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From the Editor
World Welcomes
Costa
In the News
Successful Strategies
CPG Start-Ups
& Processing Hall of Fame Welcomes Four New
Packaging Technology
Ushers Bumble Bee
of Plastic Shrink
Multipack to
Plant Floor
Case Study:
Case Study:
Equipment Helps
for
Case Study: Frito-Lay
Workplace
Wearable
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Record prices for ingredients and materials transformed the food and beverage manufacturing industry in 2022, and significantly altered consumer buying behaviors for retail goods.
OpX Intel: Supply Chain
Strengthen your supply chain through integrated business planning,
engineering and asset optimization, digital insights, and
OEM relationships.
Tech Today: Pumps and Valves Evolve to Meet Changing Needs
The latest designs ease concerns about labor availability, food safety, and
making the ubiquitous equipment easier to use and easier to clean.
PACK EXPO International Returns to Chicago
The largest packaging and processing event in North America is back inperson for
time since
Products
EDITORIAL
EDITOR-IN-CHIEF AARON HAND 312/488-3392 ahand@pmmimediagroup.com
SENIOR EDITOR MICHAEL COSTA mcosta@pmmimediagroup.com
NEW PRODUCTS EDITOR MORGAN SMITH msmith@pmmimediagroup.com
SENIOR DIRECTOR, CONTENT & BRAND GROWTH MIKE PROKOPEAK
CONTRIBUTING EDITORS
MELISSA GRIFFEN, HANK HOGAN, JEANNE SCHWEDER, STEPHEN PERRY, STEPHEN SCHLEGEL, JEFFREY BARACH
BUSINESS STAFF
PUBLISHER PATRICK YOUNG 610/251-2579 pyoung@pmmimediagroup.com
BRAND OPERATIONS MANAGER CLAUDIA SMITH 312/222-1345 csmith@pmmimediagroup.com
ART
CREATIVE DIRECTOR DAVID BACHO ART DIRECTOR KATHY TRAVIS
AUDIENCE AND TECHNOLOGY
Anna is the proud owner of a thriving plant-based food company. To meet retailer demands, she needed traceability codes on flexible packaging but was unsure where to start. As demand for her product grew, Anna knew she needed the expertise to hit the ground running.
Anna discovered Domino’s effective lasers for flexible packaging, and now she relies on our understanding and experience. She also values working with a partner who understands how to support her sustainability goals. Anna came for the lasers to reduce the risk of coding errors while driving sustainability and left with peace of mind.
Now Anna—with help from Domino—can achieve so much more.
how Anna gained confidence with Domino.
showcase/profoodworld
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Costa joins the team as Senior Editor with a wide range of experience covering the food and beverage industry.
If you haven’t noticed already over the past couple months on ProFoodWorld.com, you’ll certainly notice in our Octo ber print pages a new name peeking from our bylines. Or perhaps the name isn’t new to you at all—maybe you’ve already seen him on the pages of a competing publication.
I’m very happy to welcome Michael Costa to the ProFood World editorial team. He comes to us most immediately from Food Engineering, where he served as editor-in-chief. Before that, he was editor-in-chief of Refrigerated & Frozen Foods magazine. He also spent 12 years at Hotel F&B magazine. This understanding of the consumer-facing side of the business as well as the manufacturing space shines through in Michael’s coverage in this year’s Global 250 report. Check out “The Deep Disruption of Inflation” beginning on page 24 to learn more about how the food and beverage industry has fared amid record prices for ingredients and materials.
Michael and I first met last fall on a trip to Poland with other U.S. and Canadian journalists to learn more about the quality of European meat. As our hosts juxtaposed slaugh terhouse visits with steakhouse dining, it was clear to me that Michael knew his way around culinary discussions as well. In fact, back in the day, he studied culinary arts at the Illinois Institute of Art in Chicago.
Also read some of the reporting from this year’s Cannabis Drinks Expo, where Michael landed on Day 2 of his job at ProFood World. Leading our News section on page 9 are tips from Cann, an early cannabis beverage company, for other CPG start-ups. Look for his video coverage of the show as well at www.profoodworld.com.
This month, we’re throwing Michael in the deep end at PACK EXPO International, where he will join me and the rest of the PMMI Media Group editorial team to report on the lat est innovations in packaging and processing. You’re most likely to find Michael and me in The Processing Zone in the Lakeside Center at McCormick Place. If you see us, say hello!
EDITORIAL ADVISORY BOARD
CHRISTINE BENSE
CHIEF SUPPLY CHAIN OFFICER Turkey Hill
GREG FLICKINGER
CHIEF OPERATING OFFICER Nobell Foods
JOHN HILKER
FORMER DIRECTOR OF MANUFACTURING Blommer Chocolate Company
VINCE NASTI VP, OPERATIONS Nation Pizza & Foods
JIM PRUNESTI VP, ENGINEERING Conagra Brands
LISA RATHBURN VP, ENGINEERING T. Marzetti
MARK SHAYE VP, ENGINEERING Ken’s Foods
TONY VANDENOEVER
FORMER DIRECTOR, SUPPLY CHAIN ENGINEERING PepsiCo
DIANE WOLF
FORMER VP OF ENGINEERING AND OPERATIONS Kraft Foods
BROOKE WYNN
SENIOR DIRECTOR OF SUSTAINABILITY Smithfield Foods
JOE ZEMBAS
DIRECTOR, ENGINEERING AND TECHNICAL SERVICES
The J.M. Smucker Company
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Unlike Ribbon and Paddle Blenders with a single agitator shaft, MUNSON® Fluidized Bed Mixers feature two shafts with paddles that counter-rotate at higher speeds to uidize material, achieving homogeneous blends in 10 seconds to 2 minutes. Low shear forces minimize friction with little or no degradation and insigni cant heat generation of <0.6°F (1°C). Drop-bottom gates provide rapid discharge with no segregation and minimal residual. Ideal for short cycles and gentle handling of low- to medium-density powders and fragile akes 50 lbs/ ft3 ( 800 kg/m3) with or without liquid additions. Capacities from 0.21 to 283 cu ft (6 L to 8 m3).
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CANN WAS ONE of the very fi rst ready-to-drink (RTD) cannabis beverage companies, launching in 2018 in California, and has since produced 10 million cans of product with distribution in California, Nevada, Illinois, Massachusetts, Rhode Island, and Arizona, plus Ontario and British Columbia in Canada.
However, the years leading up to that 10 million can benchmark were not easy, according to COO Ishan Kapoor, and required a tenacious belief in the product to grow Cann from start-up to store shelves. At this year’s Cannabis Drinks Expo in Chicago, Kapoor detailed for attendees the company’s rise and consequential decisions that helped build the brand. His advice works just as well for any consumer packaged goods (CPG) startup—cannabis or otherwise—and here, we highlight some of Cann’s strategies that helped fuel its upward trajectory.
Cann launched with a clear vision of where its microdose (2 to 5 mg THC per can) product fit within the cannabis beverage market. The company could have had a less-defi ned approach, since it was among the fi rst companies in a relatively undefi ned category—Kapoor says there were only three other brands when Cann started. Instead, Cann asked several crucial questions from the outset that helped bring its brand into focus.
The Coca-Cola Company has announced John Murphy, current CFO, will become president and CFO, e ective Oct. 1, following the retirement of Brian Smith.
Diamond Pet Foods has broken ground on a 700,000-sq-ft manufacturing and distribution center in Rushville, Ind. To be operational by the end of 2024, it will produce cat and dog food.
The Bimbo Open Door food business accelerator will focus on finding, developing, and investing in bakery and snack start-ups and scale-ups chosen based on their sustainable practices and other factors.
Mondelēz International has completed its acquisition of Clif Bar, expanding the company’s global snack bar business to a value of more than $1 billion.
Kerry has opened a 108,000-sqft taste facility in South Africa to produce sustainable nutrition solutions. The facility features lowenergy equipment, solar power generation, waste heat capture, and e cient water use.
we put a cannabis beverage product in a can and make it shelf-stable? Can we build a brand in the cannabis category around a microdose prod uct when buyers are here for dollar-per-milligram sales?” Kapor explained to attendees. “Can we develop a product that has the onset of beverage alcohol and a competitor to beverage alcohol for when people don’t want a hangover, or when they want something to take to a barbecue? And can we create a brand that stands out not just in a dispen sary environment, but on a Whole Foods shelf?”
The “simplicity and bigness” of Cann’s business plan, as Kapoor describes it, made it easier to present in meetings with potential investors that could help get Cann o the ground. “As we’ve learned time and again, whether it’s on the fundraising side, the manufacturing side, or the sales relationship side, you have to keep knocking on doors and keep believing in what you are pitching and selling, and be consistent. And then you’re ultimately able to convert a no into a yes, and you can start the waterfall of value capture and bring funding into the business.”
Back in early 2019, Cann was just an idea. “It was a hand-formed can that we had to seam 20 times with a hand seamer to take to pitch meetings that didn’t even look like our product today,” Kapoor says. “But it was really an idea and belief in our selves and the vision of what we were trying to sell.”
Through what Kapoor calls “the power of hype and the necessity of hustle,” Cann secured an adequate amount of seed round funding to get started. “We needed it,” he says. “I came into this not understanding how many unexpected hurdles we would see, so bringing in money at the seed level allowed us the runway to experiment, to fail, and to jump over hurdles—it was really critical in getting this thing o the ground.”
Kapoor said “fighting for survival” was the next stage of growth for Cann. Even though the company had the seed money to start production, “I was like, ‘Oh man, we gotta figure out how to do it,’” Kapoor remembers.
“What fighting for survival was for me and my team in 2019 was figuring out how to make this product at scale. Our first 15,000 cans were done
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Cann’s RTD cannabis beverages come in more than a dozen flavors, plus limitededition seasonal options.
in kegs because we didn’t have resources and we didn’t have partnerships,” Kapoor said. “In early 2019, we selected a co-packer in California who promised us for months that their facility would be ready. We went out in April of 2019 to audit the facility and they didn’t even have power. This was very much the early years of cannabis, and thankfully we have more scrupulous operators now. But at the time, we had orders, we had the money to go fulfill these orders, and we had no idea how to get this product to market.”
Cann quickly pivoted to new partnerships that allowed it to set up a full production facility on an expedited timeline, with used equipment, mobile contractors, and Cann’s own beverage production standard operating procedures. Those at Cann also helped their new facility partner with employee training and drinks production skills.
“We networked with folks in the industry who had licenses and were willing to take a risk on us,” Kapoor said. “We iterated rapidly to make sure we can make this product, but never compromised the core tenets that we raised the initial funding on, which was this product has to compete on a Whole Foods shelf, it has to taste really good, the quality must be consistent, there can’t be any preservatives, and that we maintain our story around a microdose product.”
Cann eventually found a co-packing partner with a brand-new facility where Cann could consistently scale up manufacturing to meet demand. Cann also built a first-mile distribution company to avoid stock gaps. “We realized that we couldn’t get enough product into warehouses and inventory rooms fast enough because distribution in
this industry is set up to move pre-rolls, jars, and flower,” Kapoor explained.
A new company in a nascent category like cannabis beverages has “probably 90 to 180 days to capture a first-time consumer upon regulatory change,” Kapoor said. “Nevada and California were hard markets for us because we lost that window, so we had to put a lot of money behind getting that customer back into the channel. Whereas in states like Massachusetts and Illinois, we’ve been able to acquire that customer just through their own curiosity, and then retain that customer, so the new markets have been really powerful to us.”
Perhaps the biggest takeaway from Kapoor’s presentation is that quality partnerships are the true foundation of a successful business, and that settling for less is a recipe for failure. Like anything else in a start-up scenario, the amount of time and e ort invested in finding like-minded business partners pays dividends well into the future, but it can be a lot of work.
“I remember a time in March 2020. We were dis cussing a trip to Seattle, and we just started hearing about COVID. And we’re like, ‘Do we make the trip?
Is it worth the risk?’ And all three of us in the room decided that absolutely, we had to get out there. We had to meet partners face-to-face because we’d had enough partnerships already with folks who had disappeared,” Kapoor said. “We needed to make sure we were looking people in the eye and selling them on the vision of Cann.”
Cold storage construction is projected to reach $18.6 billion in value by 2027 — an increase of 13.8 percent per year, according to Emergen Research.1 And reports indicate that the total market for cold storage will reach $212 billion by 2025, yet capacity is only projected to grow by 1 percent per year through 2023.2
Some reasons for this cold storage deficit are2:
• Capacity has been strained by transportation back logs, inflation, and labor shortages exacerbated by the pandemic;
• Cold storage facilities are already near capacity, and more are needed because stores are responding to market demand by adding fresh products and services, in terms of both volume and variety;
• Frozen food continues to demonstrate strong demand around the world, which means existing capacity will not become available to handle new cold storage needs; and
• Many facilities are outdated; more than 78% of existing buildings were constructed before 2000 and don’t use advanced cooling technologies.
This aging infrastructure means demand for newer facilities is great, says Ken Morris, senior vice president, Brokerage, Morris Southeast Group, and a member of the Society of Industrial and Office Realtors.1 Food distributors and processors are then faced with the decision to lease, build a greenfield site, or renovate.
Lease – The availability of existing dry and cold storage capacity is extremely limited, which makes leasing existing space a challenge. Resulting in consideration for a build-to-suit or spec cold storage development (usually pre-leased quickly) with a developer. Leasing may offer less upfront costs and minimize concern for long-term maintenance of the building.
New Build – Designing and constructing a new facility is costly, as developers will require elevated rental rates to achieve a return on their investment. The alternative for a food company requiring cold storage is to finance the acquisition or development themselves via a synthetic lease structure that provides accounting, tax, and economic benefits including below-market rates (cost of the synthetic lease). A new site is an investment in advanced cold storage technologies. These may include computer-controlled refrigeration systems to reduce energy consumption, refrigerated docks that are longer (upwards of 75 feet) and colder, dock levelers that enable vertical storage and minimize air infiltration, and warehouse storage and retrieval automation to improve the efficiency, speed, reliability, and accuracy of moving products.
Renovate – The Food Institute reports that retrofits are playing a crucial role in meeting the need for cold storage.1 Renovating an existing facility in certain situations can be a viable option with many benefits. Once a project scope has been determined, a layout can be generated to review if there are changes needed to the facility’s footprint. The sites infrastructure and operational systems will need to be evaluated to accurately estimate the cost of the project.
