knives do not require sharpening and are

DID YOU KNOW?

Heat and Control was established in 1950 and boasts ten manufacturing facilities, 11 test centres and more than 30 offices globally.

inexpensive to replace. Types of cuts include varieties of full shreds, oval shreds, crescent shreds, wide oval shreds, strip cuts, granulations, and flat slices from a myriad of cheeses. The thickness of the shred can be adjusted to suit specific production environments.

One of the key strengths of all of these CC model machines is the operating principle. Product delivered to a feed hopper enters the rotating impeller and is held against the inner surface of the cutting head assembly by centrifugal force. The cutting head assembly consists of stationery, individual cutting stations.

Slices or shreds are produced as the product passes each knife smoothly and uninterruptedly, while length is controlled by the

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input product size. • Affinity Dicer – the largest product in Urschel’s range for Cheese

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Heat and Control - www.heatandcontrol.com SAFoodReview_Sept2020_88.5w x 262h_CEIA_Dairy.indd 1

15/09/2020 3:54:08 PM

September 2020 | Food Review

27

DA I RY F O O D

Go with your gut and eat SA heritage food

Just over 500 healthcare professionals attended this year’s One Health Summit under the theme “Your Gut’s Instinct”. The event was hosted in webinar format at the end of August.

S

cientific findings on the topic of

Andrea Hardy, Canada's Gut Health Expert and speaker at The One Health Summit 2020

gut health were shared by two renowned international experts,

and South Africa’s Mpho Tshukudu, a registered dietitian with a special interest in South Africa’s food culture and heritage. Tshukudu unpacked the relevance of the international findings for South Africans, taking local beliefs,

Mpho Tshukudu

behaviours and dietary practices into account.

Professor Rob Knight, founding director of the Centre for Microbiome Innovation in California, described the gut and its microbiome as the new factors impacting lifespan and health outcomes. “Your gut microbiome can be a predictor for

Professor Rob Knight, founding Director of the Centre for Microbiome Innovation in California

health and disease. Research indicates that health conditions including pain, autism, obesity, cardiovascular risk, anxiety, depression and multiple sclerosis may be affected by intestinal microbiota,” he explained.

When we think of biomes under threat, we tend to think of extinction within the environment. Our modern lifestyle has led to the disappearance of large groups of microbes in the gut microbiome.

abundance and diversity in beneficial

diet. For many, these foods are seen as

bacteria, improved overall gut health

‘poverty foods’, but they provide valuable

and a reduction in inflammation. Eating

nutrients that can promote gut health

food containing probiotics is a simple,

and, based on the findings presented by

accessible way for people to consume

the other speakers, overall health too.

nutrients and beneficial bacterial

with laxatives, herbal preparations and

fermented foods are probiotics and that

enemas as a first-line approach, which

probiotics must meet certain criteria to

can be harmful long term. Tshukudu

be classified as such. These

Maintaining equilibrium in the

include the need for bacterial

gut is protective against disease when modern life stressors influence the gut microbiome negatively. The good news is that eating fruits and vegetables rich in fibre and phytonutrients coupled with fermented food may have a positive effect.

DID YOU KNOW?

dietitian known as Canada’s gut health expert, agreed. “Nutrition is the quickest and easiest way to influence our gut microbiota,” she said, noting that Western diets, characterised by too much sugar, fat, red and processed meat and too little dietary fibre, reduces the diversity and abundance of beneficial bacteria in the gut, damages its mucous layer and leads to low-grade chronic inflammation.

Eating enough fibre, phytochemicals, omega-3 fats, probiotics, prebiotics and fermented food is associated with

28

strains to survive in the

Probiotics must meet certain criteria. This includes the need for bacterial strains to survive in food at an efficacious dose for the duration of shelf life, and at least one positive human clinical trial to prove that it addresses a specific health outcome.

Andrea Hardy, a registered

Food Review | September 2020

Some South Africans self-medicate

cultures. She explained that not all

exhorted healthcare professionals to educate their patients around dietary intervention and the benefits of eating

food at an efficacious

or drinking certain familiar, easily

dose for the duration of

available heritage or traditional foods

shelf life, and at least

for gut health.

one positive human

Tshukudu recommends integrating South

clinical trial to prove

Africa’s traditional cuisine with modern

that it addresses a

food trends:

specific health outcome.

• Onion, ginger, garlic, black pepper,

She used the example of

yoghurt containing a blend of five cultures, including the

cayenne pepper, cinnamon, oregano, rosemary, and turmeric are prebiotics that support gut health and have been

bacterial strain Bifidus ActiRegularis,

adopted into South African cuisine

which has been shown in clinical trials to

from other cultures over time. These

reduce digestive discomfort.

could be added to pre-packed meals

Tshukudu’s presentation aligned the international findings with the

and salads.

• While beans and legumes get a

South African context, calling on local

bad rap for causing bloating and

healthcare professionals to better

flatulence, sprouting, soaking and

understand all the layers influencing an

fermenting lentils and beans (grains

individual’s food choices and behaviours,

and other vegetables) avoid these

to deliver relevant, meaningful advice.

issues and is an emerging world

Some South Africans believe that

trend as well as being culturally-

traditional food has no role in a modern

appropriate. Processors should

DA I RY F O O D

FAST FACT

Danone’s One Planet. One Health initiative is based on the premise that a healthy body needs healthy food and a healthy planet. It is a movement aimed at nurturing the adoption of sustainable eating and drinking habits. To date, Danone’s online nutrition education initiatives have reached more than 7 million South Africans.

The company is the only yoghurt producer committed to the Plastic Pact in SA; it has partnered with Pick n Pay to improve food waste management and is working through the WWF with farmers to improve water catchment areas.

are unaware that lactose is digested by the intrinsic cultures in fermented dairy products. Maas may be the traditional version, but yoghurt has a modern appeal. To help promote digestive comfort and wellbeing, dairy processors should formulate yoghurts with a blend of bacterial strains, including Bifidus ActiRegularis.

A dairy food that contains this ingredient

more of these ingredients to freshpacked ready-meals.

• Fruits such as pomegranates, figs, blackberries, and baobab grow in rural areas and evoke positive childhood memories, and are fantastic additions to smoothies, baking and dressings.

• South Africa has a wealth of traditional and nutritious cooking leaves. Morogo, for example, is rich in nutrients and fibre and processors can turn these

The initiative forms part of the

is Danone’s Activia yoghurt and clinical

company’s continued investment in

trials prove that it assists with digestive

education programmes that brings

comfort. When added to a reduced-sugar

together global and local scientists.

variant, it gains even more benefits. investigate opportunities of adding

Danone donated 5 million cups of yoghurt to communities in need during the COVID-19 crisis

“The health of people and the

Danone recently launched its strawberry

health of the planet is very strongly

and goji berry variant, which features 28%

interconnected. One Planet. One Health is

less sugar.

our long-term vision and is linked to the

“One of Danone Southern Africa’s

sustainability goals of the United Nations.

many efforts towards the goals set to

We believe that education on the right

achieve its One Planet. One Health vision

nutrition choices will help to strengthen

is an annual summit, hosted for the past

the wellbeing of consumers,”

three years as The Yoghurt Summit. It

he concludes. •

was renamed this year to the ‘One Health Summit’ in line with our One Planet. One Health ethos,” explains Danone MD Hendrik Born.

leaves into an excellent pesto. These leaves can also be added to salad packs and bottled smoothies.

• In South Africa, meat consumption is high at the expense of vegetables, nuts, and legumes, partly because plant proteins are considered poverty food. The flexitarian diet is gaining interest and nuts and legumes fit right in there as protein sources.

• Due to a high prevalence of lactose intolerance, many South Africans avoid dairy food. Many consumers

September 2020 | Food Review

29

DA I RY F O O D

Farming flavour all the rage

The stevia plant yields many powerful and highly beneficial ingredients beyond just sweeteners. Stevia flavour modifying properties are a well-known tool used by flavourists to optimise taste performance, increase mouthfeel and boost a variety of flavour notes in food and beverage applications.

C

onsumers are seeking out natural

enhancers, and new dairy products launched

ingredients in response to the growing

with flavour enhancers grew nearly 30%

trend of individuals taking control

year-on-year in 2019.

of their own nutrition, health and wellness.