Keep in mind, retrofitting existing dry warehouses may look great on paper. In reality, the design will likely be a box in a box with lower than desired ceiling heights. Additional and significant costs come in to reinforce the steel structure, utility systems, adding the refrigeration system, etc. and might only accommodate a limited percentage of a company’s refrigerated and frozen products. The biggest limitation is the availability of warehouses that have any meaningful available square footage to retrofit. The benefits are speed to availability and less cost compared to a new development.
Because the cold chain crisis is expected to continue, and possibly worsen over the next few years – driven in part from spiking demand and a significant supply shortage
– it is critical for a company to proactively assess its cold storage capacity needs now so that the capacity is available when needed. This is especially critical given the development timeline of 14 to 24-plus months. Stay informed about the cold storage capacity options in your market to make the right decision for your company.
1. Fresh, Cold Food Is A Hot Commodity, Increasing the Need for Cold Storage Facilities That Make Supply Chains Possible, Morris Southeast Group, Sept. 22, 2021.
2. The Cold Storage Shortage, Capstone Logistics.
Whether leasing, renovating, or building a new site, food suppliers and distributors are responding to the increased need for cold storage. For example, one food supplier selected ESI Group to design and construct a tenant cold storage and office build-out at a new distribution center in California where the shell building was constructed by our clients’ developer. The facility is a conventional warehouse utilizing tilt wall construction, single-ply membrane roof, reinforced concrete floors and conventional steel structure with a wood panelized roof structure. ESI Group was called in to create cold space for the building, which resulted in 22,732 sq. ft. of freezer storage and almost 31,000 sq. ft. of multi-temperature coolers/perishable dock space. ESI Group designed the structure to accommodate future freezer space of 8,000 sq. ft. and 5,864 sq. ft. of future cooler space.
In another example, ESI Group design and constructed the build-out of a state-of-the-art distribution center for US Foods. The project scope included all temperature-con trolled areas. ESI Group was then called in to reconfigure 120,000 sq. ft. of dry storage to multi-cooler storage. This required re-racking 260,000 sq. ft. of storage area.
“Investor and end user demand for temperaturecontrolled storage space is surging across the U.S.”
Bobby DeGregorio, Regional Manager, ESI Group USA
THEPACKAGING & PROCESSING Hall of Fame will induct four new members to the 47th class this fall in Chicago during PACK EXPO International. Since 1971, the Hall of Fame has recognized career packaging and processing professionals for their significant contributions to the industry and education. This year’s honorees are Jean-Jacques Gra n, Rebecca Oesterle, Pierre Pienaar, and E. Je rey Rhodehamel.
The late Jean-Jacques Gra n dedicated his life to improving manufacturing and packaging for the food industry. A tireless inventor, he revolutionized dairy manufacturing and packaging; his weight filler and the rotary machine for filling milk remain in use to this day. The founder of Serac, Gra n received more than 100 patents over his lifetime, as well as multiple awards, including the Nobel Prize for Entrepreneurs by the French Academy.
During her decades-long career, Rebecca Oesterle led the charge at Energizer on several package devel opment and project management innovations; she deployed those same skills during her time at Just Born Quality Confections. Currently, she brings more than 40 years of packaging and project management experience as chair of the board of directors at the Institute of Packaging Professionals (IoPP).
Pierre Pienaar has become one of the most prolific and recognizable packaging educators in the world. President of the World Packaging Organization, his passion is educating the world about packaging, the science of packaging, and the need to properly recy cle. In addition to running a packaging consultancy in Australia, Pienaar lectures students in food innovation and packaging at universities around the world.
Je Rhodehamel, PhD, earns his spot in the Hall of Fame as a true food safety renaissance man. Between his work protecting public health in the U.S. Food and Drug Administration, innovating package design at Sealed Air, and passing the torch to the next generation of food scientists at Clemson University, Rhodehamel has been a leader throughout his career.
Organized by PMMI, the Association for Packaging and Processing Professionals, the Hall of Fame welcomes new members every other year. Members are chosen by the Hall of Fame Commission, which selects inductees from individu als who have been nominated. The commission includes a cross-section of industry professionals, including suppliers, end users and journalists.
“This year’s inductees are an exceptional group,”
says Joe Angel, president of PMMI Media Group and Hall of Fame Commission member. “Their knowledge, vision, and lifelong dedication are an inspiration to our entire industry.”
Jim Pittas, president and CEO of PMMI, adds, “We look forward to welcoming these four profes sionals to the Hall of Fame, Class of 2022. It’s with gratitude and appreciation that we acknowledge their contributions, which have enriched the pack aging and processing industry worldwide.”
Fourteen individuals comprise the Packaging & Processing Hall of Fame Commission.
• Joe Angel, president, PMMI Media Group; publisher, Packaging World
• Kim Carswell, consultant, formerly with Target
• Kay Cooksey, PhD, professor and Cryovac Endowed Chair, Department of Food, Nutrition and Packaging Sciences, Clemson University
• James Downham, president and CEO, PAC Global
• Suzanne Fisher, CPP, Fisher Packaging
• Mary Gregg, president, Springboard Packaging Solutions
• Glen Long, senior vice president, PMMI
• James Perry, director, package innovation and sustainability, Abbott Nutrition
• Bill Rice, principal, packaging technology, SC Johnson & Son
• Michael Richmond, PhD, co-founder, PTIS
• Mark Shaye, vice president of engineering, Ken’s Foods
• Thomas L. Schneider, CPP, past chair man, Institute of Packaging Professionals; past president, World Packaging Organization
•David S. Smith, PhD, R&D executive, consultant, David S. Smith Associates •Nancy Wilson, CEO, Morrison Container Handling Solutions
The 2022 Packaging & Processing Hall of Fame ceremony will take place Monday, Oct. 24, at PACK EXPO International. Find additional information, as well as PACK EXPO International registration and event details, at www.packexpointernational.com
Strengthen your supply chain through integrated business planning, reliability engineering and asset optimization, digital insights, and transformational OEM relationships.
MORE THAN EVER , manufacturing’s role in the company’s supply chain is critical for reliably delivering on its customer requirements, consumer expectations, and financial performance. Market conditions have created a tsunami of special deviations from the norm for manufacturing.
And while consumer packaged goods (CPG) manufacturing professionals are committed to delivering for their stakeholders in the face of these deviations, the most challenging question facing them is how to ensure that their operations are the
strongest link in their supply chain.
This article focuses on four critical factors in strengthening your supply chain: integrated busi ness planning (IBP), reliability engineering and asset optimization, Industry 4.0 digital insights, and transformational OEM relationships. To address each, in turn, FSO Institute has sought the insights of industry subject matter experts Jon Doering, senior vice president supply chain, DecoPac; John Robertson, vice president life cycle engineering; Bob Gates, senior director, GE Digital; and Paul Schaum, partner + coach, FSO Institute.
JON DOERING, SENIOR VP SUPPLY CHAIN, DECOPAC | JOHN ROBERTSON, VP, LIFE CYCLE ENGINEERINGRoss rotor-stator High Shear Mixers work fast to mix, disperse, emulsify and homogenize at speeds up to 4000 ft/min. Batch models o er greater control when mix composition and timing are critical, production quantities are small, or when producing multiple formulations on one process line.
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FSO INSTITUTE: Jon, you have always been a strong advocate for integrated business planning. You have described it as necessary to link the “how we go to market,” forecasts, and the ability of the business to supply. How would you recommend a consumer products company pursue IBP?
JON DOERING: IBP’s power enables month-to-date business performance discussions, evaluation of performance against overall business enterprise objectives, and EBITDA performance. This is crucial information for leadership. So, whether it be in my current role or prior leadership roles, when consid ering IBP, I have always started with the following questions:
• What is the current state of the business and why?
• Do we have the long-term visibility to future business initiatives and expected outcomes?
• Do we have facts and options to change the first two questions?
Previously, in meetings with my fellow leadership team, we were working to understand and solve for what we perceived as “present time issues” when we could and should have seen them months prior or at the onset of our strategic planning process. The recognition of need for integrated business planning lies within your reflection and ability to understand how you are operating today vs. how you need to operate tomorrow to maintain relevan cy in the market.
Today might look like the following if you reflect on the state of your business:
• Reactive mode
• Lack of correlation of business information and impact to business
• Lack of financialization of business changes
• The need for structure and KPIs that drive dis cussion through all feeder meetings and IBP process meetings
• Lack of executive summary narratives that drive thought and understanding of the busi ness
By installing an IBP process and a culture of empowerment, you will find yourself with a team that not only shows up to a meeting but has given thought to the state of the business and is prepared to contribute to conversation in a way that can shape the growth of the business. You will also find that your business has transformed and provides information that your business can make decisions from, such as the following:
• Providing better cost-benefit analysis to risks and opportunities that drives improved busi ness decision-making
• Securing capacity to deliver business growth and meeting customer service expectations
• Measuring performance to drive improvement
• Easier and more e cient translation of infor mation across functional areas (marketing, sales, operations, and finance)
• Improving trust throughout the team with one process and clear accountabilities
FSO INSTITUTE: Life Cycle Engineering’s expertise in reliability engineering is well known. What would you suggest to minimize the supply chain risks to manufacturing in the food and beverage industry?
JOHN ROBERTSON: The current supply chain issues, lack of a skilled/motivated workforce, coupled with growing demand, substantially increases risks for food and beverage manufacturers.
To minimize these risks, leaders need to build a smart culture promoting the application of pro active asset management best practices while embracing technology and innovation.
When engaged employees apply reliability and operational excellence processes to manufacturing assets, they minimize risks by increasing availabil ity, production rate, and quality while ensuring regulatory compliance. This improvement in plant performance can also increase the level of attrac tion and retention of a more productive workforce. Engaging teammates in proactive asset manage ment also results in extended asset life and an increase in shareholder return.
FSO INSTITUTE: Given the pervasive discussions around Industry 4.0, how would you suggest a manufacturer start taking advantage of 4.0 to fortify its supply chain?
BOB GATES: Supply chain issues can disrupt busi ness when lacking digital insight on the network. Industry 4.0 can drive agility as it is key to making sure the supply chain is robust. Robust in the past was focused on what was on hand in the ware house. As inventories shrink, the need to under stand the factory floor becomes even more import ant for avoiding stockouts. Industry 4.0 drives companies to pull their data together and apply better intelligence against the data, enabling bet ter forecasting and real-time adjustments to meet business needs.
FSO INSTITUTE: Paul, when you were the CTO of Pretzels Inc., how did you overcome the supply chain crisis when you were adding new production lines into the plant?
PAUL SCHAUM: Partnering with key OEMs has value. Are they going to pull out all the stops when a crisis hits? The best example is when we ran into electronic component supply issues which could cause
multiple months’ delay on equipment delivery and start-up. The OEM told us the situation and then went about finding alternate solutions.
The first thing they did was search the world for alternate parts. Their next step was to purchase the entire electrical stock of a used electronics parts supplier. The used parts could be used in the new equip ment with spare used parts as backup for start-up. Then when the new parts were available, they would be swapped out and all new machine warranties would be intact. This resulted in one production line starting on time and the second produc tion line having only a six-week delay.
Fortifying your supply chain is reliant upon your company’s manufacturing health. Beginning with a strategic imperative as IBP, managing risk through asset optimization, developing digital insights to your manufacturing performance, and strengthening your partnering relationships with suppliers have proven to be a strong path forward.
PMMI’s OpX Leadership Network has produced more than 20 manufacturing process-improvement documents for CPGs and OEMs. The FSO Institute has facilitated the adoption and implementation of these documents, especially for food and beverage manufacturers. This series of articles shows how CPGs are using OpX and FSO documents to improve their overall manufacturing health and collaboration with OEMs and other suppliers. Learn more at
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An enterprise-wide refocusing on sustainability pushed Bumble Bee Seafood to reinvent multipacking in a more readily recyclable paperboard format. The engineering e ort centered around a cartoner that could handle the speed and volume.
THE ICONIC BUMBLE BEE TUNA brand went through a highly publicized transformation in recent years, being led out of bankruptcy by then-CEO Jan Tharp in 2020. It emerged with a fresh brand identity, complete with an enter prise-wide commitment to sustainable practices.
Predictably, packaging came under scrutiny during this brand revolution. At that point, mul tipacks for just about every brand and variety of canned seafood had long used robust, printed shrink bundling film, capable of tightly containing heavy cans of seafood in the formats we still see on retail shelves, like a 4x2 8-pack of 5-oz cans.
Specific to the Bumble Bee facility in Santa Fe Springs, Calif., shrink film was applied to build shrink bundle packs by a 25-year-old shrink overwrap machine that was on its last legs. The company couldn’t secure good support for such an old model, and it was frequently causing downtime on the line.
That was an internal, operational drawback to the shrink-bundling situation at Bumble Bee, but it was one that could be easily solved with investment in a new shrink bundler. A more enterprise-altering, consumer-facing drawback? The films aren’t readily recyclable. This second drawback was key, since con sumer perceptions around plastics were changing.
“We started looking at paperboard a cou ple of years ago as part of our Seafood Future Commitment,” Tharp says. “That brought us forward to this package, and our partnership with R.A Jones.”
As mentioned, the older shrink bundling unit in San ta Fe Springs was causing downtime, so a change was needed.
“The upstream equipment wasn’t new per se, but the shrink bundler was definitely the bottleneck and it had to be replaced,” says Brett Butler, vice
Bumble Bee now produces 5- and 7-oz cans of tuna in paperboard multipacks from 4-count to 12-count. The tallest, 10- and 12-count multipacks, take advantage of an overhead squaring lug feature on the cartoner.
president and general manager. “But the decision to go to a recycled paperboard unit, that was a whole new venture for us here at the facility.”
In late 2019, Joe Carney, facilities engineering manager, created a checklist of cartoner criteria to qualify for consideration. The primary driver was being able to run printed, recycled-content paper board cartons that could be readily recyclable. Beyond that, Carney sought an OEM partner that could deliver equivalent line speed to the legacy equipment (pushing 300 multipacks/min for small er formats) and deliver good changeover charac
teristics to be able to handle a lot of di erent SKUs and formats.
“Because we weren’t accustomed to cartoning, we had to find out if there were even machines available that could keep up with our speeds,” Butler says. “How many machines would we need? We only had limited space in our facility.”