Due in part to the innovations with next-

This dovetails with consumer demand for

generation, more taste-advanced stevia leaf

cleaner food and beverage product labels and

ingredients, stevia has seen a steady increase

environmentally-sustainable ingredients.

in global launches of food and beverage

One food and beverage sector recognising

“While stevia is increasing year-on-year, other nonnutritive sweeteners, including acesulfame K, aspartame and sucralose, have declined each year since 2017”

products since 2012. In 2019, the increase was

ingredients come from the leaves of stevia

these trends is the flavour enhancer and

more than 16% vs. 2018, and there have been

plants and are completely non-GMO. PureCircle

modulation space. Flavour enhancers used in

over 26 000 products launched with stevia

works alongside food and beverage companies

products with natural claims increased 32%

cumulatively since 2012.

to enable optimal taste performance across a

from 2018 to 2019, according to Innova. Sports

PureCircle is a prominent producer and

nutrition was the largest new product launch

innovator of stevia ingredients for the global

and innovative portfolio of next-generation

category for “natural” products using flavour

food and beverage industry. All of PureCircle’s

stevia leaf ingredients.

30

Food Review | September 2020

wide array of applications by utilising its vast

DA I RY F O O D

Stevia is experiencing significant growth and adoption in the dairy sector. New dairy products launched which included stevia

and sustainable supply of stevia leaf ingredients to food and beverage companies.

Due to its extensive research, PureCircle

ingredients grew 22% last year. While stevia is

has discovered many ingredients in the

increasing year-on-year, other non-nutritive

stevia leaf, including ones with flavour-

sweeteners, including acesulfame K, aspartame and sucralose, have declined each year since 2017. Among all new dairy products launched in 2019,

modifying properties. These ingredients work in harmony with the stevia sweeteners, and can contribute to sweetness quality, target flavour

drinkable yoghurt and

intensity, modify taste

spoonable dairy yoghurt

and remove bitterness.

made up the largest

Stevia flavour solutions

share of launches with

can even contribute to

stevia ingredients.

reducing sodium.

The company recently announced the development of a new proprietary stevia leaf variety, which provides significant advantages compared with previous

PureCircle’s NSF-02 natural stevia flavour is one of its most versatile stevia solutions because it works across food and beverage categories to

generations of stevia plants. These new stevia

enhance sweetness quality and balance overall

plants yield greater quantities of our next-

flavour profile, while minimising off-notes and

generation stevia ingredients. This agricultural

aftertaste. Like other stevia ingredients, it is

innovation yields more efficient production

non-GMO and has no calories.

of the best-tasting stevia leaf sweeteners

NSF-02 stevia flavour is an important

and powerful flavour-enhancing ingredients.

solution for product developers working

The new stevia plant variety further improves

in the dairy category. Using it in combination

PureCircle’s ability to deliver a cost-effective

with stevia leaf sweeteners, such as the

Reb M, enables food and beverage companies to produce great-tasting products with costefficient, plant-based ingredients. Like other stevia-based flavours in PureCircle’s portfolio, NSF-02 natural stevia flavour provides different synergies depending on what application the ingredient is used in.

PureCircle is the industry pioneer regarding the use of Glycosilated Steviol Glycosides (GSG) flavour. Flavour ingredients have high standards of review by the FDA and other regulatory food safety agencies like EFSA. Next-generation stevia leaf ingredients provide food and beverage companies with the tools necessary to achieve optimal taste performance, improved mouthfeel and sweetness quality parity in low and zero-added sugar products. PureCircle’s robust portfolio of stevia leaf ingredients, including stevia sweeteners, flavours and optimised stevia blends, satisfy and exceed consumer expectations for great-tasting food and beverage products, supporting healthier lifestyles. •

Savannah Fine Chemicals – www.savannah.com

September 2020 | Food Review

31

DA I RY F O O D

Cultures to reshape the fermented dairy industry A new range of dairy cultures allows for the production of yoghurt with faster fermentation time and higher probiotic counts – important factors for consumers and producers.

D

uPont Nutrition & Biosciences’ new

acidity before cooling and packaging. Yo-

range ensures innovative dairy

Mix Prime 900 offers manufacturers the

culture and probiotic formulations

option to fine-tune the texture of yoghurt

“These cultures demonstrate how

according to consumer preferences.

market-driven innovation, combined

that will result in new food solutions. In combination with fermentation and higher

• Yo-Mix Fast 1.0 enables fast fermentation,

a higher dose of documented probiotics in premium probiotic yoghurt.

with local expertise in regions around

probiotic counts, it offers a mild taste and

delivers a thick and smooth texture,

the world, brings faster fermentation,

premium texture.

and can be adapted to different yoghurt

higher probiotic counts, milder taste and

The new cultures include:

recipes and processes.

a healthier brand image to fermented

• Yo-Mix Prime offers manufacturers

• DuPont Danisco LPC 800 allows for refreshing

dairy products,” explains Morten Boesen,

the ability to create optimal mildness

beverages without too much acidity, while

global product line manager, Dairy

coupled with a premium creamy texture.

maintaining high Lactobacillus bacteria

Cultures, DuPont Nutrition & Biosciences.

The culture enables the reduction of

count until the end of product shelf life.

added sugars and a high probiotic count,

Compared to market alternatives, it enables

costs for customers while maintaining

while maintaining quality throughout

faster fermentation within 24 hours, which

quality and taste for consumers,

challenging distribution channels such

assists in reducing the risk of contamination.

effectively reshaping the future

as the African continent. It also allows

DuPont Danisco LPC 800 is an ideal choice in

of fermented dairy products,”

manufacturers to save on formulation

low-sugar recipes, resulting in a more stable

he concludes. •

costs by reducing protein addition in

and refreshing flavour.

recipes, and greater process flexibility due to fast fermentation and full control of

“These cultures lower formulation

• Howaru Bifido combined with Yo-Mix

DuPont – www.dupont.co.za

cultures creates new opportunities for

A first in organic dairy ingredients Arla Foods Ingredients has launched the first organic micellar casein isolate, helping manufacturers meet the demand for organic, natural and functional protein products.

M

icellar casein isolate is a new

they think healthy, sustainable and

and functionality with an offer of healthy

ingredient which is rich in native milk

wholesome. A shortage of natural, organic

wholesomeness that increases the appeal."

proteins. It is extracted from milk

protein ingredients has prevented many

Samples of MicelPure are available

using gentle processing without the addition

manufacturers from entering this market.

for food applications such as cooking-

of acids. The protein maintains its chemical

MicelPure Organic fills the gap, allowing

stable cheeses, yoghurts and ice cream

structure, allowing the creation of products

companies to extend their portfolios with

and puddings, as well as health and

that are as close to nature as possible.

products that are both organic and packed

performance applications, such as ready-

with high-quality protein.”

to-drink high-protein beverages and

MicelPure contains a minimum of 87% native protein. Suitable for food,

Research shows that “healthy” and

functional health food and active nutrition

“natural” are the two most important

applications, it is low in lactose and fat,

characteristics for consumers of food

heat-stable and taste-neutral.

products.1 Because it is rich in the native

As the first-ever organic micellar casein isolate on the market, MicelPure Organic meets a clear need. Research indicates

protein, MicelPure also helps manufacturers

products healthier, tastier and more

Foods explains, “Protein benefits for muscle

nutritious, with one in three saying they

growth, recovery and weight management

would buy more organic, high-protein

has driven consumer demand in a range

snacks if they were available.1

of categories. While the high-protein trend is here to stay, manufacturers

manager at Arla Foods Ingredients

also have to meet many other needs.

says, “When consumers hear ‘organic’,

MicelPure combines high protein levels

Food Review | September 2020

Lindberg International ‘Consumer study on perception of organic food products and organic purchasing habits’, 2019f

Joe Katterfield, business development manager for Sports Nutrition and Health

32

1

respond to these needs.

that European consumers consider organic

Barbara Jensen, business development

powder shakes. •

Arla Foods Ingredients – www.arla.com

S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E

How to stop COVID infection during food production Global hygiene and cleaning company, Diversey has applied its expertise in the food and beverage sector to provide key safety advice designed to protect against airborne transmission of COVID-19.