The existing space constraints in the facility made a single machine the preferred route, and R.A Jones’ Meridian XR MPS-300 won out as the car toner of choice.
“One of the bigger reasons that Brett and I decided to go with R.A Jones was that they already had an in-market machine doing the same size can, stacked four high, for a pet food application,” Carney says. “So they were already handling the stacked can.”
In Carney’s experience, stacked cans can prove problematic. Bumble Bee’s legacy shrink bundler,
Read the complete, extended version of this story.
High pressure processing (HPP) technology is a non-thermal processing technique by which products, already sealed in their final package, are subjected to a high level of isostatic pressure transmitted by water.
for instance, had issues with the stacks falling over prior to bundling, or sometimes even during bun dling, thanks to nesting issues with the cans. The in-market pet food application proved to Carney that the R.A Jones equipment had solved that problem.
Using the new cartoner purchased from R.A Jones, Bumble Bee’s new paperboard pack format began appearing on shelves in late spring of 2022. For Butler, the success of the project only moves the continuous improvement ball down the field, and highlights another bottleneck to tackle next. But that’s a good thing.
“On the smaller packs, the four-packs, the equip ment isn’t only meeting our speed goals. It looks like there’s potential for it to surpass them and go even faster,” he says. “Since it’s not the bottleneck anymore, it’s making us look at other facets of the line to see if we can get that speed increased. Now the worry isn’t multipacking operations, the worry is what can we do on the rest of our equipment to make sure we’re getting the most speed that we can. It’s a good problem to have.”
R.A Jones www.rajones.com
COCA-COLA BEVERAGES has un veiled a paperboard packaging system that replaces the plastic ring handles on can mul tipacks. The local Coca-Cola bottler has partnered with Graphic Packing International to manufacture the new packaging format, called the KeelClip, and use multipack carton application equipment. It will soon be delivering this pack format for its 7.5-oz minicans to stores across the Philadelphia market.
KeelClip equipment is a sustainable packaging system that has already been successfully imple mented and distributed through other local CocaCola bottlers in Europe. It is estimated that the transition will remove 75,000 lb of plastic packaging per year from the supply chain for about 3.1 million cases across Liberty’s service area, which includes Philadelphia, New Jersey, New York City, and parts of Connecticut and Delaware.
The installation of the KeelClip 1600 machinery means the sustainable fiber-based packaging is manufactured at one of Liberty’s facilities in New
York and is being distributed across its entire footprint.
“This technology has seen incredible success wherever it has been used, winning 10 industry awards and becom ing the gold standard for can multipacks in over 20 countries,” says Bret Arnone, vice president of commercial operations and beverage packaging at Graphic Packaging.
The KeelClip packaging implementation is the lat est e ort Liberty is taking to advance its sustainabil ity e orts. Last year, Liberty became the first local Coca-Cola bottler in the U.S. to produce and distrib ute bottles made from 100% recycled materials.
Matt Reynolds, Chief Editor, Packaging World
Graphic Packaging
Record prices for ingredients and materials transformed the food and beverage manufacturing industry in 2022, and significantly altered consumer buying behaviors for retail goods.
THOSE WHO REMEMBER the late 1970s and early 1980s with a sense of nostalgia likely don’t extend that fondness to the record inflation that defined the economy during Jimmy Carter’s presidency and the early years of Ronald Reagan’s administration, eventually leading to a recession that ended in late 1982.
The inflation rate during that time reached dou ble digits three consecutive years from 1979 to 1981, with a peak of 13.55% in 1980. The U.S. never reached double-digit inflation again in the ensuing 40+ years, but 2022 isn’t over yet. Inflation this year reached a peak of 9.1% in June, according to the U.S. Bureau of Labor Statistics, and hasn’t come down significantly since then.
What this means for consumers today is an increase in food prices not seen since 1979-1981. In July this year, food prices were up 10.9% year-overyear (YOY) from 2021, which is the biggest jump since May 1979. Prices for groceries increased 13.1% YOY, the highest rise since March 1979.
No matter how people buy their food—at the store, via e-commerce/direct-to-consumer (DTC), or through restaurants and foodservice—they are feeling the current pinch on their wallets. A recent survey by Vericast revealed 60% of shoppers are looking for more discounts and deals to o set inflation, with some shopping at dollar stores and other discount outlets rather than traditional grocery chains.
1112
1211
1313
1414
1515
Unilever Group
Danone
Heinz Co.
Inc.United StatesConfectionery,
KingdomReady
Products,
FoodAptamil,
Belvita, Cadbury
Lipton, Hellmann’s40,468
Danone, Evian
StatesSauces, Ready Meals, ConcentratesKraft, Oscar Mayer, Heinz, Philadelphia, Kool-Aid34,156
Mars Inc. United StatesConfectionery, Biscuits, Pet FoodM&Ms, Extra/Orbit, Snickers, Mars29,342 74
Groupe Lactalis France Dairy Products, Ready Meals President, Galbani, Rondelé 23,503250
Ferrero & related parties Italy Confectionery
Inner Mongolia Yili Industrial Group Co. Ltd. ChinaDairy Products, Ready Meals
General Mills Inc. United States Dairy Products, Ready Meals, Breakfast Cereals
Kellogg Co. United States Breakfast Cereals, Sweet and Savory Snacks, Snack Bars
Kinder, Ferrero Rocher, Nutella 22,218 18
Yili, Ambrosial, Satine 19,860
Yoplait, Häagen-Dazs, Annie’s 18,535 51
Corn Flakes, Pringles, All-Bran 18,280 40
Grupo Bimbo SAB de CV Mexico Baked Products Bimbo, PlusVita, Sara Lee 16,761194
China Mengniu Dairy Co. Ltd. China Dairy Products Mengiu, Deluxe, Jun Le Bao 16,00733
1619 s Suntory Holdings Ltd. JapanBottled Water, Tea, SpiritsBoss, Suntory Tennensui, Iyemon, Green Dakara13,324 67
1716 Keurig Dr Pepper Inc. United StatesCarbonates, Sport Drinks, JuicesDr Pepper, Canada Dry, Snapple 13,219 32
1817 Campbell Soup Co. United StatesSauces, Ready Meals, ConcentratesCampbell’s, Pepperidge Farm, Arnott’s, V812,684 32
1918
Conagra Brands Inc. United StatesSauces, Ready Meals Rotel, Hunts, Frontera 12,420 51 2020 Red Bull GmbH Austria Energy Drinks Red Bull 12,223 2
2122 s Wilmar International Ltd. Singapore Vegetable Oils Arawana, Gold Ingots, Olivoila 11,636 450
2221
The Hershey Co. United StatesConfectionery, Snack Bars Hershey’s, Reese’s, Kit Kat 11,622 9 2324 s Monster Beverage Corp. United StatesEnergy Drinks, Carbonates Monster, NOS, Burn 10,960 1
2423
Ting Hsin International Group Taiwan Vegetable Oils, Ready Meals, Sauces, Soft Drinks Master Kong, Wei Chuan, High Quality10,643
25unranked NA JDE Peet’s BV Netherlands Co ee, Tea
L’Or, Peet’s, Douwe Egberts, Kenco, Tassimo, Pilao, Jacobs 10,306 43
2625 Royal FrieslandCampina NVNetherlandsDairy Products, Ingredients Hollandia, Campina, Dutch Lady 8,927 14 2735 s Yamazaki Baking Co. Ltd. JapanBaked Products, ConfectioneryYamazaki, Hear, Peko, Lunch Pack 8,580 2832 s Arla Foods Amba DenmarkDairy Products, Ingredients, Ready Meals Arla, Lurpak, Yoggi 7,445 3 2928 Barilla Holding SpA ItalyBaked Products, Ingredients Barilla, Mulino Bianco, Voiello 7,401 30
3026
WH Group China Meats Shineway, Farmland, Armour, John Morrell7,228 13 3131 Lotte Group South KoreaConfectionery, Ready Meals, Ice CreamLotte, Lotte Icis, Chilsung Cider, Cantata6,981 3229 Meiji Holdings Co. Ltd. JapanDairy Products, Baby Food, ConfectioneryMeiji Oishii Gyunyu, Meiji Bulgaria Yogurt, Savas6,614 12 3327 Asahi Group Holdings Ltd. JapanBottled Water, Tea, ConfectioneryWonda, Mitsuya, Calpis Water 6,505 95
3441 s Hormel Foods Corp. United States Sauces, Ready Meals, Concentrates, Frozen Food, Vegetable Oils Hormel, Spam, Skippy, Valley Fresh6,480 75
3538 s Chocoladefabriken Lindt & Sprüngli AG Switzerland Confectionery Lindt, Ghirardelli, Whitman’s 6,402 8
Tyson Foods Inc. United StatesReady Meals, SaucesTyson, Jimmy Dean, Hillshire Farm, Ball Park6,092 241
Saputo Inc.
CanadaDairy Products, IngredientsSaputo, Alexis de Portneuf, Armstrong, Baxter5,855 58
Uni-President Enterprises Corp. ChinaDairy Products, Tea, Ready Meals Uni-President, Uni Milk Tea 5,833 44
Yakult
2021
Rank
Change 2020/2021
Company
Major industries
Major Brands
Global Retail Food and Beverage Sales ($Millions)
5159 s TC Pharmaceutical Industry Co. Ltd.Thailand Energy Drinks, Carbonates, Snack Bars, Sports Drinks Red Bull, Kratingdaeng, Sponsor Active4,942
5252
5349
5460 s
Number of Manufacturing Plants
Gujarat Co-operative Milk Marketing Federation Ltd. India Dairy Products, Ice Cream Amul, Mithai Mate, Kool Koko 4,728 18
Indofood Sukses Makmur Tbk PTIndonesia Ready Meals, Dairy Products, Ingredients, Tea Indomie, Supermi, Indomilk, Tiga Sapi 4,726
Adani Group IndiaVegetable Oils, Rice, Soy Products Fortune, Alpha, Raag 4,717 25
5591 s HelloFresh SE Germany Prepared Meals
5633
HelloFresh 4,705 12
Kirin Holdings Co. Ltd. Japan Tea, Health Products Kirin Gogono-kocha, Namacha, Kirin Fire4,688
5744 Groupe Bel France Dairy Products Leerdammer, GoGo squeeZ, La Vache Qui Rit, Boursin 4,657 30
5855
5957
6051
ITO EN Ltd.
China National Cereals, Oils & Foodstu s Imp & Exp Corp. (COFCO)
JapanTea, Co ee, Bottled Water Oi Ocha, Kenko Mineral Mugicha, Ito En Tennen Mineral Mugi Cha 4,629 2
ChinaVegetable Oils, IngredientsFortune, Xiangxue Flour, Sundry, Le Conte4,585
Yangshengtang Co. Ltd. China Health Products Nongfu Spring, Tea Pai, Nongfu Orchard 4,459 2
6147 Abbott Laboratories Inc. United States Baby Food Similac, PediaSure, Ensure 4,456 11
6261
6346
6469
Nomad Foods Ltd. British Virgin Islands Frozen Food Iglo, Findus, Lutosa 4,377 17
The J.M. Smucker Co. United States Ready Meals, Ingredients, Ice Cream, Juices, Co ee Folgers, Dunkin’ Donuts 4,362 26
s Fonterra Cooperative Group Ltd.New Zealand Dairy Products Anchor, Mainland, Perfect Italiano4,04414
6558 Pladis Ltd. United KingdomConfectionery, Biscuits Godiva, McVitie’s, Ulker 4,041 10
6667 s Grupo Lala SAB de CV Mexico Dairy Products Lala, Yomi Lala, MiLeche 4,004 9
6762 Associated British Foods PLCUnited Kingdom Breakfast Cereals, Ready Meals, Vegetable Oils, Tea Twinings, Ovaltine, Jordans 3,989 46
6865 JA Group (Japan Agricultural Cooperatives)Japan Rice N/A 3,844 47
6973 s Want Want Holdings Ltd. TaiwanBiscuits, Snack Bars, Dairy Wang Zai, Want Want, Toshitaka-Kun Shuzawa, Mum-Mum 3,768100
7072 s Megmilk Snow Brand Co. Ltd. JapanDairy Products, Baby Food Hokkaido, Snow Brand, A1 3,736 18 7180 s Sigma Alimentos SA de CV MexicoDairy Products, Ready Meals, Frozen FoodFud, Noche Buena, San Rafael, La Villita3,642 31 7285 s Starbucks Corp. United StatesCo ee, Tea, Bottled WaterStarbucks, Seattle’s Best Co ee, Teavana3,516 9 7371 Shijiazhuang Junlebao Milk Co. Ltd.China Dairy Products Jun Le Bao 3,49416
7474 Fujian Dali Food Co. Ltd. China Baked Products, Ready Meals, Sweet and Savory Snacks, Tea Hi-tiger, Heqizheng 3,464 7575 CJ Corp. South Korea Ingredients, Health Functional Foods, Desserts, Snacks Snow White, The Healthier, Go Back 3,459 15 7668 Toyo Suisan Kaisha Ltd. Japan Ready Meals, Frozen Food Maruchan, Sanshoku Yakisoba, Sanshoku Udon3,431 11 7783 s Haribo GmbH & Co. KG Germany Confectionery Haribo 3,342 15 7863 Ebro Foods SA Spain Sauces, Ready Meals Panzani, Brillante, La Cigala, Sundari3,135 38
7979 Almarai Co. Ltd. Saudi Arabia Dairy Products, Baked Products, Poultry, Baby Food, Juices Almarai, L’Usine 3,113 9
8082 s Morinaga Milk Industry Co. Ltd. Japan Dairy Products, Ingredients, Nondairy Drinks Parm, Creap, Morinaga Oshii, Piknik3,08720 81100 s August Storck KG Germany Confectionery Campino, Merci, Bendicks 3,083 3
Vietnam Dairy Products JSC (Vinamilk)VietnamDairy Products, Soy Milk, Baby Food Vinamilk, Dielac, Dielac Alpha 3,030 9
s Bunge Ltd. United StatesIngredients, Vegetable Oils Espiga, Primor, Nutra-Clear NT 3,027 166
Ezaki Glico Co. Ltd. Japan Ice Cream, Confectionery, Baby Food, Sweet and Savory Snacks Pocky, Papico, Bifix, Cratz 2,98810
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Consumers who make the trek to a traditional grocery store are more discerning than ever about how they spend their money. Research by The Food Industry Association shows 41% of shoppers are actively seeking less expensive store brands, and the Private Label Manufacturers Association (PLMA) says store brand sales were already on an upswing even before 2022’s inflation set in. PLMA reports store brands’ annual dollar volume increased by $1.9 billion in 2021, for a record $199 billion in total sales.
Other inflation-inspired decisions by shoppers in 2022 include “trading down” from beef to less expensive chicken, cutting back on perceived luxu ry items like chocolate, and eating less to make gro cery purchases last longer. Those hunting for deals on Amazon during its annual Prime Day sale bought more household items than previous Prime Days,
While 2022 will likely be remembered for record inflation and a dysfunctional supply chain, food manufacturers still added some fun to store shelves with a growing number of cross-branded food and beverage mashups to catch consumer eyes and possibly dollars too.
Cross-branded mashups—which can be two separate companies partnering, or di erent brands from the same parent company—have a multi-level strategy behind them: First, they’re a way to expand a brand’s visibility and attract new customers. Second, they’re social media gold, often going viral when unusual mashups are announced and released. Finally, they inspire genuine curiosity from con sumers, wondering what those products might taste like, potentially generating incremental sales.
Some notable mashups this year include:
• Swiss Miss (Conagra, No. 19 on our Global 250) and Lucky Charms/Cinnamon Toast Crunch cereals (General Mills) flavored cocoa mix
• Nabisco (Mondelēz): Ritz X Oreo cracker cookies—one side has Ritz, the other Oreo, held together by Oreo’s cream filling
• DiGiorno (Nestlé, No. 3) and Honey Hut: DiGiorno pizza crust ice cream cones, with Strawberry Tomato Basil and Parmesan Cheese ice cream flavors
• Oscar Mayer (Kraft Heinz) and Popbar: The “Cold Dog”—a hot dog-flavored popsicle that looks like a frank on a stick with drizzled mustard
• Kraft Heinz and VanLeeuwen: Kraft Macaroni & Cheese ice cream
• Mars (No. 8) and Perfect Day: animal-free CO2COA chocolate bars
according to CNBC, with Frito-Lay snack packs among the top-selling items.
For many of our Global 250 companies this year, inflation has been the proverbial double-edged sword: The cost of materials and ingredients has skyrocketed (if those ingredients are even available), which in turn leads to higher prices for finished goods. Some of the big players have been able to take advantage of the situation, though, gaining bet ter-than-expected profits as their costs are passed on to consumers.
Those price hikes led to pushback from some major retailers, who threatened to stop carrying products they deemed too expensive. Kraft Heinz (No. 7 on our Global 250) had stopped supplying items like ketchup and baked beans to U.K.-based
Oscar Mayer’s Cold Dog is a hot dog-flavored popsicle manufactured and sold in partnership with frozen treat retailer Popbar. It’s one of several cross-branded F&B mashups going viral on social media and generating incremental sales in 2022.
• Pepperidge Farm Goldfish (Campbell Soup, No. 18) and Old Bay Seasoning (McCormick, No. 45) snack crackers
• Coca-Cola (No. 1) and Jack Daniel’s (Brown-Forman, No. 44 on our Top 50 Alcoholic Beverage Manufacturers list) RTD canned cocktails
• Frito-Lay (PepsiCo) Lay’s Flavor Swaps, which combine Lay’s Potato Chips and another Frito-Lay snack (Chee tos, Funyuns, Doritos, Fritos) in the same bag
• Ace Hardware and Benjamin Moore paint ice cream: not among our Global 250 companies, but still a curious combination of ice cream in four of Benjamin Moore’s most popular paint colors, given away by Ace Hardware to customers in July.
Packaged Cascade
Transcritical
Transcritical
Industrial Racks
Major Brands
2020/2021
9964
Global Retail Food and Beverage Sales ($Millions)
Number of Manufacturing Plants
Oetker-Gruppe Germany Frozen Food, Ingredients, Dairy Products Beer Dr. Oekter, Backin, Paula, Wölkchen 2,470 5
100119 s Cargill Inc. United StatesPet Food, Vegetable Oils, Ingredients Liza, Pomarola 2,456 101132 s Patanjali Ayurved Ltd. India Ingredients, Baked Products Ruchi, Patanjali 2,425 102109 s Bonduelle Groupe SA France Ready Meals, Frozen Food, VegetablesBonduelle, Cassegrain, Artic Gardens, Globus 2,371 54 103107 s Jinmailang Food Co. Ltd. China Noodles, Snacks, Flour, Juices Jinmailang, Want Want, Foco 2,370 38 104110 s Sodiaal SA (Société de Di usion Internationale Agro-alimentaire)
France Dairy Products, Baby Food, IngredientsYoplait, Candia, Entremont, Le Rustique, Viva 2,362 70
105114 s Shenzhen Ganten Industry Co. Ltd. China Bottled Water
Ganten 2,356 10 106112 s Tine SA Norway Dairy Products, Juices Tine, Go, Iste, Biola, Sommer 2,350 31
10786 Nong Shim Co. Ltd. South Korea Sweet and Savory Snacks, Ready Meals, Bottled Water Shin Ramyun, Baeksansoo, Jeju Samdasoo2,349 11
108125 s Parle Products Pvt. Ltd. India Biscuits, Confectionery, Sweet and Savory Snacks
Parle, Melody, 20-20 2,348 9
109111 s McKee Foods Corp. United States Snack Bars Little Debbie, Sunbelt Bakery, Drake’s 2,335 4 110127 s Mayora Indah Tbk PT Indonesia Co ee, Tea, Biscuits, ConfectioneryKopiko, Torabika, Energen 2,328 2 111106 Unternehmensgruppe Theo Müller SecsGermany Dairy Products, Meats Müller, Almholf, Homann, Lisner 2,310 19 11296 JDB Group China Tea Jiaduobao, Kunlun Mountain 2,266 11397 Calbee Foods Co. Ltd. Japan Sweet and Savory Snacks, Frozen FoodCalbee, Harvest Snaps, Yushoi 2,208 15 114unranked NA Bega Cheese Ltd. Australia Dairy Products, Juices, SaucesBega, Dairy Farmers, Pura, Moove 2,20420 115116 s Orion Group South Korea Biscuits, Confectionery, Sweet and Savory Snacks Orion, Choco Boy 2,170 12 11690 Kikkoman Corp. Japan Sauces, Ready Meals, Non-dairy DrinksKikkoman, Del Monte 2,158 3 117128 s Chobani LLC United States Dairy Products Chobani 2,153 2 118117 China Resources Holdings Co. Ltd. China Bottled Water, Tea C’estbon, Afternoon, Fire 2,115 40 119150 s Shikishima Baking Co. Ltd. Japan Baked Products, Snack BarsShikishima Baking Kashipan, Choujuku, Pasco 2,03715 120118 Kewpie Corp. Japan Sauces, Ingredients Kewpie 2,026 17 121124 s BRF SA Brazil Pet Food, Frozen Food, Vegetable OilsSadia, Qualy, Perdigao, Bocatti 2,019 45 122153 s Fuji Baking Co. Ltd. Japan Baked Products, Cakes, Noodles Fuji 2,009 6 123123 The Wonderful Co. LLC United StatesJuices, Nuts, Bottled Water, WinesFiji, Justin, POM, Wonderful 2,005 9 124135 s Karnataka Cooperative Milk Producers Federation Ltd. India Dairy Products Nandini 2,004 27 125133 s Premier Foods PLC United Kingdom Ready Meals, Sweet and Savory Snacks, Baked Products Ambrosia, Batchelors, Angel Delight, Mr. Kipling 1,953 10 126115 Britannia Industries Ltd. India Baked Products, Dairy Products, Biscuits Britannia, Tiger, VitaMarieGold 1,952 13 127113 JG Summit Holdings Inc. Philippines Snacks, Co ee, Ice Cream, Noodles, Confectionery, Vegetable Oils, Tea Great Taste, C2 Cool, Jack n’ Jill 1,939 128103 Guangzhou Pharmaceutical Holding Ltd.China Health Drinks Wong Lo Ckat, Wang Lao Ji 1,921 129120 Agropur Co-operative Agro-Alimentaire Canada Dairy Products biPro, Natrel, OKA 1,907 130141 s Land O’Lakes Inc. United States Dairy Products Land O’Lakes, Alpine Lace, Kozy Shack 1,907 131183 s Charoen Pokphand Group Thailand Ready Meals, Meats, Poultry Michelina’s, Authentic Asia, Kitchen Joy, Thai Thai, Royal Umbrella 1,894 10 132136 s Karl Fazer Oy Ab Finland Baked Products, Confectionery Pihlaja, Mignon, Fazer Blue 1,877 22 133130 Maple Leaf Foods Inc. Canada Meats Maple Leaf, Larsen, Shopsy’s, Mitchell’s 1,864 134143 s Groupe Fleury Michon France Snacks, Sauces, Ingredients, Processed Meats Fleury Michon 1,828 15 13595 Strauss Group Ltd. Israel Dairy Products, Co ee, Juices, Confectionery, Biscuits Sabra, Elite, Doncafé, Pedro’s, Frisco 1,811 20 136138 s Valio Oy Finland Dairy Products, Ingredients Valio, Valsa, Eila 1,770 18 137168 s Kagome Co. Ltd. Japan Dairy Products, Soft Drinks Yasai Seikatsu 100, Kagome 1,761
Dongwon Group South Korea Seafood StarKist 1,740
Blue Diamond Growers
Britvic PLC
States Non-dairy Drinks, Sweet and Savory Snacks, Biscuits
Almond Breeze 1,738
Kingdom Carbonates, Sport Drinks, JuicesRobinsons, DaFruta, Club Mixers, Energise Sport1,706
Czech RepublicPet Food, Frozen Food Olma, Krahulik,
2020
Rank
151145
Change 2019/2020
Headquarters
Industries
Major Brands
Global Retail Food and Beverage Sales ($Millions)
Number of Manufacturing Plants
House Foods Corp. Japan Ingredients, Species, Sauces House, Gaban, New Crown Ace 1,568 8
152155 s Tchibo GmbH Germany Co ee Tchibo, Eduscho, Cafissimo 1,561
153157 s Foshan Haitian Flavouring & Food Ltd. China Sauces, Condiments Haitian 1,559 1 154148 Australia Ausnutria Dairy Pty Ltd. China Baby Food Ausnutria, Neolac, Allnutria 1,555
155161 s Tata Consumer Products Ltd. India Tea, Co ee, Bottled Water, Dairy Products Tetley, Tata Tea, Eight O’Clock 1,524 12
156unranked NA Hornell Brewing Co. United StatesTea, Juices, Energy Drinks
Arizona 1,521 1 157192 s Thai Union Frozen Products PCL Thailand Fish Chicken of the Sea, John West, Bellotta1,512 11
158186 s Gruma SAB de CV Mexico Ready Meals, Baked Products, Flour
159152
Sargento Foods Inc. United States Cheese
160181 s Emmi Group Switzerland Dairy Products, Soft Drinks
161160
Ocean Spray Cranberries Inc.United StatesJuices, Fruit Snacks
Mission, Maseca, Masa Rica, Tortimasa, Guerrero, Tortiricas 1,510 59
Sargento 1,483 4
Emmi Ca é Latte, Comella, Aktifit, Benecol, Emmi 1,481 30
Ocean Spray, Craisins 1,478 9
162187 s Vital Pharmaceuticals Inc. (VPX) United States Energy Drinks Bang, Redline 1,476 2
163174 s The Hain Celestial Group Inc.United States Tea, Grains, Ingredients, Ready Meals, Snack Bars, Juices, Sauces
Celestial Seasonings, Blue Print, Ella’s Kitchen, Almond Dream 1,459 14
164178 s Ottogi Foods Co. Ltd. South Korea Condiments, Vegetable Oils, Ingredients, Noodles, Frozen Food Ottogi 1,440
165159
M Dias Branco SA Indústria & Comércio de Alimentos Brazil Biscuits, Margarines, Spreads, Flour Adria, Vitarella, Piraquê 1,436 15
Kapal Api Group Indonesia Co ee, Biscuits, ConfectioneryABC Susu, Kapal Api, Good Day 1,439 1 166121
167163 Strauss/São Miguel Brazil Co ee 3 Coracoes, Santa Clara, Pimpinela, Grao Fino1,431 34 168171 s Ganaderos Productores de Leche Pura SA de CV Mexico Dairy Products Alpura, Alpura Light, Alpura Kids 1,429 10 169158 Hebei Yangyuan Zhihui Beverage Co. Ltd. China Non-dairy Drinks Yangyuan 1,428
170179 s IDS Borjomi International Ukraine Bottled Water Svyatoy Istochnik. Borjomi, Morshynska, Myrgorodska 1,393 12
171unranked NA Hochland SE Germany Dairy Products, CheeseHochland, Almette, Patros, Grünländer1,386 15 172190 s Cloetta AB Sweden Confectionery Läkerol, Cloetta, Jenkki 1,382 5 173166 People’s Food Holdings Ltd. China Frozen Meats, Poultry Jinyu 1,358 174134
ITC Group India Noodles, Pasta, Sauces, IngredientsSunfeast, Yipee!, Kitchens of India1,352 175172 Dydo Drinco Inc. Japan Co ee, Bottled Water, Sports DrinksDyDo, Saka, Wakagokochi, Miu 1,323 176176 Primo Water Corp. United States Bottled Water RC Cola, Eden Springs, Mey Eden, Alhambra1,322 177170 Thai Beverage PCL Thailand Beer, Spirits, Bottled Water Crystal, Chang, Mekhong, SangSom 1,317 20 178239 s Shenzhen Eastroc Beverage Co. Ltd. China Bottled Water, Juices Ganten, Eastroc Super Drink 1,310 6 179219 s The Bolton Group Italy Sauces, Vinegars, Fish, Canned MeatsRio Mare, Saupiquet, Palmera 1,291 12 180207 s Guangdong Strong (Group) Co. Ltd. China Snacks, Instant Seaweed, Milk Tea, Confectionery U-loveit, Strong, Cici 1,289 3
181unranked NA BA Sports Nutrition LLC United StatesSports Drinks, Water Body Armor 1,274 1 182191 s Savola Group Saudi Arabia Vegetable Oils, Pasta Zaaki, Yudum, Shams 1,274 183185 s Shenyang Toly Bread Co. Ltd. China Baked Products, Cakes Taoli 1,269 184193 s Granlatte Societá Cooperativa Agricola arl Italy Dairy Products Granarolo, Granlatte, Candia 1,251 185167 Mizkan Group Corp. Japan Sauces, Ingredients Mizkan, Ragú, Zenb, Bertolli 1,250 24 186180 Anhui Three Squirrels Electronic Commerce Co. Ltd. China Snacks, Tea, Fruit Products, Nuts Three Squirrels 1,242 1 187182 Americana Group Kuwait Meats, Poultry, Frozen Food, Canned Food
Rain Beverage
Foods
Brands
Drinks, Flavored Water
Garden, Farm Frites, Koki, Americana Meat 1,239
Ice, Talking Rain, Tre 1,236
NH Foods, Hoko 1,228
Madison, Hostess, Twinkies, Donettes 1,222
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REPORT
Tesco because the grocery chain wouldn’t sell them at inflated prices to customers. The two reached an agreement in July.