E

FAST FACT

urope has seen a large number of

damp, are perfect environments for coronavirus

outbreaks of infection in a diverse

to linger and spread.1

For your copy of Diversey’s New Air Handling Guide, please visit: https://diversey.com/en/blog/ considerations-improvingfacility-air-quality

range of production facilities and in

factories that handle everything, from chilled

Change to the WHO Guidelines

supermarket ready meals, to meat processing

The World Health Organisation (WHO)

and snack foods.

initially ruled out airborne transmission,

Hein Timmerman, global sector specialist

contending that COVID-19 is spread mostly

comments, “Initially the investigation into the

through respiratory droplets, usually from

primary causes of outbreaks in food production

sneezes or coughs. This has now been re-

facilities has seen the focus directed toward

evaluated due to evidence and broader

typical working practices in F&B plants - such

lobbying by scientists engaged in emerging

as the close proximity of workers in production

research and with the recent factory

lines. With heavy physical work - such as in

outbreaks in mind. 2

meat processing - staff breathe heavily from

As COVID-19 is thought to be primarily

the effort involved; or have to shout above the

transmitted via large respiratory droplets,

loud noise of production machinery.”

an increasing number of outbreak reports

It has been identified that workers can

implicate the role of aerosols in indoor

spread infection in droplets from coughing,

environments - with the duration of

sneezing, or simply exhaling breath. Factories

infectivity depending on temperature

and indoor areas with refrigerated areas and

and humidity.

Hein concludes, “Diversey has created essential guidance for the F&B production industry. This details methods to increase air quality and reduce the risk of transmission.

It is timely insight due to the growing body of factory evidence, and the WHO’s acceptance of developing scientific research of the potential threat involved. • https://www.bbc.co.uk/news/53137613 https://www.nytimes.com/aponline/2020/07/06 2 health/ap-eu-med-virus-outbreak-airbornecoronavirus.html 1

Diversey - www.diversey.com

NOW OFFERING COVID-19 SURFACE AND ENVIRONMENTAL TESTING As employers prepare to welcome their workforces back to work, concerns about surface and environmental contamination will be top of mind, which includes restaurants, hotels and schools.

Businesses across every industry sector are seeking peace of mind in terms of compliance, occupational health and safety, and their social responsibility towards employees and customers to create a clean and safe environment.

NOSA Testing Laboratories, an ISO 17025 accredited laboratory facility, can help. We are now able to carry out surface and environmental sampling for the detection of coronavirus S gene specific to COVID-19, in accordance with the World Health Organization (WHO) protocol for health care and public health. NOSA Testing can help South African Businesses detect the presence of COVID-19 by means of our RNA virus determination real time PCR method. NOSA Testing has more than 20 years’ experience in diagnostic and zoonotic analysis and is performed by competent HPCSA registered professionals. These laboratories meet the current biosafety and biosecurity standards according to the OIE Standards for biological risks, and all testing takes place in a BSL2 testing environment which is a minimal requirement recommended by the World Health Organization.

NOSA Testing methodology of analyses tests for two protein genes on the virus to confirm presence. They are: > E gene which detects corona viruses (Envelope protein) > S gene specific to COVID-19 (Spike protein) COVID-19 results shall be reported within 48 hours from date of sample receipt.

For more information please contact: Venisha Bachulal (Managing Director) +27 (0) 76 511 3850 | venisha.bachulal@nosa.co.za Keshav Beachen (Sales Manager) +27 (0) 76 114 9420 | keshav.beachen@nosa.co.za

September 2020 | Food Review

33

S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E

Success depends on a lean and flexible facility The food and beverage industries remain important contributors to the manufacturing and FMCG sectors, as well as the local economy, writes Darryl Macdougall.

F

ood and beverage manufacturers

This has placed a lean, flexible

no preservatives added, which makes it

are some of the most highly-

manufacturing process as the engine

difficult to keep microbes out of

regulated (and penalised)

of a successful operation. The process

the food.

businesses – and rightly so, given the

needs to be consistent and reliable to

impeccable standards of process and

accommodate perishable

product quality, and safety, that must

ingredients, storage, short

food and drink products – with every

be maintained to protect consumers and

lead times for retail clients

batch – requires machines that are

end-users.

and maintain a safe and

Modern consumer tastes and corporate

hygienic production line.

With the above in mind, being able to produce high-grade safe and quality

100% reliable, meet today’s hygiene standards and can handle

retail demands for new flavours, fashions

This process also needs

and fads have created a demand for

to be repeatable, ensuring

order, but in reality – and

ever-greater quantity of product lines.

the quality of each batch, to

when the quality of the

This demand runs somewhat contrary to

maximise on outputs and minimise

the operation of traditional dedicated

on waste and potential losses. As a result,

process lines where there is one pipe-run

production efficiencies and product

behaviour of the customer, which directly

for one product.

quality remain key performance indicators

impacts the bottom line, then – there can

for food and beverage processors.

be no shortcuts.

Previously, if a company wanted to produce more lines of products,

There are challenges

they needed to build more

with the multi-product

production lines,

line approach that

products with care. A tall

product can directly impact the safety, experience and buying

Directives from the European Hygienic Engineering Design Group (EHEDG) – which have been accepted and are

recommission an

every production

widely applied across related industries

existing line or

line manager will

in South Africa – are aimed at setting

suffer downtime

invariably face.

universal standards that are founded

cleaning and

Deciding on how best

turning around a

to manage the transition

line in operation.

of one product to another

Modern production facilities – particularly in food and beverage

when using the same line for batch production is an example. A

on science-based knowledge in the hygienic engineering and design of food and beverage production equipment and facilities. As an example, a core aim of the EHEDG standards is to prevent

production – have moved from a

potential hazard to a multi-product line

contamination of consumable products

dedicated production line for each

approach is cross-contamination, which

– and directly related to this, one of the

product to an innovative multi-product

can result in spoiled product, shorter

major directives from EHEDG states that

line which could be processing several

shelf life, production downtime

every part of the production line should

different foodstuffs, liquids or slurries

and risks to employees during the

be accessible for cleaning.

every day.

cleaning process.

A multi-product line can increase

“Modern production facilities – particularly in food and beverage production – have moved from a dedicated production line for each product to an innovative multi-product line which could be processing several different foodstuffs, liquids or slurries every day”

34

Food Review | September 2020

The cleanability requirements – including, clean in place (CIP) and

the exposure risk to microbes, which

sterilisation in place (SIP) – to meet

present an ever-looming threat to food

hygiene standards alone present

and beverage manufacturers. This has

several challenges for processors, and

also been compounded by the current

particularly those operating multi-

consumer trends in food,

product lines. With a modular design,

as the sector

however, there is a great opportunity

has seen an increase in favouring fresh,

to address many of the challenges presented by a multi-product line and the

flavourful,

cleanability

easy-to-prepare

requirements.

foods with little sugar, salt, and less to

For example, modular design to the production line can allow

S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E

processors to add, remove, change out

hygienic pumps with a modular design

or undertake maintenance to machines

can be integrated. Such solutions allow

and equipment on a production line

for ready disassembly, cleanability

processes must be reliable, repeatable

with minimal disruption, which also

and reassembly.

and error-free – and integrating

means less downtime.

Taking this a step further, and at

Additionally, when reviewing the

3A-certified manufacturing processes.

In the food and beverage industries,

the right equipment is critical to

production line, processors should

maintaining this sustainably. Navigating

the heart of maintaining the highest

consider speciality twin-screw pumps

the technical obstacles of selecting the

levels of hygiene standards means

that were designed for reliable pumping

right pumping solutions for specific

selecting fit-for-purpose hygienic

– from low- to high-viscous, volatile

applications can be complex.

pumping solutions that have been

or gaseous products – across multiple

designed and built to eliminate any risk

applications and fulfil the utmost

therefore, need to look to a trusted

of contaminants during production. For

hygienic and efficiency requirements

and reputable brand that can offer not

example, throughout the production

according to the highest hygienic

only a wide range of pumping solutions

process, there are many areas where

specifications such as EHEDG and

but solutions that are long-lasting,

Food and beverage processors,

cost-effective and efficient – because they are 100% fit-for-purpose for

Production efficiencies and product quality remain key performance indicators for food and beverage processors

the application. •

ABOUT THE AUTHOR DARRYL MACDOUGALL is managing director of Verder Pumps South Africa.

Verder Pumps – www.verder.co.za

At Verder Pumps we offer a wide range of fit-for-purpose pumps and solutions for every phase in the food and beverage manufacturing process.

VERDER HYGIENIC PUMPS Offering a wide range of hygienic solutions

Our range of hygienic pumps and solutions include the Packo Centrifugals, Verderair double diaphragm, Verderflex Peristaltics and JEC rotary lobe and twin-screw pumps.

With this complete range of solutions we can address all your hygienic pump requirements!

Your benefits:

Verder is manufacturer of: Verderflex, Verderair, Packo and JEC pumps VERDER PUMPS SOUTH AFRICA (PTY) LTD Tel.: +27 (0)11 704 7500 www.verder.co.za info@verder.co.za

September 2020 | Food Review

35

S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E

The lowdown on disinfection, HACCP management & microbial air monitoring Food suppliers, manufacturers, and regulatory bodies are adapting to keep their products, industry workers and the consuming public safe. There is an increase in demand for accurate and reliable food and safety testing.

M

erck has created easy access

Food Review explores some of the industry-

portals for key testing products and

leading products used in food and beverage

training materials requested by the

in-process control testing:

industry. These products and trainings support disinfection control, HACCP management and

• Semi-quantitative disinfectant testing MQuant test strips These items are pocket-sized laboratories

pathogen testing.

for quick and simple analyses of chemical 1, 2: Merck Millipore offers a range of semi-quantitative disinfectant testing

1

of your production line after disinfection.

Digital value readout and data storage is available with the MQuant StripScan app for instructions on sample preparation for inprocess control of disinfection makes the process simple and effective.

• Reflectoquant system The RQflex 20 reflectometer is an economical mobile laboratory that performs critical analyses in the fields of agriculture, food,

The need for improved food and beverage safety is resulting in frequent in-process disinfection control testing. Merck has increased production of reagents for reflectometry, photometry, traditional and rapid surface monitoring, sterilisation process validation, and certified disinfection reference standards.

Attention to hygiene during the manufacture of food and beverage products is paramount due to the ever-present risk of dangerous microorganisms that can cause foodborne illness by infection or intoxication.

Equally thorough disinfection control testing of filling and processing equipment must also be conducted to ensure that disinfectant residues do not remain and subsequently contaminate final food and beverage products.

The group continues to develop efficient, sensitive and compliant disinfection control testing solutions based on its Supelco analytical reagents and Millipore biomonitoring tools expertise.

beverages, water analysis and during disinfection control. The peracetic acid test strips are suited for the selective determination of the peracetic acid concentration in aqueous solutions and to check for the absence of peracetic acid after rinsing processes, also in cases in which hydrogen peroxide is present.

• Spectroquant Move instruments A robust portable handheld colorimeter for rapid on-site analyses with reliable results for disinfection control: no matter what or where you need to test. Spectroquant Move instruments offer dependable in-process testing in a broad range of pre-programmed parameters with an independent instrument.

HACCP & ENVIRONMENTAL MONITORING Discover a complete HACCP management system with audit-ready reporting that combines high-sensitivity bioluminescent detection with room-stable sampling swabs that are resistant to sanitiser interference, allowing for fast, accurate detection of low levels of adenosine triphosphate (ATP) and other parameters on surfaces after cleaning,

“Attention to hygiene during the manufacture of food and beverage products is paramount due to the ever-present risk of dangerous microorganisms that can cause foodborne illness by infection or intoxication”

36

Food Review | September 2020

and more temporary workers, there is an increased need for training on the correct protocols to help keep staff and products they produce safe and compliant.

disinfectant parameters to ensure the safety

selected test strips. Application notes with

DISINFECTION CONTROL TESTING

FAST FACT: With reduced staff

and even after sanitising.

The MVP ICON is the first system to provide true HACCP management capabilities. It features advanced photon counting sensor (PCS) technology; the MVP ICON provides superior accuracy, sensitivity, and reproducibility for ATP,

pH, temperature, conductivity, and concentration. The innovative design is sleek, lightweight and features an easy to use touch-screen interface.

The ICON Dashboard software displays key performance metrics at a glance, allowing quality assurance managers to instantly determine if sanitation standard operating procedures (SSOPs) are being followed and are effective. Dashboard data is updated in real-time after results are synched.

A wide selection of print-ready reports, including Action, Trending, HACCP, and raw data will allow you to generate necessary documentation in seconds.

MICROBIAL AIR MONITORING Hygiene standards in a production environment are directly linked to the microbiological safety of the finished products. Merck’s technology ensures that active microbial air sampling solutions generate precise, reliable and reproducible results for effective use in the food and beverage industry where regulations are on the rise, and standards are becoming more stringent.

The range of air samplers are based on different principles, enabling selection of the technology to suit your needs. The range includes MAS-100 air samplers which are based on the Anderson impaction principle that uses settle plates or contact plates, as well as RCS (Reuter Centrifugal Sampler) that uses dedicated agar strips.

There are product variants specifically designed for explosion hazard areas and for monitoring of compressed gases. •

2 Merck Millipore – www.merckgroup.com

MVP ICON® System Your daily defense in the battle for food safety Bring your HACCP and hygiene monitoring program to the next level with the MVP ICON®, the only system that lets you monitor multiple HACCP parameters using a single instrument.

Results for all parameters are automatically compiled and reported in a colourful, intuitive dashboard format allowing effective management of your quality assurance program.

KEY BENEFITS • Superior ATP swab design with best-in-class sample release • Room-temperature stable swabs are ready for immediate use • Flexible testing options that complement existing workflows • Perform instrument calibrations and verifications on site, anytime • Easily track failure rates, retest compliance and monitor overall program effectiveness

To find out more, visit SigmaAldrich.com/mvp-icon

For further information please contact: Tel: 08600 63725 labsupply@merckgroup.com www.merckmillipore.com

S A FE T Y, H YG I E N E & Q UA L I T Y C O N T R O L

When food is too good to waste BiobiN is an easy and efficient on-site waste management system, which processes food and organic waste into rich compost. Food Review looks at how this technology could impact waste streams at processing facilities, retailers and restaurants that handle fresh produce waste and offcuts.

DID

A

patented in-vessel composting

black bins is increasing rapidly,” Küsel

unit, the technology is designed

points out. “Composting with a BiobiN

with on-site waste management

is a cost-effective and long-term

in mind. “It is a great food waste

sustainable solution for managing food

management solution for facilities

waste and at the same time enriching

such as shopping centres, retailers,

our soils.” •

restaurants and fast-food outlets,” managing director Brian Küsel explains.

Food waste poses a big environmental issue at landfill sites. When it biodegrades in landfills, methane and

YOU KNOW?

Methane is a greenhouse gas that has 84 times more atmospheric warming potential than carbon dioxide2.

References https://www.fasa.co.za/tackling-south-africas-foodwaste-problem/ https://www.edf.org/climate/methane-otherimportant-greenhouse-gas

leachate are produced. Methane is a greenhouse gas that has 84 times more atmospheric warming potential than

BiobiN - www.biobin.co.za

carbon dioxide2. Leachate consists of water that seeps through the landfill layers and mixes with liquid waste from decomposing food waste; it is a contaminant that has the potential to

Turning organic wa ste into rich compos t

pollute nearby groundwater resources.

South Africa has introduced waste management regulations that place stricter requirements on the disposal of food waste to avoid burdening landfill sites. “These new waste regulations are starting to put owners of hotels, shopping centres, restaurants, and fast-food outlets under pressure and the cost of ‘dumping’ food waste in

FAST FACT: South Africa

generates a total of 10 million tonnes1 of food waste per year, with the majority ending up in landfills. The BiobiN model diverts food waste from landfills and gives it back to the soil.

An outside view of a BiobiN unit

BiobiN® is a clean and simple solution to managing organic and wet waste that would otherwise end up in landfill.

Find out more about this innovative way to deal with your company’s food waste, visit

www.biobin.co.za

38

Food Review | September 2020

Quick and precise testing at every production step Supelco® test strips, reflectometer & colorimeter for accurate food and beverage analysis We offer rapid, flexible and reliable analyses for accurate food and beverage testing. Find ideal methods to support your production process and analyses. Select the sensitivity you need from the diverse portfolio, which includes: MQuant® test strips are high-tech products – your laboratory on just a few square millimetres of backing, which can be used anywhere. Suitable for semi quantitative detection of ions, organic and inorganic substances.

• Pocket-size for quick and simple analyses • Broad field of applications for various checking -quality of frying oils, ensuring safety after disinfection or testing concentration content in food.

• Digital value readout and data storage is available with MQuant® StripScan app for selected test strips.