“Shrinkflation” is one area where food manufactur ers can make up for high production costs by slightly reducing the package size and/or volume but keep ing prices the same—the reductions often go unno ticed by shoppers. “A 10% product size shrinkage is equivalent to an 11% price increase, but most people wouldn’t really think of it that way,” says Je Inman, professor of marketing at the University of Pittsburgh, in an interview with the Pittsburgh Post-Gazette.
Since inflation is on the radar of many consumers in 2022, they’re noticing shrinkflation in their pur chases. It’s so prevalent this year that there’s even a Reddit forum devoted to the subject with more than 36,000 members, who post side-by-side photo comparisons of original and shrinkflated products they’ve bought.
The top two brands on our Global 250 list this year (Coca-Cola and PepsiCo) each announced Q2 results in July that exceeded expectations for earn ings and revenues but were tempered somewhat by higher operating costs.
In its Q2 statement, PepsiCo Beverage North America noted its core operating profit “decreased 3% and primarily reflected a di cult comparison with the second quarter of 2021 in which we deliv ered 84% core operating profit growth. The decline in core operating profit also reflects an increase in inflationary pressures across our commodity, labor, transportation and supply chain costs…these pres
THE GLOBAL 250 Food and Beverage Manufacturers list ranks the world’s food and beverage companies by retail sales, while the Global 50 Alcoholic Beverage Manufacturers are ranked by volume produced. Compiled by Euromonitor International and commissioned by ProFood World, this exclusive research features much more data available online at www.profoodworld.com/global-250. It includes information such as the major manufacturing loca tions of the Global 250 companies, statistics on U.S. sales for each company, U.S. beverage sales by company, U.S. packaged goods sales by company, global beverage sales by company, and global packaged goods sales by company. Sort and search functions are available for both the Global 250 and Global 50 lists at www.profoodworld.com/global-250 and www.profoodworld.com/global-50.
sures were partly o set by strong topline perfor mance and a gain on sale of an asset.”
Inflation a ecting operating costs might also have played a part in Chobani’s short-lived (less than three months) foray into ultra-filtered dairy milk pro duction for retail sale. In a statement sent to Food Dive, the company said it is impacted by inflation like many other companies. “We have come to the tough conclusion that it does not make sense for Chobani to be in the dairy milk business at this time.”
Two other factors a ecting ingredient availability and pricing in 2022 are the conflict in Ukraine and climate change, creating a global shortage of wheat and cooking oil, in particular. Drought-related agricul tural shortages that escalate the price of commodi ties is known as “heatflation”—another new-for-2022 buzzword. As commodities become scarcer, prices go up, and consumers pay higher prices, whether shopping for groceries or dining in a restaurant.
Even if raw ingredients are available, delivering them to manufacturers has been a major hurdle a ecting food companies this year as ports, trucks, trains, and other transportation avenues have struggled to stay consistent. An unpredictable sup ply chain has also forced some brands to simplify recipes and find ingredient substitutes to meet pro duction demands.
Once ingredients reach a manufacturer and products are made, there’s no guarantee they’ll arrive in stores on schedule. Some brands that make seasonal products, for example, are producing those items when they can in 2022 and distributing months in advance. For Halloween this year, companies like General Mills (No. 12 on our Global 250) and Post Holdings (No. 97) sent their seasonal monster cereals (Count Chocula, Franken Berry, Boo Berry, Frute Brute, and Halloween Fruity Pebbles) to grocery stores in late July/early August, perhaps to avoid relying on an inconsistent supply chain to deliver closer to the holiday in September and October. Hershey (No. 22) and Boston Beer (No. 28 on our Top 50 Alcoholic Beverage Manufacturers list) followed suit by putting Reese’s Peanut Butter Pumpkins, and Jack-O Pumpkin Ale in stores over the summer.
Many of the companies on our Global 250 list this year made moves to expand their reach in the marketplace by either partnering with or acquir ing other companies. Mondelēz (No. 4) acquired Clif Bar for $2.9 billion, and also bought Ricolino candy from Grupo Bimbo (No. 14) for $1.3 billion;
2021 Rank 2020 Rank Ranking Change 2020/2021
Company Headquarters Major Industries
Major Brands
Global Retail Food and Beverage Sales ($Millions)
Number of Manufacturing Plants
201231 s Seoul Dairy Cooperative South KoreaDairy Products, Juices, IngredientsAnpan, Seoul Milk, Co eePoly, Ampang, reeve 1,133 4 202196 Kameda Seika Co. Ltd. Japan Snacks Kameda no Kaki no Tane, Tsumami Dane, Usuyaki 1,121 4
203218 s New Hope Dairy Co. Ltd. China Dairy Products
Sichuan Huaxi, Yangping Milk, Kunming Xuelan Milk 1,120 11 204165 Emami Ltd. India Health Products, Vegetable Oils Enami 1,115 3 205216 s Maeil Dairies Co. Ltd. South KoreaDairy Products, Baby FoodBaristar Rules, Maeil Milk, Absolute, Maeil Bio 1,112 7 206248 s National Beverage Corp. United StatesBottled Water, Energy Drinks
La Croix, Shasta, Faygo 1,107 13 207164 National Dairy Development Board India Milk, Vegetable Oils Wamul, Quality Mark, Dhara 1,104 208206 Itoham Yonekyu Holdings Inc. Japan Frozen Meats, Processed MeatsItoham, Yakituba, Niku Dango 1,102 4 209208 Shandong Luhua Group Co. Ltd. China Vegetable Oils Luhua 1,099 17 210213 s Mastellone Hnos SA Argentina Dairy Products La Serenísima, Yogurísimo, Danonino 1,096 7 211212 s Utz Quality Foods Inc.. United States Snacks Utz, Bachman, Zapp’s, Dirty Potato Chips1,089 11 212unranked NA Bestore Food Co. Ltd. China Snacks Bestore 1,089 213129 Tiger Brands Ltd. South Africa Processed Fruits and Vegetables, Baby Food, Soft Drinks Koo, Albany, Enterprise, Oros 1,074 5
214unranked NA Camil Alimentos SA Brazil Rice, Grains, Ingredients, Sugar, Fish Camil, União, Coqueiro 1,065 13 215220 s Tamil Nadu Cooperative Milk Producers Federation Ltd. India Dairy Products, Ingredients, Non-dairy Drinks
Aavin 1,057 4 216224 s Jiabao Group Co. China Ready Meals Jiabao 1,055 6 217unranked NA Laticinios Bela Vista Ltda. Brazil Dairy Products Piracanjuba, LeitBom 1,041 7 218245 s Roshen Kondyterska Korporatsia Ukraine Confectionery
Roshen, Bombonetti 1,041 8 219unranked NAHipp GmbH & Co. Vertrieb KG Germany Baby Food Hipp, Bebivita 1,041 220227 s Wonder Sun Dairy Co. Ltd. China Dairy Products, Baby Food, Non-dairy Drinks WonderSun, Anlicong, Wanda 1,033 24 221247 s Harry-Brot GmbH Germany Bread, Baked Products Harry, 1688 1,032 10 222232 s UCC Holdings Co. Ltd. Japan Co ee UCC, Shokunin No Co ee 1,027 9 223215 Coca-Cola Hellenic Bottling Co. SA Switzerland Carbonates, Juices, Iced Tea, Sports Drinks, Bottled Water Dobry, Rich, Pulpy Dobry, Moya Semya 1,019 14 224169 Bourbon Corp. Japan Snacks, Rice, Confectionery, Chocolate, Baking Products Bourbon 1,016 11 225unranked NALuohe Pingping Food Co. Ltd. China Snacks
Weilong 1,000 3 226unranked NAZhejiang Xiangpiaopiao Co. Ltd. China Tea Meco Fruit Tea, Fragrance, Lan Fong Yuen 990 4 227199 Johnsonville Sausage LLCUnited StatesMeats, Ready Meals, Sauces Johnsonville, Giddy Up 984 228unranked NA Kroger Co. United States Dairy Products, Baked Products, Cereals, Dressings, Sauces Home Chef 983 35 229241 s Carlsberg A/S Denmark Carbonates, Bottled Water Flash Up, Klebny krai, Taras Kvas 982 230unranked NAAlfred Ritter GmbH & Co. KG Germany Confectionery Ritter Sport 982 2 231221 JBS SA Brazil Frozen Meats, Poultry Seara, Swift, Friboi 977 31
232unranked NA Postobón SA Colombia Soft Drinks, Juices, Tea, Water, Energy Drinks Hit, Postobón, Colombiana, Crostal, Speed Max, Mr Tea 975 19
233unranked NA S&B Foods Inc. Japan Sauces, Ingredients S&B, S&B Torokeru Curry, S&B Stew, S&B Golden Curry 973 3 234unranked NA FCF Co. Ltd. Taiwan Fish, Seafood Bumble Bee, Clover Leaf, Brunswick 972
s Acqua Minerale San Benedetto SpA Italy Bottled Water, Juices, Carbonates San Benedetto 972 11 236223 Lorenz Snackworld GmbH Germany Sweet and Savory SnacksCountry Chips, Crunchips, Crustics, Naturals 970 6
Ready Pac Produce Inc. United States Vegetables, Salads Ready Pac 961 4
NA Zott GmbH & Co. KG Germany Dairy Products, Cheese Zott, Jogobella,
Dual use TVP and HMMA extruder
Plant based ingredient material
Strict adherence
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High accuracy loss-in-weight feeding
Proven industry leader with installed TVP
meat analogue systems
Worldwide service
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Our dual use TVP and HMMA extruder for plantbased products gives developers and manufacturers of these products the highest flexibility.
John Sheehy Global Key Account Manager Plant Based Foods
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Email our expert at: info@coperion.com
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+ Widest variety of feeding and material handling solutions in the industry
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Safe food and ingredient handling. Feeding, weighing and conveying systems provided by Coperion and Coperion K-Tron o er the highest in e ciency and safety standards for plant-based food processing applications. www.coperion.com/foodtransfer
InBev
NV
A/S
Resources Holdings Co. Ltd.China
Ready-to-drinkBudweiser, Bud Light, Brahma, Corona, Skol, Harbin, Castle52,255
Ready-to-drinkHeineken, Tecate, Tiger, Kaiser, Nova, Amstel
Ready-to-drinkTurborg, Carlsberg, Baltika, Kronenbourg, Wusu 12,264
Blue Sword, Kingway 10,782
Coors Brewing Co.United StatesBeer, Ready-to-drinkMiller, Coors, Carling, Keystone, Staropramen, Blue Moon8,493
Brewery Co. Ltd.
Laoshan, Hans Beer 7,979
-Asahi Group Holdings Ltd.JapanBeer, Spirits, Ready-to-drinkAsahi, Zubr, Peroni, Velkopopovicky Kozel, Zubr 6,521
Diageo PLC
KingdomSpirits, Ready-to-drink
910 s Constellation Brands Inc.United States Beer, Wine, Spirits, Ready-to-drink
Beijing Yanjing Brewery Co. Ltd.China Beer
Smirno , McDowell’s, Johnnie Walker, Senator, Tanqueray 4,600 138
Modelo, Corona, Svedka, Pacifico, Casa Noble, Woodbridge 3,459 44
Yanjing, Liquan, Huiquan 3,070 37
-Kirin Holdings Co. Ltd. JapanBeer, Ready-to-drinkKirin Tanrei, Nodogoshi, Kirin Ichiban Shibori, Hyoketsu2,742
1212 Thai Beverage PLC ThailandBeer, Spirits Saigon, 333’ export, Chang Beer, Ruang Khao 2,610 21
1313 -Suntory Holdings Ltd. Japan Beer, Wine, Spirits, Ready-to-drink
1415 s San Miguel Corp. Philippines Beer
1514
Suntory, Kinmugi, -196°C Strong Zero, Yamazaki 2,502 14
Red Horse Beer, San Miguel, San Miguel Light, San Miguel Cerveza Negra 2,339 100
Castel Groupe France Wine, Ready-to-drinkSt George, Castel, Nocal, Maison Virginie, Aimé Roquesante2,317 24
1616 -Cervejaria Petrópolis SA Brazil Beer, Spirits Itaipava, Crystal, Nordka 1,844 5
1717 Anadolu Group Turkey Beer Efes, Bely Medved, Gold Mine Beer 1,613 61
1819 s Pernod Ricard Groupe France Wine, Spirits, Ready-to-drinkImperial, Royal Stag, Absolut, Havana Club, Chivas1,514 101 1921 s Cía Cervecerías Unidas SA Chile Beer, Spirits Cristal, Escudo, Schenider, Royal Guard 1,421 23 2020 Hite Jinro Co. Ltd. South KoreaBeer, Wine, Spirits Chamisul, Hite, Terra, Filite 1,407 6 2118 Oetker-Gruppe Germany Beer, Wine, Spirits, Readyto-drink Radeberger, Jever, Binding, Henkell 1,360 17 2222 -Guangzhou Zhujiang Brewery Co. Ltd.China Beer Zhujiang, Supra Beer 1,226 20 2326 s E&J Gallo Winery Inc.United States WineBarefoot, Carlo Rossi, Twin Valley, Peter Vella, Liberty Creek1,179 19 2425 s Grupo Mahou-San Miguel SASpain Beer San Miguel, Mahou, Mixta Shandy, Alhambra Especial1,151 5 2524 s Boon Rawd Brewery Co. Ltd.Thailand Beer Leo, Singha Beer, Singha Light Beer, Thai Bee 1,112 8 2627 s Blue Ribbon Intermediate Holdings LLCUnited States Beer Pabst, Old Milwaukee, Colt 45, Jacob Best 1,025 27unranked NA Delta Corp. Ltd. ZimbabweBeer, Spirits, Wine Chibuku, Umqombothi, Castle 992 12 2830 s The Boston Beer Co. Inc.United StatesBeer, Ready-to-drink
Samuel Adams, Twisted Tea, Truly Spiked & Sparkling, Angry Orchard 928 7 2929 -Mark Anthony Brands Ltd.IrelandSpirits, Ready-to-drinkWhite Claw Hard Seltzer, Mike’s Hard Lemonade, Cayman Jack 878 3028 Sapporo Holdings Ltd. Japan Beer Sapporo, Mugi To Hop, Goku Zero, Okanagan 751 12 31unranked NAPaulaner Brauerei GmbH & Co. KGGermany Beer
Paulaner, Orginal Münchner, Hacker Pschorr 690 1 3233 s Distell Group Ltd. South AfricaWine, Spirits, Ready-to-drinkHunter’s, Savanna, 4th Street, Bernini 677
3331 Paulaner Brauerei GmbH & Co. KGGermany Beer
Paulaner, Orginal Münchner, Hacker Pschorr 655 1 3438 s Cia da União de Cervejas de Angola SAAngola Beer Cuca, Nova Cuca
Bacardi & Co. Ltd. BermudaSpirits, Ready-to-drinkBacardi, Martini, Grey Goose, Havana Club
Bitburger Braugruppe GmbHGermany
Shunxin Agriculture Co. Ltd.China
Krombacher Brauerei Bhd
König Pilsener, Köstritzer, Wernesgruener
Niulanshan
Guo
Cargill (No. 100) and Continental Grain purchased Sanderson Farms for $4.5 billion, then merged it with Wayne Farms, a subsidiary of Continental Grain; Sapporo (No. 31 on our Top 50 Alcoholic Beverage Manufacturers list) bought Stone Brewing for $165 million; J&J Snack Foods acquired Dippin’ Dots for $222 million; Hershey purchased Dot’s Pretzels and its co-manufacturer for $1.2 billion; and Coca-Cola bought full control of Bodyarmor for $5.6 billion, making it Coca-Cola’s largest brand acquisition ever.