MQuant® Test Parameters visit: SigmaAldrich.com/mquant Reflectoquant® system is an economical transportable laboratory to perform critical analyses, for monitoring raw materials in all stages of the production processes in food & beverage manufacturing, hygiene control, industrial and rapid QC analysis. This Quantitative analysis system comprises of RQflex® 20 reflectometer, Test Strips & Kits for rapid, precise and reliable results directly on-site.

RQflex® 20 • • • •

Light and compact Display shows easy-to-follow pictograms AQA supported – RQcheck for total system monitoring Calibration for easy reset of baseline – reliable results

Test Strips • Barcode with batch specific calibration • Mobility with accuracy Reflectoquant® Test Parameters visit: SigmaAldrich.com/mobile-lab Application Notes offer step-by-step sample preparation guide to determine various parameters for agriculture, food & beverage or disinfection control processes. Over 100 applications for finding the ideal method to support your production.

• Rapid quantitative detection of hydroxymethylfurfural (HMF) in honey • Vitamin C (ascorbic acid) – for over 15 sample materials • Monitor acrylamide formation in fried or baked goods For further information please contact: Tel: 08600 63725 labsupply@merckgroup.com www.merckmillipore.com

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

Perfect control of process water quality The food processing industry is one of the largest in the world and the entire sector strives to make sure that fresh ingredients are converted to tasty finished products. Maryke Foulds asked Nikki Wilson to explain how ECA solutions can impact the quality of water used in the F&B industry.

W

hen done right, processing helps

the water unknowingly, but some, such as

food look and taste good while also

Legionella, are born in water.

allowing for consistent shelf life.

Harmful microbial intruders can make the

When done wrong, these aspects are affected

water extremely hazardous, especially when

in extremely negative ways. This is most likely

we look at its importance to food processing.

caused by poor-quality water, that may lead

Microorganisms can be introduced into the

to food spoilage and the possibility of product

system from the environment and could

returns and harm to the consumer.

be present in piping or from contaminated

Water is essential and used for a variety of

Water is used extensively in the food processing industry

equipment. Once in the water, they begin to

purposes in food processing. In many cases,

thrive. Manufacturers must ensure that the

water comes into direct contact with food

water used in food processing is of the best

and food contact surfaces. The quality of the

possible quality – with Radical Waters ECA

significant benefit is that the consumption of

water used must be of the highest standard;

(electrochemical activation) this is a guarantee.

harmful and undesirable chemical reagents is

otherwise, there is a risk of food contamination and the spawning of disease.

When treated using outdated and ineffective

Radical Waters’ electrochemically-activated (ECA) water generators produce two solutions

markedly reduced or can be avoided altogether.

Radical Waters is a global leader in

by running an electrical current through a

electrochemically-activated (ECA) water

methods, the condition of the water is greatly

weak brine mixture. The first is a detergent

technology and has spent more than 24

reduced. In these cases of negligence, bacteria

known as catholyte. This is a weak sodium

years developing and commercialising this

and viruses will develop in poor-quality water.

hydroxide solution with a pH greater than 11.4

patented technology. Dozens of patents have

Such pathogens are often transferred into

and a concentration of between approximately

been granted to Radical Waters, meaning

400PPM to 1 000PPM, which can be used to

industries such as meat processing, beverage

clean. The second solution is a potent natural

manufacture, CIP processes, treatment of

disinfectant called anolyte, used to disinfect/

raw grains and starches, dentistry, sterilising

sanitise with. Anolyte is a hypochlorous acid

of medical and healthcare equipment and

solution with a neutral pH of around 6.7 and

microbial resistance management all fall within

between 170PPM to 500PPM of free available

their ever-expanding portfolio.

“The quality of the water used must be of the highest standard; otherwise, there is a risk of food contamination and the spawning of disease”

chlorine depending on the ECA generator’s

Radical Waters has installed and maintains

configuration. The two solutions are also

ECA technology in 27 countries over six

compatible, so rinsing between applications is

continents, primarily for blue-chip companies,

no longer needed.

with some very high-profile clients like Coca-

Radical Waters’ ECA solutions are 100% natural and safe to use with foodstuffs. ECA is

Cola, Danone Water China, Suntory, aQuellé and Valpré along with several others. •

such an efficient cleaning and sanitising agent that it has started to replace the widespread use of chemicals in many factories. Another

food & beverage ECA hygiene technology

Radical Waters – www.radicalwaters.co.za

* of tested organisms

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

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

40

Food Review | September 2020

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

The age of CO2-neutral bottling plants has arrived

T

he aim is to build an entirely CO2 -neutral factory but also reduce water consumption to

a minimum, treating and re-using as

Following years of contract bottling, Dutch-based smoothie and juice producer innocent has decided to build its own bottling plant. Krones won the order for four complete PET bottling lines and the corresponding Food Manufacturing Africa, 132 mm, CC-en46-AZ416 11/19 ITx 200 landscape.

CO2-neutral bottling plant is equipped with four Krones PET bottling lines

much of it as possible. Each of the four identical PET lines handles up to 32 000 containers an hour. The new plant has been tasked with filling about 400 million bottles of chilled drinks a year.

“The company invested approximately $250m in this project,” explains Sam Woollett, engineering and facilities lead.

The Contipure AseptBloc DA blow-moulder/filler block consists of a Contiform 3 Pro stretch blowmoulding machine and a Modulfill Asept aseptic filler. The Contipure D preform sterilisation module is a very sustainable version. This ensures a reduced total cost of ownership, thanks to lower consumption of hydrogen peroxide, steam and energy, plus shorter preparation times. All containers, after being filled, are fitted with a tamperevident seal and – depending on the format involved – dressed in a wraparound or pressure-sensitive label. The modular Topmodul labeller is blocksynchronised directly with the Variopac Pro FS packer.

As the group’s digitalisation specialist, the Krones subsidiary Syskron has developed a turnkey MES concept for innocent that through appropriate interfaces also integrates the ERP system, the process control and warehouse management systems in the new plant. This concept includes various solutions from the SitePilot IT family brand, not least the Planning production planning system, the Line Management

Vision. Feasibility.

Cost-Efficiency.

We embrace a holistic approach to your beverage factory.

order and administration system, plus Line Diagnostics for production data acquisition and analysis. From the category of Share2Act services, innocent will in future be using Connect: this enables all information, such as shift

www.krones.com

schedules, to be made available to all staff in digital form. •

Krones – www.krones.com CC-en46_AZ416_11-19.indd 1

11.11.2019 11:11:43

September 2020 | Food Review

41

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

Optimal water use can support food security Wastewater re-use presents a sustainable solution to support food security amid looming water shortages, but the cost of the necessary infrastructure means it is not being widely adopted in South Africa.

M

anufacturing plants, particularly local branches of international food and beverage producers,

are increasingly investing in treatment facilities, enabling them to re-use their own wastewater and achieve zero liquid discharge status.

This is according to Hennie Pretorius, industry manager water and wastewater at Endress+Hauser South Africa, who will participate in IFAT Africa next year.

Endress+Hauser, recently named by Frost & Sullivan as 2020 Global Company of the Year in the global liquid analyser market, is seeing growing adoption of wastewater treatment and analysis solutions in the South African private sector.

This contributes to food security by eliminating megalitres of waste in food processing, Pretorius says. However, the re-use of treated wastewater in agriculture has some way to go. “In South Africa, treated wastewater is not being used directly for agriculture at scale,” he notes. “The reasons for this include the costs of infrastructure to pipe treated wastewater to remote farms, and the fact that many of the country’s wastewater treatment plants are not operating optimally. Inadequately treated wastewater used for agriculture could pose a risk to crops, farmworkers and groundwater.”

With megalitres of water wasted daily, more efficient wastewater use will become

“Wastewater re-use presents a sustainable solution to support food security amid looming water shortages, but the cost of the necessary infrastructure means it is not being widely adopted in South Africa”

gap between water supply and demand –

not sustainable. The Minister of Human

expected to top 17% by 2030.

Settlements, Water and Sanitation, Lindiwe Sisulu, and her team appears

water demand is met from surface

to have the political will to change the

water resources, but this approach is

water environment, but we will have to move faster towards more sustainable approaches to water and wastewater use,”

FAST FACT: Endress+Hauser

has been recognised with Frost & Sullivan’s 2020 Global Liquid Analyser Company of the Year Award.

The group impressed the jury with its robust product line, customeroriented approach and industryleading knowledge of liquid analysis.

The global award recognises a high degree of innovation with products and technologies and the resulting leadership in terms of customer value and market penetration.

he points out.

ADDRESSING FOOD WASTE TO REDUCE WATER DEMAND IN MANUFACTURING Prof Linda Godfrey, Manager: Waste RDI Roadmap Implementation Unit, DSI and Principal Scientist: Waste and Circular Economy at the CSIR, notes that better utilisation of resources in production and manufacturing would go a long way to addressing food security in a sustainable way.

42

Food Review | September 2020

and energy needed to produce food,” she says. With around a third of edible food produced either lost or wasted each year, a great deal of work is now being done to address the issue, in support of the Sustainable Development Goals: the Department of Environment, Forestry and Fisheries, in partnership with the CSIR, have developed consumer food waste prevention and management guidelines

increasingly important in closing the

“Currently, most of the country’s

“Addressing the food waste problem would impact on resources such as water

aimed at preventing avoidable food waste, and minimising and properly managing unavoidable food waste in South Africa.

The Consumer Goods Council of South Africa is collaborating with the EU and the South African government to establish a food loss and waste voluntary agreement, Prof Godfrey says. The agreement on reducing food waste and loss is expected to be signed later this year at the annual CGCSA summit, and is intended to mark the beginning of initiatives to ensure that surplus food which is still safe for human consumption can be donated to needy families in South Africa, where an estimated 13 million people go to bed hungry every night. •

Endress+Hauser – www.endress.com

C A R T O N & B OA R D

Growing demand for sustainable carton packs Retailers and brand owners are driving greater demand for renewable, recyclable and more sustainable carton packaging than before, writes Stefan Fageräng.

T

hese businesses want to assist

Tetra Pak is on a mission to increase

in lowering the impact on the

the renewable content of its products

climate while reducing their

and role players at the company are

carbon footprint. Consequently, they

looking at some of the elements of the

are looking at alternatives to fossil fuel-

packs, such as the polyethylene layers

based packaging. One such example is

and the closures, which are increasingly

carton packaging that is manufactured

being derived from renewable sources.

mainly from paperboard – sustainably-

That grows the renewable content of the

sourced from renewable forests that

carton packs and reduces the carbon

are certified by the Forest Stewardship

impact on the environment.

Council (FSC).

The approach takes into

ABOUT TETRA PAK

The corporation works closely with customers and suppliers to develop safe, innovative and environmentallysound products that meet the requirements of hundreds of millions of people in more than 160 countries.

With more than 25 000 employees globally, it believes in responsible industry leadership and a sustainable approach to business.

consideration the entire lifecycle of the carton packs and the full climate impact Tetra Prisma Aseptic is made mainly from paper, a renewable source, and is available with FSC (Forest Stewardship Council) certified packaging material, ensuring that the wood fibre is sourced from responsibly managed forests and other controlled sources

of the liquid paperboard packaging. An

recovered from used liquid cartons is

important part of that is post-consumer

carton packaging reel cores. Tetra Pak

waste and it’s great that it is recycled

uses these reel cores at the converting

right here in South Africa.

factory in Pinetown. Cartons are

Gayatri Paper Mills and

manufactured as flat packs and

Mpact Recycling, for example,

wound around reel cores, which

are paper mills that collect and

are an important component

process used liquid carton to

in maintaining the health and

make packaging from recycled

safety integrity of the packs

materials, such as container-

throughout the supply chain.

board and carton-board. These two organisations specifically benefit from the good quality

The latest development Stefan Fageräng

fibre they can extract from the

with regards to the polyethylene and aluminium recycling is the manufacturing

post-consumer carton packs for use in their

of a rigid plastic pallet. The pallet is a

paper products manufacturing process.

key component of the logistics value

Liquid cartons are a valuable source

chain and Tetra Pak is exploring how to

of raw materials for paper mills. This

make use of this pallet to distribute new

is because liquid cartons are made

packages to customers’ sites.

with high-quality virgin fibre. At the

The value of the liquid cartons

mills, paper is extracted for use in

extends down through the chain

manufacturing secondary packaging

to support a nationwide kerbside

products and the other components

collection programme that feeds

of the carton, such as polyethylene

through to the two mills for recycling.

and aluminium, are recovered for

Carton packaging helps retailers and

onward recycling. Polyethylene and

brand owners meet their sustainability

aluminium are combined and used in

objectives and affords them a credible

manufacturing rigid plastic products.

means to engage consumers on the

One of the latest products that

issues that resonate with them. •

is made from recycled paperboard

“The value of liquid cartons extends down through the chain to support a nationwide kerbside collection programme that feeds through to the two mills for recycling”

44

Food Review | September 2020

ABOUT THE AUTHOR STEFAN FAGERÄNG is managing director of Tetra Pak Southern Africa.

Tetra Pak – www.tetrapak.co.za

C A R T O N & B OA R D

Ambitious plans underpin growing demand for adhesives

H.B. Fuller has announced the opening of its new business office in Johannesburg. Food Review looks at how this expansion, which includes a network spanning three warehouses across the country, will support its ambitious growth plans in the sub-Saharan region.

Head office in Johannesburg

“The ability to learn quickly and leverage digital technologies to meet with customers, develop creative solutions at distance, and attend to shifting priorities has been a game changer for the company”

the shipment and storage processes.

It should be easy to handle, safe to transport, and resistant to injuries and punctures.

• Agricultural packaging needs to be different from traditional carton closing applications because of the higher humidity conditions, heavier package contents and coated stocks to help fight moisture. H.B. Fuller’s adhesives for food packaging delivered reliable bond

T

he global adhesive manufacturer

their reparability and reuse, as well as

is committed to strengthening its

creating the opportunity to minimise waste

relationship and product scope

and recycle materials through end-user

with an impressive portfolio of the latest

responsibility initiatives.

adhesive technology for high-impact sustainable packaging.

South Africa business manager Ronald

HIGH-PERFORMANCE SUSTAINABLE ADHESIVES

Prinsloo explains, “We can offer customers

By promoting resource-efficient design,

local adhesive expertise and a globally

production and consumption, H.B. Fuller

connected team with deep industry

technologies are playing a key role in helping

knowledge spanning 28 market sectors. We

food and beverage packaging manufacturers

approach customers with the same quality

meet their sustainability goals.

and expertise, no matter the market they

Global associations, consumer demand,

operate in. We are committed to following

and regulatory changes are significantly

common values by developing customised

impacting industry trends and have set

products and leveraging our substantial

the need for change. H.B. Fuller’s new

research and development capability.”

Sustainable Packaging Solutions section of its website, along with new product

SUPPORTING THE CIRCULAR ECONOMY

upgrades, will enable customers to deliver

Adhesives and sealants make everyday

food, beverage and consumer goods.

products possible, playing an essential

Examples:

role in thousands of items. In many

Innovative packaging solutions for the

cases, they also empower manufacturers

South African agriculture market:

to produce more cost-effectively and

• Agricultural packaging has taken on

sustainable packaging for their range of

responsibly, allowing them to work with

a new level of importance due to

more sustainable substrates, improve

increased food waste. Everyone in the

efficiencies, and reduce materials usage,

food industry, from farmers to retailers,

energy consumption, and greenhouse gas

rely heavily on the packaging to deliver

(GHG) emissions.

fresh products to consumers while

These products are true enablers of the

minimising food waste. The packaging

benefits of the circular economy, including

is an important medium to conserve

extending the durability of products and

the quality and reduce loss during

strength to a wide range of packaging materials, even in the hot and sunny South African climate. The range of adhesives enables food to stay fresh longer, thereby reducing food waste.

Additionally, our food-safe packaging adhesives are externally approved for direct food contact.

As packaging manufacturers search for more sustainable case and carton closing options, H.B. Fuller has introduced low application temperature hot melts: • By maintaining hot melt tanks at a lower temperature, manufacturers will use less energy than with traditional hot melt technology. Depending on the energy source, these energy savings can translate directly into carbon dioxide savings.

• The patented low application hot melt adhesives are versatile and work with a wide range of substrates. To help customers improve efficiency on their lines, the company’s adhesive technology is designed to close more cases and cartons with less adhesive.

Food waste reduction is a value of flexible packaging: • H.B. Fuller’s global line of Flexa adhesives safely protects food as it moves throughout the supply chain.

This product range includes both solvent-based and solvent-free products for medium- and highperformance applications.