Kellogg (No. 13) made headlines not through acquisitions, but by dividing itself into three di erent companies in 2022, focused on snacking, cereal, and plant-based foods.
Despite the rising popularity of plant-based meats and alternative proteins—the global market is esti mated at $7.9 billion, with the U.S. market at $1.4 billion—it’s barely a blip compared to traditional meat sales, which are about $1.4 trillion globally.
It has been a busy year for meat companies, with Tyson Foods (No. 36) posting Q2 sales of more than $13 billion, a YOY increase of 16%. Tyson also opened
a new, highly automated case-ready meat plant in Eagle Mountain, Utah. Case-ready meats are trend ing in retail due to the lack of labor in many grocery meat departments.
Other notable news for meat companies in 2022 had to do with pricing. The largest foodservice distributor in the world, Sysco, is suing the four biggest beef producers for alleged price fixing, which includes Tyson, Cargill, JBS (No. 231), and National Beef Packing. Grocery chain Giant Eagle also filed a similar suit against the same four companies this summer. In an earlier suit filed by a group of grocers and wholesalers against the same four brands, JBS settled its portion for $52.5 million in February, but admitted no wrongdoing.
Smithfield Foods settled a $42 million suit in July for pork price fixing filed by a group of restaurant owners and caterers (Smithfield also settled a similar suit in 2021 for $83 million).
Food and beverage recalls spiked in 2022, possibly due to an ongoing labor shortage coupled with inexperienced new employees working in food manufacturing facilities.
Abbott Laboratories (No. 61 on our Global 250) made headlines this year after Cronobacter found in the company’s baby formula brands manufactured at its Sturgis, Mich., plant (Similac, Alimentum, and EleCare) prompted a nationwide recall and subsequent shortage. Production at the Sturgis facility was also temporarily shut down while the FDA investigated, increasing the scarcity of baby formula further.
Other high-profile CPG recalls this year include:
• Jif peanut butter products (manufactured by J.M. Smucker, No. 63 on our Global 250) for possible salmonella contamination
• Capri Sun (Kraft Heinz) Wild Cherry juice blends for possible cleaning solution contamination
• Home Run Inn frozen pizzas for possible metal contamination
• Wayne Farms ready-to-eat chicken breast fil lets due to possibly being undercooked
• Premier Protein ready-to-drink shakes for pos sible Clostridium botulinum contamination
• Daily Harvest French Lentil + Leek Crumbles for possible issues with the ingredient tara flour causing illness
• Big Olaf Creamery ice cream for Listeria mono
cytogenes contamination (its Sarasota, Fla., production plant has been shut down)
• Built Brands’ Banana Cream Pie Pu s protein bars for possible E. coli contamination
• Skippy peanut butter for possible inclusion of stainless-steel fragments from manufacturing equipment
• Kinder chocolate (made by Ferrero, No. 10) for possible salmonella contamination
Some consumer habits accelerated by the pandemic are still here in 2022, and that includes online grocery shopping. In July, total U.S. online grocery sales increased 17% YOY to $7.8 billion, according to research by Brick Meets Click. More than 68 million households bought groceries online in July, up 3% YOY.
While the pandemic is waning, it’s still a factor for many in deciding to shop for groceries online in 2022. “COVID-19 concerns coupled with inflation have forced a tradeo between two fundamental desires for shoppers—not getting infected and not paying more than necessary,” says Brick Meets Click’s David Bishop.
Haskell, a design-build architecture, engineering and construction firm, was selected by United Airlines to update their Newark, NJ, catering kitchen by renovating a 218,000 SF brownfield warehouse into a state-of-the-art, food safe facility. The collaborative e ort was successful and we are proud to celebrate this award with our project team and partners.
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The latest designs ease concerns about labor availability, food safety, and sustainability, making the ubiquitous equipment easier to use and easier to clean.
FOOD AND BEVERAGE PROCESSORS are being challenged by labor shortages, the threat of product recalls or losses due to contamination, and the growing demand for sustainable operations. As a result, the selection criteria are changing for the pumps and valves that are ubiquitous in nearly every processing plant.
Suppliers are evolving their products to meet these demands, with new designs that require fewer skills to operate and maintain them, can be cleaned more thoroughly, and consume less water and energy.
“All of these market challenges, like the huge workforce reductions that came with the COVID-19 pandemic, are forcing processors to do more with less,” explains Michael David, manager of pump and heat exchange solutions for Central States Industrial (CSI). Though CSI doesn’t make pumps or valves itself, it acts as a distribu tor and provides installation and engineering services to the food and beverage industry. “Frankly, we’re seeing a slowdown in the uptake of new technology. Companies want to get more out of the technology they already have, and that means learning how to optimize their processes. They’re also trying to compensate for the labor they can’t get by replacing existing technology with pumps that are
easier to maintain, can be cleaned automatically and faster, and can handle di erent product viscosities on the same production line.”
No matter what types of pumps or valves they choose, the primary goals for processors continue to be increased productivity and reduced downtime and operating costs. The di culty in finding skilled workers is one reason for the continuing adoption of remote monitoring technologies that can alert oper ators before components fail.
Moving to electric Graco has made significant advances with its pump lineup in an e ort to provide the equipment capabilities that processors are demanding. “We’ve primarily produced pumps operated with pneumatics, but we’re now moving to electric products that reduce energy consumption and enable us to provide smarter controls as well as condition monitoring tools to deliver the feedback necessary for preventive and predictive maintenance,” explains Je rey Sha er, senior product manager and North American sales manager for Graco’s Process division.
Graco’s Quantm all-electric diaphragm pumps have smarter controls, making them suited for condition monitoring.
Food and beverage processors are looking for more energy-e cient pump designs.
The Wilden Saniflo Hygienic pump reduces compressed air costs by up to 60%.
The company is introducing an entirely electric line of diaphragm pumps, the Quantm series, in the fourth quarter of this year. “This is an important technology breakthrough,” Sha er says. “Until now, electric diaphragm pumps were big, bulky, and much more expensive than their pneumatic counterparts. These new products are as easy to service as existing Graco pumps but will greatly reduce operational costs for end users and contribute to a smarter, more sustainable facility.”
A candy and energy bar maker is using Graco’s new electric pumps to achieve better control of its production processes, which is saving on ingredients, according to Sha er. “While the pump’s initial cost is higher, the lifetime costs will be significantly lower because it uses less energy than the pneumatic pumps,” he says. “It’s also quieter for an improved working environment. In addition, the improved control and remote monitoring capabilities mean it requires less hands-on worker involvement for maintenance if connected to a control system.”
Condition monitoring is proving to be an e ective tool for reducing both downtime and maintenance costs. By enabling maintenance sta to focus on tasks that prevent unplanned equipment failures, companies can significantly reduce the time and expense of routine maintenance activities that ultimately deliver little value.
A new subscription-based condition monitoring and cloud gateway service introduced by Alfa Laval detects machine vibrations and other operating information, providing an early warning of potential equipment failure. It gives plant operators remote access to data from pumps and other rotating equipment on processing lines, including actual runtime, trend analysis, and time to next service.
Acting as a gateway communicating via Bluetooth, CM Connect can link up to 10 Alfa Laval CM wireless vibration monitors and transmit the data to the cloud for review and analysis, so operators can make informed maintenance decisions. Advanced vibration analysis enables early detection of any deviation from pre-set equipment threshold values.
Fewer resources, less waste Reducing resource consumption and the related waste from production and cleaning processes has become a priority, particularly among multinational corporations that have made a commitment to achieving sustainability goals, according to Jim LeClair, fluid handling commercial manager for Alfa Laval.
“Pumps make up over 50% of a typical pro cessing plant’s energy costs,” he explains, “so customers are demanding products that use less energy and produce fewer CO2 emissions. Many companies are also committing to zero waste goals, so they want water-e cient pumps, valves, and cleaning processes that produce less waste. Alfa Laval, for example, o ers valves that use significantly less water to accommodate these requirements.”
The company also recently launched a refreshed version of the Alfa Laval ThinkTop, its valve sensing and control unit for hygienic valves used in the dairy, food, beverage, brewery, and pharmaceutical industries. This second-generation control unit o ers fast and intuitive setup and commissioning and provides operators with enhanced 360-degree LED visual status indication.
A CM Connect wireless vibration monitor is attached to an Alfa Laval DuraCirc circumferential piston pump, helping operators make informed maintenance decisions.
The redesign repositions the Gore Vent for greater durability and less risk of water ingress. The more compact design features burst seat cleaning functionality that significantly reduces water and cleaning agent con sumption during clean in process (CIP). A QR code provides easy online access for maintenance sta to support materials and direct support. The ThinkTop fits on any Alfa Laval valve, making retrofits easier.
The war in Ukraine, high inflation, and climate concerns are having an economic impact on processors, changing priorities for product specification in both Europe and the U.S. “We’ve seen a higher level of focus on automation to increase e ciency standards to compensate for these e ects,” says Russell Jones, commercial sales manager for pumps at Alfa Laval.
“Manufacturers are doing everything possible to avoid product recalls or losses,” says Tom Zuckett, Americas Northeast regional sales manager for PSG, a Dover company. “That’s why we’ve designed our Wilden Saniflo Hygienic Series air-operated double-diaphragm (AODD) pumps to be highly cleanable and drainable.”
A free-draining flow path enables CIP capability. “Additionally, when equipped with Wilden’s PureFuse integral pistol diaphragm technology, the com mon bacteria trap in standard diaphragms is elim inated,” Zuckett says. “Pure-Fuse diaphragms are also much easier to clean between product change overs and have a much longer service life. Because the diaphragm doesn’t hold back fluids, bacteria traps are eliminated.”
The AODD pumps also help in production environ ments commonly manned by new operators, Zuckett points out. “These operators have fewer skills, so air-operated systems are easier for them; they’re more forgiving,” he says.
Energy e ciency is also a factor for the Wilden Saniflo Hygienic Series pumps. An innovative air dis tribution system reduces compressed air costs by up to 60%, Zuckett notes.
While centrifugal pumps are the most widely used in the food and beverage industry, Zuckett says, rotary style positive displacement pumps come in second. “Their drawback is that they need to be taken apart to be cleaned,” he says. “That’s one reason why twin-screw pumps, which can be cleaned in place, are increasingly popular. Since motor speed can be controlled with a variable-frequency drive, processors don’t need to buy a second pump to produce the higher speeds required for the cleaning process.”
AODD pumps are earning a growing share of the marketplace. This style of pump o ers gentle handling and can handle large solids, such as found in the making of wine, yogurt, or jams, or in the vis cous syrups used for soft drinks and energy drinks.
Labor shortages continue to trouble every industry sector, and this factors heavily in cleaning and maintenance of pumps, notes Chris Stevens, CEO of Unibloc Hygienic Technologies. “Sanitation and maintenance demand a significant amount of time and attention,” he explains. “Within a meat and poultry processing plant, for example, an entire eight-hour shift is typically devoted to cleaning and sanitation. During this shift, pumps must be disassembled, cleaned and then reassembled, with the goal of accomplishing this process as quickly, safely, and e ciently as possible.”
This complex cleaning and maintenance cycle requires specialized tools and causes significant wear and tear on the pump, causing up to 95% of all pump damage. Parts can be lost or pumps damaged due to incorrect reassembly, which in turn results in the need for more replacement parts and extra maintenance.
“This makes it a priority for the pump and valve industry to consider both pump maintenance and performance to be critical design factors,” Stevens says. “A pump with fewer parts makes the entire process of disassembly, cleaning, and reassembly easier and quicker without ignoring performance and while adhering to the highest sanitation standards.”
He points to Unibloc’s Flotronic “One Nut” pump as one example. “While a typical air operated double diaphragm pump will take two to three hours to disassemble, clean, and put back together, an operator can complete the same process on a one-nut pump, which has one bolt and one washer, in 15 minutes or less,” he says. “Reassembly is a simple process and requires no special tools. This means fewer parts to potentially
Guacamole and Salsa
Thanks to Avure HPP, avocado has a shelf life of up to 45 days.
HPP offers the great taste and fast preparation times that consumers demand.
Vegetables
Fresh-picked taste and long shelf life. No chemicals or preservatives.
Seafood
Our seafood machine boosts yield and reduces costs.
Avure HPP machines
process most of the world’s HPP treated juice!
Boost shelf life. Ditch additives. And dip into new markets with HPP.
Meat
Safe and great shelf life.
Pet Food
HPP offers health benefits for pets.
Baby Food
Convenient, all natural with no additives or preservatives for little ones.
Extend shelf life for cheese, sauce, dips, and milk and other beverages.
High Pressure Processing is a natural method of food pasteurization that uses pure cold water, and up to 87,000 psi (6,000 bar) to inactivate pathogens, and dramatically extend shelf life. No chemicals No heat.No additives Learn more about how high-pressure processing works.
Without tools, cleaning crews can quickly open the Unibloc clean-out-ofplace (COP) pump cover and swing it aside.
lose or misplace, fewer challenges for the labor force, and a much swifter cleaning process without sacrificing performance or sanitation.”
Other Unibloc pumps designed for ease of cleaning include the compact Flotronic Slimline, which is e ective in the transfer of highly viscous products such as dairy and mayonnaise. It features a crevice-free design with no internal welding to help facilitate thorough cleaning. A Texas-based salsa manufacturer, Stevens notes, found that a Slimline stainless-steel pump was able to save
them an hour of time in the daily sanitation process compared to an AODD pump.
Verder Hygienic Pumps makes a wide range of pump types, including high-e ciency centrifugal, twin screw, and peristaltic pumps. “Many fruit and vegetable processors are switching to sanitary style pumps in applications where previously a less hygienic pump or conveyor was always used,” explains Michael O’Grady, hygienic sales manager.
Though pumps might be a wise choice for these processors due to the high maintenance costs of conveyors, some were choosing ine cient pumps, O’Grady notes. In some cases, pumps were made of cast iron, which is not compatible with some of the acids released in the cutting process. Even pet food processors are switching to sanitary pumps from the less expensive industrial pumps they used in the past, he adds.
Manufacturers continue to make more pumps using the food-grade materials necessary for food and beverage applications. Verder’s twin screw Packo Fruit & Vegetable pumps, which are used for processing large particulates such as fruits,
Elevators combine vertical and horizontal transportation of bulk materials in one integral unit.
Ryson Bucket Elevators are designed for gentle handling and well-suited to transport a broad range of bulk products. Our signature feature is that they are completely enclosed with overlapping pivoting buckets, that prevent spillage and helps mitigate foreign debris.
Their modular design enables us to customize with ease. They can be configured with multiple inlets or outlets that can individually be emptied. The design makes them easy to install and modify. Available in three standard bucket sizes, yielding capacities up to 300, 700 or 1,800 cubic feet per hour. They can also be delivered in powder-coated carbon-steel, stainless-steel or washdown versions.
No matter the application, the Ryson team is up to the challenge of finding solutions for your conveying needs. For application assistance or more information, give us a call or visit www.ryson.com
FDS twin-screw pumps can be cleaned in place, so they do not need to be taken apart for cleaning.
vegetables, shellfish, and pasta, are one example.
“Due to their e ciency, they can pump whole fruits and vegetables like limes or potatoes without damaging them,” O’Grady says. “They’re also electro-polished, enhancing their CIP-ability.” The company’s Verderflex line of peristaltic pumps are also made with food-grade materials, with processors finding them a low-cost alternative to lobe and screw pumps.
Fristam Pumps USA has seen an increase in demand for pumps in prepared food applications such as sauces, condiments, soups, or canned foods, according to Hannah Ihlenfeldt, bilingual applications engineer for the supplier.
“Maybe it’s a result of the pandemic, which had more people eating at home and shopping at grocery stores instead of eating out,” she says.
Fristam’s recently developed line of FDS twin screw pumps fits well with this type of application. “Especially in plants which use batch processing, the FDS is very useful, since it can pump products with di erent viscosities and densities on the same processing line,” Ihlenfeldt says. “Another advantage is its gentle handling of product, such as soup with chunks of vegetables or fruit in a juice cocktail.”
She points to one FDS customer using them on their soup cookers, where they can handle thicker cheesebased soups, as well as thin broths and food pieces. “This type of pump can also be used for CIP, eliminating the need for extra pumps and valves.”
Alfa
Newsome Drive
Fristam
Unibloc Hygienic
Verder Hygienic Pumps
Visit Us in the Processing Zone Booth: LU-7636
HPP for Food and Beverages - like freshly processed or even better?
High Pressure Processing (HPP) using cold water is an in-pack, non-thermal process for reducing spoilage and pathogenic microorganisms in fresh-made food products, like cold-pressed juices, smoothies, protein products, dairy and ready-to-eat products.
HPP has the following advantages compared to thermal preservation methods:
• Simply tasty: HPP is a non-thermal process, which means that the original taste, nutritional value and texture as they are not treated with heat. Nor do any new compounds form. The result is products with a fresh and natural taste.
• Simply safe: Hydrostatic pressure works instantly and homogeneously throughout the product reaching every cell of harmful microorganisms – all without altering the product.
• Simply longer shelf life: It only takes a few minutes to eliminate harmful microorganisms and reduce the activity of oxidative enzymes that deteriorate the quality of fresh food & beverages.
• Simply clean: The process applies only physics – no chemicals – resulting in clean label and organic food and beverages.
With over 90 years of experience in high pressure technologies and equipment, UHPT offers a range of HPP systems matched to the individual requirements of food producers - from pilot plants with small production requirements (~200 l/h) to large-industrial scale plants (~3,200l /h).
We look forward to meeting you at Pack Expo 2022 from October 23rd - 26th. We are located in the Processing Zone in Lakeside Upper at Booth LU-7636.
For more information, contact: David Benevento (david.benevento@thyssenkrupp.com)
Website: www.uhde-hpp.com
The largest packaging and processing event in North America is back in-person for the first time since 2018.
THE LAST TIME PACK EXPO International was in Chicago, it was two years before the pandemic, and concerns like supply chain reliability, auto mation, ingredient availability, and a labor shortage might have been on the industry’s collective radar but weren’t the urgent challenges they are today. This year, as the event returns in-person for the first time since 2018, those top-of-mind issues will be addressed in a multitude of practical ways, giving processors the tools and strategies they need to overcome those operational hurdles.
PACK EXPO International will take place Oct. 23-26 at Chicago’s McCormick Place, with more than 2,100 exhibitors displaying the latest technol ogies in packaging and processing for more than 40 vertical markets in 1.2 million net square feet of exhibit space, as well as 100+ free educational ses sions located on the show floor.
That’s a lot of territory to cover, so to help narrow it down, here are some of the must-see attractions for food and beverage processors at PACK EXPO International 2022.
In today’s manufacturing environment, processing and packaging are integrated systems, making it critical to bring both solutions under one roof. The Processing Zone returns this year, showcasing the latest industry breakthroughs and widest variety of food and beverage processing equipment. Start your search for front-of-the-line solutions to in crease e ciency, achieve total system integration, and ensure safety. Visit The Processing Zone in the Lakeside Center (upper level) at McCormick Place, Booths LU-7000 to LU-7799.
Adding to the Innovation Stages in the North Hall, new at PACK EXPO International is the Processing Innovation Stage, focusing on the new est food and beverage processing breakthroughs.
The Processing Zone returns to PACK EXPO International this year, showcasing the latest industry breakthroughs and widest variety of food and beverage processing equipment. Attendees will have an up-close view of front-of-the-line solutions for their operations.
Conveniently located in the Processing Zone (Booth LU-7130), no additional registration is required for attendees to take a break from the show floor and learn something new. Education sessions will take place there Sunday through Tuesday (Oct. 23-25).
On that Innovation Stage, ProFood World will rec ognize food and beverage processors excelling in the areas of sustainability and manufacturing break throughs. On Sunday at 4 p.m., Editor-at-Large Joyce Fassl will present our Sustainability Excellence in Manufacturing Awards. Stop by to hear what exec utives from Conagra Brands, Smithfield Foods, and Bob’s Red Mill Natural Foods have to say about their winning e orts in sustainability. Then on Tuesday at
PACK EXPO International has more than 2,100 exhibitors display ing the newest technology in packaging and processing for over 40 vertical markets in 1.2 million net square feet of exhibit space, plus dozens of free educational sessions located on the show floor.
4:15 p.m., we’ll present our Manufacturing Innovation Awards to Sugarlands Distilling and United Airlines Catering Kitchen Operations for being at the forefront of cost-e ective and e cient food and beverage processing.
Also new this year is the Emerging Brands Summit, brought to you by PMMI Media Group. The Emerg ing Brands Summit is a one-day event featuring educational content and tabletop exhibits aimed at founders and leaders of start-up manufacturing companies looking to scale their brands to larger production through in-house facility build-out, or outsourced relationships with contract manufactur ers and packagers.
Exhibitors will include packaging machinery, packaging materials, processing equipment, and contract manufacturing and packaging. The Emerging Brands Summit will take place Sunday, Oct. 23, from 8:45 a.m. to 5:30 p.m., in Room S-100 at McCormick Place.
Go PACK to the Future in an interactive exhibit new to PACK EXPO International. PACK to the Future celebrates the role of packaging and processing through history, and the impact it is poised to have on our future.
This curated exhibit includes historical equipment, materials, and photographs spanning 250 years, journeying through the evolution of packaging and
Venue: McCormick Place, Chicago, Ill.
Dates: Oct. 23-26, 2022
Hours: 9 a.m.-5 p.m. Sunday, Monday, and Tuesday; 9 a.m.-3 p.m. Wednesday Register: www.packexpointernational.com
processing, and highlighting how the industry devel oped alongside civilization. PACK to the Future is located in the West Building at Booth W-20001.
While there, don’t miss the nearby PACK to the Future Stage (Booth W-20025) for thought-provoking sessions on groundbreaking industry advancements, with presentations by industry experts on advances in pharmaceutical and cannabis packaging, wireless factory automation, sustainable alternatives, smart packaging, artificial intelligence, and more.
PACK EXPO’s annual event, PACK gives BACK, returns to PACK EXPO International, and for the first time in its Chicago history, the event will be a musical concert, performed by the multi-mil lion-selling rock band Styx at McCormick Place.
Styx has sold more than 20 million albums, including four consecutive triple-platinum records from 1977 to 1981. The band’s catalog contains over four decades of hit songs, including Come Sail Away, Mr. Roboto, Too Much Time on My Hands, Lady, Babe, The Best of Times, Fooling Yourself, Renegade, and Blue Collar Man.
Tickets to the concert are $95 each. Or take advantage of a 10-tickets-for-the-price-of-nine deal to treat customers or business partners to the show. Guests can enjoy pre-show networking with refreshments and appetizers before the concert. PACK gives BACK is sponsored by Rockwell Automation and proceeds benefit the PMMI Foundation, which provides financial support for packaging and processing education in the U.S. and Canada.
For a more complete processingfocused preview of PACK EXPO International, check out The Processing Zone Showcase.
Built to simultaneously freeze di erent products with di erent freezing times, the AATFreezing freezer has a throughput up to 30 tons/hr. The BoxFreezer/VRT tunnel carton freezer features cooling systems with transverse airflow to cover a greater sur face area with cold air. Cartons or crates are rolled into the system; no carton or box is ever pushed. The prod uct carriers (airflow shelves) are designed to be cooled down from all sides by cold airstream flows. Multiple freezing zones within the freezer can be used, with unneeded zones switched o .
Advanced Equipment | advancedfreezer.com
Operated using glycol or CO2 refrigerants, the Heatcraft cooler provides extended capabilities required by large industrial cool ing/freezing and cold storage applications. Built on a durable chassis, the warehouse unit cooler features installation- and ser vice-friendly features, such as composite hinged and removable access panels, an easy-service motor mount, and a hinged drain pin. It is available in air, electric, and hot gas defrost versions.
Heatcraft Refrigeration Products | heatcraftrpd.com
Designed with economy, e ciency and hygiene in mind, the IQ cryogenic freezer o ers continuous high throughput on a broad range of foods with easy clean up. Ten-foot modular sections make it eld expandable with a minimal capital investment. A remote monitoring system allows for trouble shooting from afar.
Increase your IQ and pro ts . . . visit airproducts.com/IQ or call 800-654-4567 (code 9050)
airproducts.com/IQ
Combining variable speed technology with an auto tank leveling algorithm, Delta T Systems chillers have integrated redundant VFD pumps for both hot and cold water processes. The modular units include an integrated PLC and HMI for redun dancy. Available in water-cooled and air-cooled systems, the chillers support up to 14 units in parallel with a total cooling capacity of up to 840 tons.
Delta T Systems | deltatsys.com
Designed for walk-in cooler and freezer applications, the Danfoss Climate Solutions unit cooler features cross-rifling inside the heat exchanger tubing to maximize air turbu lence. It features a variable-speed-capable fan motor, stainless-steel slotted brackets in both front and back, and an electric defrost coil design with coil-embedded heaters. The Optyma cooler has a capacity range with 6 and 4 fpi. Low/medium- and high-profile models are available.
Danfoss Climate Solutions | danfoss.com
Using a high-speed airstream from above and below products, the OctoFrost impingement freezer achieves quick freezing in a few min utes. Multiple straight belts allow processors to run di erent products at each level. The com pact, multi-level unit is suitable for freezing thin food products, such as hamburgers, fish and chicken fillets, shrimp, and dumplings, and for crust freezing prior to slicing larger products.
OctoFrost | octofrost.com
Pressure Processing
non-thermal
technique
which products, already sealed in their final package,
subjected to a high level of isostatic pressure
by water.
As a post-packaging process, HPP requires the manual loading of packaged products into baskets. Automation & material handling solutions allow manufacturers to improve processing e ciencies, while also reducing labor costs and heavy loading, which can result into injuries.
Based on high-temperature heat pumps, the GEA heat pump system recovers waste heat from the exhaust air or other plant cooling processes. With the GEA AddCool system, warm water flows through an evaporator containing liquid CO2 that absorbs the water’s heat as it vaporizes. Passing through the compressor, the gaseous CO2 is further pressurized, resulting in a commensurate rise in temperature and transferable energy, which is used to heat up the air in the spray dryer. As a result, the CO2 refrigerant cools again and moves through an expansion valve that reduces the gas’s pressure, further lowering its temperature. The hot air for use in the dryer is produced at the same time as cold water, which can be channeled to chillers elsewhere in the plant.