September 2020 | Food Review

45

C A R T O N & B OA R D

Sustainable Packaging Solutions

Sustainable Packaging Solutions RENEW Developing bio-based adhesive solutions

Aligned with UN goals for sustainable growth

RENEW Developing b adhesive solu

Aligned with UN goals for sustainable growth

Enabling Packaging Sustainability

Committed to reduce water, energy, waste and GHG

Committed to reduce water, energy, waste and GHG REDUCE Reduce energy use, packaging materials and food waste

REDESIGN Circular-ready packaging design solutions

Enabling Packaging RECYCLE Enable recycling of primary Sustainability packaging materials

Advanced portfolio of adhesives for manufacturing paper straws is expanding as the market and consumer needs grow and develop:

Detect . Reject . Protect

CEIA metal detectors by Heat and Control

REDUCE Reduce energy • Consumers are aware of use, the packaging impact of convenience packaging materials and on the environment andfood arewaste demanding low-impact alternative options to conventional plastic packaging. One area of focus is replacing plastic drinking straws with paper straws.

• Scientifically-designed Swifttak adhesives deliver food-safe solutions that maintain straw integrity while the consumer is enjoying a beverage.

SOUTH AFRICAN EXPANSION Prinsloo and his highly-skilled team will draw on H.B. Fuller’s global network capabilities and technical centres, especially in Europe, India, the Middle East, and Africa by supporting sales in local currency. It also offers ex-stock deliveries.

The new commercial organisation aims to grow H.B. Fuller’s share of the substantial local market for adhesives, leveraging significant combined experience to increase the company’s share of a potential €100m per year market1.

“Our in-depth understanding of specific customer needs and local market requirements, together with H.B. Fuller’s high-quality solutions, technologies, and research capabilities, means we’re ideally placed to meet the increasing demand for

Improve inspection results with the world’s only multi-spectrum metal detector.

CEIA’s unique technology achieves the highest sensitivity to small metal fragments by applying a broad spectrum of frequencies simultaneously and continuously - with no reduction in sensitivity.

CEIA metal detectors from Heat and Control assure precise, consistent detection and rejection of metal contaminants.

adhesives in South Africa,” Prinsloo explains.

“This fits with our overall strategy to build on our success around the globe and expand our business footprint in key market segments through strategic investments. We are now in a better position to offer outstanding local knowledge of customers’ production processes in the hygiene, graphic arts, paper converting, end-of-line and flexible packaging, and labelling markets, among others, and help customers find a competitive advantage through their adhesive applications.”

With safety as its top priority, H.B. Fuller wants to be first and fastest at serving customers. The aim is to provide quick technical expertise on-site combined with the latest adhesive technologies across the African continent. During the pandemic, the local team embraced a completely new way of working – either on-site or at home. The ability to learn quickly and leverage digital technologies to meet with customers, develop creative solutions at distance, and attend to shifting priorities has been a game changer for the company.

With this new commercial expansion in South Africa, H.B. Fuller enhances its capacity to respond to the rising demand

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

from customers in what is considered one of the largest and fastest-growing markets on the continent. •

H.B. Fuller - www.hbfuller.com

46

SAFoodReview_Sept2020_88.5w x 262h_CEIA.indd 1

Food Review | September 2020

5/08/2020 9:25:46 AM

RECYCLE Enable recyc packaging m

I N T E L L I G E N T PAC K AG I N G

Pick and place without a hitch Manufacturing processes used to consist of a line of workers solely responsible for an operation’s material-handling functions. Whether assembly, picking or packaging, it was a manual, laborious process.

T

he detrimental effect on worker

While the usual suspects, such as the

biggest benefits of pick-and-place robots as

health has been well-documented:

automotive and pharmaceutical industries, are

they do the work that would prove too much for

many employees were subjected to

already deeply invested in the use of industrial

human workers.

conditions that resulted in serious illness,

robots, the South African food manufacturing

injury, and death.

sector has also embraced this technology.

As automation became widely

“Speaking specifically about the KwaZulu-

In the first industrial revolution, workers’ health and safety were at risk when they lifted heavy items and handled hazardous materials

accepted and implemented

Natal region, we’ve seen an increase in

and liquids. Fortunately, advancements made in

throughout various

the implementation of pick-and-place

technology ensure safer working environments

industries, robotics took it one step further with robots designed for specific applications, such as handling, packaging and palletising. These new pick-and-place robots allowed for

DID YOU KNOW?

Yaskawa was founded in 1915 and is one of the largest manufacturers of industrial robots, with over 400 000 robots installed worldwide. Since 1991, Yaskawa Southern Africa has installed more than 2 500 Yaskawa Motoman robots in the automotive, manufacturing and packaging industries in South Africa.

robots in food manufacturing,

where the robots are responsible for these

especially in the big

demanding and repetitive tasks. Whether it be

bakeries,” says Yaskawa

handling litres of burning-hot cooking oil or

Southern Africa’s Durban branch manager, Rudi

moving around thousands of glass milk bottles.

“Palletising in the beverages industry is

von Fintel. “The bakeries

another area where we’ve seen a massive

produce over 8 000 loaves

uptake,” Von Fintel explains. “Due to the different sizes of bottles, cans or cartons, it is important to have robots that are easily adaptable to the products coming down the line. Since the volumes are so high, the

more speed and consistency

robots are instrumental at the end of the

in throughput, while also

production line.”

customisable to meet

Another notable example in the beverage

production requirements.

industry is Bavaria Brewery, which now manages to palletise 100 000 beer cans per hour after the business decided to revolutionise its picking, packing and palletising processes.

More impressively, it boasts a high process

Some bakeries produce over 8 000 loaves of bread an hour, 24 hours a day, so speed and consistency are vital

reliability with maximum fail-safety. It is results like these that you simply cannot ignore, especially if you’re looking for more efficiencies in your processes.

While many businesses might be concerned about robots taking up additional floor space or being too bulky to operate, the opposite is true.

Pick-and-place robots are capable of operating in the tightest spaces with minimal hassle. The end-of-arm tooling is simple enough to swap out, while fewer components means easier Palletising in the beverages industry is massive for pick-andplace robots

“As we move into a world where production needs to happen without ‘human touch’ or intervention, pickand-place robots could be the solution to many industry concerns”

of bread an hour, 24 hours a day, so speed and consistency are vital to their operations. In terms of application, the robots are responsible for taking the bread out of hot ovens and placing them onto the conveyor belts.”

Considering the sheer amount of loaves in production, as well as how hot the loaves are,

access for maintenance. Since robots support a wide variety of communication protocols as well as digital signals, they are easily integrated into existing automation or production lines.

As we move into a world where production needs to happen without “human touch” or intervention, pick-and-place robots could be the solution to many industry concerns. At the same time, they could also prove to be the productivity boost that every business so desperately needs. •

it is a task that would be difficult to do without the assistance of robots. It’s almost physically impossible. Undoubtedly, this reveals one of the

Yaskawa – www.yaskawa.com

September 2020 | Food Review

47

I N T E L L I G E N T PAC K AG I N G

Mono material polypropylene lidding films launched Global flexible packaging and lidding films supplier KM Packaging has launched a new range of mono-polymer material lidding films, made from polypropylene (PP), that is designed for recyclability.

T

he sustainable films seal and peel

would be a really difficult thing

to PP and PE-lined PP trays and can

to segregate and put into a

be used during microwave cooking

recycling stream.”

as well as being suitable for ambient, chilled, or frozen applications.

Part of KM’s K Peel range, it allows food manufacturers to meet the growing demand, particularly from supermarkets,

It is anticipated that the globally extended packaging producer responsibility regulations, will penalise packaging like this that is difficult to recycle.

The new PP lidding film is also designed

for mono-material packaging that is

for recycling around the world, with some

designed for recycling.

countries having well-developed recycling

The lidding films are ideal for the

infrastructures for polyolefin (polyethene

packaging of poultry, meat, and chilled

and polypropylene) plastics.

prepared foods. Features include:

In the UK, front-of-store recycling facilities

• Mono structure made of one

allow consumers to return polyolefin-based

material type.

flexible packaging. A similar approach

• Designed for recyclability.

is taken in other markets. For example,

• Ideal for use during food preparation

Australia’s REDcycle initiative and, in South

and microwave cooking.

• Peelable from the tray.

• Suitable for ambient, chilled, or

Africa, polyolefins are the largest plastic commodity recycled by weight.

Therefore, putting a tray/film

• Protecting products throughout the entire process, from the factory to table.

• Presenting food in a way that is attractive, professional, and recognisable.

• Preserving food and extending shelf-life across the food industry.

frozen applications.

combination of polypropylene onto

Graham says, “The main goal of our

• Exceptional transparency.

the market feeds into an already well-

packaging is to look after and protect

• Excellent anti-fog capability.

established recycling system.

food. We don't compromise on that. We're

• Available with or without barrier.

And the new Designing for Circular

also trying to make sure it’s designed for

As well as satisfying the needs of

Economy guidelines from CEFLEX focus on

recyclability and, when appropriate, it's

supermarkets and consumers who are

polyolefin-based flexible packaging. This is

thinner and lighter. These are big drivers

seeking more recycle-ready solutions,

due to the material making up an estimated

in our product-development process.”

KM is helping to future-proof its

70 to 80% of the flexible packaging waste

food packaging.

stream and because the ability to sort and

products follow KM’s recent launch of all-

mechanically recycle it is already proven at

polyester (PET), weld-seal, mono-material

an industrial scale in Europe.

lidding films within its K Seal range. •

KM Packaging’s commercial director Graham Holding explains, “If you have a piece of flexible packaging that, for

KM Packaging’s main purpose is to

example, is a combination of paper,

“protect, present, preserve”. That is

plastic, and aluminium foil, then that

delivering the best packaging solutions by:

48

Food Review | September 2020

The new polypropylene lidding film

KM Packaging - www.kmpackaging.com

I N T E L L I G E N T PAC K AG I N G

Electronic position indicator for absolute spindle adjustments Instrotech is offering the Siko AP20 position indicator, ideally equipped to detect the position of spindle adjustments in machines. It displays the corresponding positional data to the operator and passes it on to the machine control system.

S

imple system integration in

that protects the cable mean that star-

maximum efficiency in application and

combination with modern

shaped wiring to the control system is

job set-up.

interfaces is all that is required.

no longer essential.

This ensures the shortest possible

The performance features of the AP20 combine the functionality of a high-

INDUSTRY 4.0 AND SMART FACTORY READY

precision multi-turn absolute value

provide loss-free data communication between the position indicator and the

The AP20 must achieve a certain level of

still in an extremely compact form with

machine control system.

connectivity to satisfy the requirements

dimensions of 48 x 88 x 61mm. It can

of Industry 4.0. For the smart factory of

be installed in the machine in an area

suitable for flexible manufacturing

the future, pure exchange of operational

roughly the size of a credit card.

with production machines such as

process data is no longer adequate.

downtimes, on the other the interfaces

The compact system is particularly

encoder with a position indicator, but

and machines for further processing of

extend evaluation of the device

EXTREME CONVENIENCE AND INTUITIVE USABILITY

printed products.

packing machines, printing machines

Comprehensive diagnostic options status in this connection and convert

The AP20 also has numerous advantages

Wherever manual adjustment is

position indicators such as the AP20

from the perspective of the operator.

carried out on production machines,

into intelligent automation systems.

The option of displaying the target

bus-compatible Siko position

The latest network technologies and

and actual position directly on the

indicators are able to optimise the

the electronic type plate take care of

adjusting spindle significantly increases

production process in such a way that

this. The latter serves to identify the

convenience and usability for the

costly refitting times during product

device type, serial number and current

machine operator. The inverted backlit

changeovers are kept to a minimum.

software version. Additional integration

display plays a part in this, as it makes

Once installed, position indicators

aids, function modules, libraries and

the information displayed easy to read

provide 100% process reliability. During

add-on instructions make installation

even under the most unfavourable

product and size changeovers, incorrect

and commissioning easier and provide

lighting conditions. Two-coloured status

machine settings and the associated risk of damage to tools or batches with defects can be eliminated consistently with the AP20.

In addition to the SikoNET5 and

Siko AP 20 position indicator

LEDs also aid intuitive user guidance.

In addition to the positioner status (InPos or OutPos), the LEDs indicate the direction of rotation required to reach the intended target position. Product

CAN interfaces already on offer,

and size changeovers can therefore be

Siko is now extending its AP series

carried out very quickly and without

position indicators to include the most

much work.

common industrial Ethernet-Fieldbus

All Siko position indicators feature

interfaces, namely Profinet, Ethernet/IP,

a hollow shaft, which facilitates the

EtherCAT and Powerlink., thus meeting

easiest assembly possible. The basic

requirements for easy integration into

configuration of the AP20 comes with a

almost any current control system from

hollow shaft with a diameter of 20mm.

a wide range of manufacturers without

Hollow shaft diameters up to 25.4mm

any other accessories.

are also possible without changing the

Compared to a converter solution, the variety of components is reduced, as is

compact dimensions of the product.

The hollow shaft of the AP20 is

the space required in the machine. This

made of stainless steel. In conjunction

significant gain in flexibility ensures

with the protection rating of IP65, the

loss-free communication between the

position indicator is also suitable for

machine control system and position

applications in the food industry, and

indicator at all times, in particular for

beverage manufacturing sector. â&#x20AC;˘

systems that run a complex production process and for which, as a result, a large number of sensors or long cable lengths are required. Two M12-D coded bus connections for a bus line design

Instrotech â&#x20AC;&#x201C; www.instrotech.co.za

September 2020 | Food Review

49

To advertise in WWW.FOODREVIEW.CO.ZA

Coffee time

Anita Raath

Sales executive +27 (0)82 976 6541

Carla Melless

Sales executive +27 (0)83 260 6060

Càndida GiambÒ-Kruger

Fast facts

Sales executive +27 (0)71 438 1918

1. Octopuses are widely considered to be the most intelligent of all invertebrates.

2. Octopuses have three hearts and blue blood.

3. They aren’t called “tentacles,” they’re called ‘’arms.”

4. Each arm has a mind of its own.

5. If Houdini were an animal, it’s safe to say he would have been an octopus.

6. Octopuses are considered erotic in Japanese culture.

7. Their camouflage abilities are out of this world.

8. They can “see” with their skin.

9. Rather than swimming, octopuses often walk along the seafloor.

Source: HuffPost

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CALL US NOW FOR A QUOTATION

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

ADVERTISERS’ INDEX SEPTEMBER 2020 Aspirata.................................................33......www.nosa.co.za BiobiN....................................................38......www.biobin.co.za Bühler....................................................21......www.buhlergroup.com Endress & Hauser.................................5......www.endress.com Frutarom SA ..............................OFC, 15......www.iff.com / www.tastepoint.com Heat & Control SA ........................27, 46......www.heatandcontrol.com Ishida.....................................................19......www.ishidaeurope.com ISW Shrink............................................48......www.iswshrink.co.za KHS Manufacturing SA ....................43......www.khs.com/water Krones Southern Africa......................41......www.krones.com

50

Food Review | September 2020

Merck ..............................................37, 39......www.merckmillipore.com Polyoak Packaging..............................13......www.polyoakpackaging.co.za Radical Waters SA...............................40......www.radicalwaters.com Savannah Fine Chemicals.................31......www.savannah.co.za Symrise SA........................................ IFC......www.symrise.com Syspro ...................................................12......www.za.syspro.com Tetra Pak.......................................... OBC......www.gonature.tetrapak.com Verder Pumps SA................................35......www.verder.co.za Vivit Foods..................................... 23, 29......www.vivit.co.za Zeelandia SA .......................................22......www.zeelandia.co.za

WEB REVIEW HOME

NEWS

ABOUT

C O N TA C T

BUTCHER MEAT PROCESSING EQUIPMENT

MATRIX SOFTWARE

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

BUTCHER MEAT

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

PROCESSING EQUIPMENT Tel: +27 11 664 8212

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

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

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

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

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

FORMPAK

Tel: +27 (0) 11 828 8870/1/2 Fax: +27 (0) 11 828 8880 email: haase@formpak.com or service@formpak.com www.formpak.com

DINNERMATES

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

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

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

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

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

QUANTUM COLOURS SA

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

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

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

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

What if

food packaging were carbon-neutral?

Go nature.

Go carton.

Food packaging plays a critical role in getting food safely to consumers around the world. But it can also cause problems for the planet. What if all food packaging came from plant-based materials and didn’t impact the climate? At Tetra Pak, we already have paper-based carton packages with reduced climate impact. But we won’t stop there. Our aim is to create cartons made solely from plant-based materials that are fully renewable, fully recyclable and carbon-neutral. It’s all part of our journey to deliver the world’s most sustainable food package.

Learn more at gonature.tetrapak.com