GEA
Built for processing meat, poultry, and alternative proteins, the Urschel dicer creates 2D dices, strips, or shreds from product of a predetermined thickness. The belt-fed M VersaPro (MVP) 2D dicer has 12-in. infeed and takeaway belts that work together for even transitioning of product and discharging into totes. An IP69Kcertified electrical enclosure features a double-sealed door for protection during washdown. An optional fluted crosscut is driven by a 5 hp (3.7 kW) motor equipped with a variable-frequency drive. An available intuitive touchscreen HMI option gathers data; monitors machine components, including sensors and amperage; adjusts operating speeds; and saves recipes. Urschel Laboratories | urschel.com
Compatible with the Deco-Mate, the Unifiller decorating system has an intuitive interface to simplify operator use. The Electro-Mate automated system includes an onboard computer to fine-tune settings and save recipes. Capable of creating shell borders and other decorations, it can be used with round or sheet cakes.
The Munson Machinery vee cone blender features two inclined cylinders mounted on pillow block bearings that rotate end-over-end at 30 rpm, causing bulk material to fall, converge, and divide with each rotation, typically achieving consistent blends in 15 to 30 min. Able to blend materials with bulk densities up to 100 lb/ft3 in capacities up to 8 qt, the Model VB-.25-SSXHDI laboratory-sized blender is equipped with an independently powered intensifier bar that breaks up soft agglomerates; a dispersion bar that sprays liquid additions onto the moving materials also is available. Housed in a safety-interlocked polycarbonate enclo sure with lifting handles, the unit is constructed of carbon steel with stainlesssteel material contact surfaces finished to industrial standards. Munson Machinery | munsonmachinery.com
The Bastian Solutions robotic system combines advanced AI, machine vision, end-of-arm tooling, a six-axis robot, and seamless software integration to turn a GTP system into an e cient GTR solution. As new products are introduced, the SmartPick order fulfillment sys tem AI software builds a library of objects it has handled, along with optimal picking informa tion, which is shared across the entire fleet, allowing the robots to continuously learn from each other and improve the system’s accuracy. The AI directly inter faces with Bastian Solutions intralogistics software, allowing the cells to run with autonomy.
Bastian Solutions bastiansolutions.com
Constructed entirely of stainless steel, Ezquerra round can seamers come in versions from two-head models for slow production up to six-head units that run at speeds up to 500 cpm. The Somme Series Q seamers feature a straightline infeed table, single-roll cover feeder for end feeding, and LED-illuminated seaming area. The CE-compliant enclosure has an HMI integrated into the structure by a rotary arm. Seamer options include undercover gassing/ steam injection, motorized height adjustment with an HMI display, a topper device to control can head space, and a lid feeding extension. Palmabriz Industries | palmabriz.com
Devised to accommodate frequent recipe changes, the Gericke controller automates control over weighing, dos ing, and feeding from up to four feeders on up to four di erent processing lines from a single HMI screen. The GUC-F universal feeder controller is preconfigured based on the type of feeder or feeders, required modes of opera tion, and use of frequency converters for easy installation and setup. Potential software updates, upgrades, and expanded capabilities may be provided over the air by Gericke. The system can be installed with new feeders or retrofitted onto existing Gericke feeders. Gericke USA | gerickegroup.com
more
full, partial,
for
Heated either electrically or with gas, the PPM Technologies continuous snack frying system o ers cook times of 10 to 90 sec. A conveyor feeds product into the fryer, which is then compartmentalized within the rotating wheel’s flight cavities and submerged in the low-volume oil bed before being carried up and out of the discharge end of the fryer. The Roto-Cook fryer includes a clean-in-place sys tem, low-level oil detection, and a telescopicstyle exhaust stack that lifts o . Applications include pellets, plant-based proteins, tortilla chips, pork rinds, extruded snacks, and more.
Technologies | ppmtech.com
Designed to gently mix fria ble solids, abrasive mate rials, and shear-sensitive products, the Ross vertical blender con sists of a low-speed auger that orbits the periphery of a conical vessel. Product from the top portions of the batch cascade to the bottom, while blending with material being drawn upwards by the auger. The steep-angled vessel allows the blending of batches as small as 10% of the maximum working capacity. In addition to solid blends, the blender handles wet applications, such as flowable slurries and pastes. Available in lab-scale to fullproduction models, it can be jacketed for heating or cooling with water, oil, or steam.
Charles Ross & Son | mixers.com
Built to facilitate product settling of filled, open-flap cor rugated cases, Multi-Conveyor settling conveyors feature a series of square shafts strategically placed in an o set position underneath the flat top belting, which causes the motion required for the settling process. They have a mildsteel, bolted construction, and an open-frame design that uses fixed and adjustable stainless-steel flat bar guide rail brackets for double-high extruded-aluminum guide rails. Each section is comprised of about 8-ft x 12-in. straightrunning plastic modular belting. Stationary H-style tubular support weldment with adjustable articulating feet and a single bolt mounting tab for floor anchors stabilizes each conveyor section.
Multi-Conveyor | multi-conveyor.com
Eriez
sugar,
bulk metering
other
Steam Boilers
earned a reputation as the world-leader through innovative technology that addresses specific user needs, while respecting our environment. These include a compact design for easier installation, operation and maintenance; On-Demand Steam (full steam in less than five minutes); Loadfollowing technology that provides only the steam you need when you need it;
that can adjust to your requirements, and best-in-class safety.
The Emerson machine visualization solution is designed with projective capacitive touch screen technology that allows users to inter act with the visual display with 10-point multitouch capabilities, such as swipe, pinch, or zoom, to move to the next screen or expand a chart. The PACSystems RXi HMI allows users to collaborate from anywhere and is IIoTready for data analysis, troubleshooting, and diagnostics. It provides protocol support with OPC UA for data contextualization and MQTT for cloud connectivity. The HMI is approved for use in temperatures of -20 to 65°C, and is resistant to chemicals, impacts, scratches, and dust.
Emerson emerson.com
Using web-based architecture, the Fortress Technology solution captures production data across an entire suite of networked Fortress inspection machines. The Contact 4.0 smart data capture solution remotely monitors the performance of equipment, tracks events, and documents all potential product risks. With the solution, multiple frontend inspection machines can be tethered to back-end reporting software in real time. It
can be installed on all Fortress digital Stealth, Interceptor, and Interceptor DF metal detec tors, as well as the Raptor checkweigher, Raptor XL caseweigher, and Raptor combina tion unit.
Fortress Technology fortresstechnology.com
Accommodating a range of sensors, the Endress+Hauser flow assembly o ers flow monitoring and diagnostic indicator options. The Flowfit CYA27 modular assembly enables measurement of up to six param eters in process and drinking water, and pro vides a flexible basis for the measurement of disinfection parameters, including chlorine, chlorine dioxide, ozone, bromine, and further parameters of liquid analysis, such as pH, ORP, dissolved oxygen, and conductivity. A status light provides the measuring point’s operational state. The light also can be used to display flow status, showing a red light if the flow is too low, or can be connected to a transmitter’s alarm relay to indicate the NAMUR status of the measuring point.
Endress+Hauser us.endress.com
Zipper packaging has never been simpler or more sanitary for protein, produce and frozen food processors. Easily package bulky foods in bags that fully open while ensuring food safety. Quick change jaws offer ultimate versatility.
Barilla’s flagship pasta manufacturing plant in Parma, Italy, boasts a fully automated, lights-out distribution facility, equipped with 120 laser-guided vehicles and 35 robotic systems.
OWNED since 1877, Barilla is the world’s leading pasta maker—more than 160 shapes and sizes sold in more than 100 countries. In Italy, it accounts for 45% of the pasta market, and 35% in the U.S. market. In addition to pasta, Barilla owns 16 brands in related product categories such as sauces and breads.
While steeped in history, Barilla is no stranger to technology. The Italian pasta maker is using connected technologies and analytics to improve traceability in its supply chain. Its field-to-fork ini tiative tracks all stages of food production—from local harvesting to storage, processing, packaging, distribution, and even consumption.
Barilla has been an early adopter of sustainable practices in its facilities. More than two-thirds of the electricity used in Barilla plants comes from renewable sources. Since 2010, Barilla facilities have
reduced water consumption by 21% and green house gas emissions by 30%. The company also promotes more sustainable agricultural and farming practices for its suppliers.
It was amid this culture of technology and envi ronmental initiative that Barilla announced plans in 2018 to invest €1 billion over five years into its industrial assets, aimed at boosting sustainability by optimizing processes and technologies. A pivotal focus of this plan was transforming the distribution operations of its flagship pasta production facility in Parma, Italy, into a showcase of integrated robotic processes and energy conservation.
Highly automated flexible systems enable Barilla to respond to the needs and capabilities of the facil ity, notes Alessandro Spadini, plant director for the Parma facility. “Any distribution system that is not su ciently flexible, that is based on a rigid scheme, sooner or later, will become an issue,” he says. An essential part of the distribution project is the systemic integration of the project rather than single, discrete systems, according to Spadini. To realize this strategy, Barilla called on E80 Group to create the all-encompassing solution. E80 has enabled a 430,000-sq-ft distribution facility that is fully automated, lights out, operating 24/7/365. It’s equipped with 120 laser-guided vehicles (LGVs), and 35 robotic systems, including high-density automated storage and retrieval systems (AS/RS), palletizers, labelers, and stretch wrappers. In 2019, these systems combined handled 438,000 tons of pasta; about 1,000 di erent packaged SKUs.
A key impetus of this renovation project was the wish to replace conveyors with LGVs for pallet transport within the facility, Spadini notes. “Tradi tional conveying systems are sized for production peaks and not flexible enough to manage variations
in throughput, in terms of both flows and volume,” he says. “Therefore, pallet conveyor systems are typi cally highly ine cient.”
The Parma facility uses three main types of LGVs— carrying a single pallet, two pallets, or four pallets at a time. The LGVs interact with floor-positioned pal lets and AS/RS induction stations. They pick up and drop o pallets between receiving and manufacturing, palletizing, stretch wrapping, labeling, finished-goods warehousing, and staging locations for shipping. Roller beds on the LGVs allow e cient roll-on/roll-o .
Each LGV is equipped with a rotating laser that scans 360 degrees around the vehicle for laser tar gets mounted on columns, walls, and stationary machinery. The reflections from these targets are triangulated to determine position, which is compared to a CAD-type map stored in the LGV’s memory.
Developed for E80, lithium Flash Battery tech nology provides a high level of performance for industrial vehicles. The lithium iron phosphate delivers low toxicity, well-defined performance and long-term stability. Having a very constant dis charge voltage, Flash Battery technology delivers virtually full power until the battery is discharged.
Running the LGVs, as well as all integrated robot ics systems within the Parma distribution facility, is E80’s Smart Integrated Logistics (SM.I.LE80) controls platform. SM.I.LE80 continually updates the positional status of each LGV—including whether it is loaded or unloaded, emergency stopped or soft stopped, operating in manual mode, and battery level. An HMI screen gives the operator a graphical overview of the LGV locations in the system and monitors each in real time.
The SM.I.LE80 controls ensure the integrated and automated management of systems, commu nicating with AS/RS, palletizers, wrappers, and shipping staging locations. The entire LGV logistics flow within the Parma distribution operation can be centrally managed from this platform.
Barilla’s high-density automated warehouse— where six stacker cranes support 47,000 pallet locations—integrates perfectly with the LGV tech nology. E80’s AS/RS Crane Store systems are equipped with automatic product handling devices
for double-depth storage. Because they can oper ate at heights of up to 130 ft, these systems signifi cantly increase warehousing capacity. An additional 50,000 pallet locations are used for LGV drive-in high-density low-bay storage.
In addition to managing LGV tra c and the other integrated robotics systems, SM.I.LE80 maintains control and identification of each case of products throughout the distribution facility. Once cases and pallets leave the facility, the labeled identification pro vides a tracking mechanism for complete track-andtrace throughout the supply chain.
Barilla’s facility uses a unique palletizing process. Robotic palletizing stations form cases in palletized configurations directly on the palletizers’ platforms. The configurations are then moved onto LGVs and transported to other end-of-line process stations in the facility, where a pallet is inserted underneath prior to storage and shipping.
This removes wood pallets from much of the oper ating area. “Removing wood from production and many distribution areas means removing an element that may pollute the environment where we produce and package our products,” Spadini points out. “But also, managing pallets without wood parts opens up the opportunity of handling and reprocessing of pal lets in a completely automated way, improving e ciency and minimizing environmental impact.”
As with the other systems in the distribution operations, Barilla’s end-of-line stretch wrapping and labeling are also robotic and fully integrated with the LGVs and other robotic processes. The high-speed stretch wrappers employ automatic wrapping head changeovers, eliminating the need to stop production.
Robotic palletizing stations form cases in palletized configurations directly on the palletizers’ platforms, eliminating wooden pallets.
Melitta solves line issues a decade apart through the co ee maker’s ongoing partnership with Precision Automation.
IS A BRAND known for its widely available household and foodservice co ee products, including paper filters, brewing systems, ground and whole-bean java in a variety of pack sizes, serving vessels, and more. Melitta also has a robust business in co ee co-packing for other high-profile brands. The Germany-based company was founded in 1908, and has operations around
the world, including a roastery in Brazil and a co ee processing facility in Cherry Hill, N.J.
The Cherry Hill plant has been in operation since 1964, employing around 100 people. While the facility has e ciently served the needs of Melitta’s customers over the years, co ee production there has jumped from 10 million lb a year to 40 million lb over the past decade, so improvements and upgrades during that time were necessary to han dle the increased capacity.
Melitta started working with Precision Automation in 2008 to assess those capacity issues and manage the ensuing solutions, right down to identifying avail able equipment in the marketplace within budget and overseeing installation. Precision Automation was also tasked with keeping downtime to a minimum while new equipment was put in place, and to find machines that would fit Melitta’s existing footprint.
The partnership between Melitta and Precision Automation resulted in a new canning line at the Cherry Hill plant, which was a turnkey solution for the co ee producer. The new line included a depal letizer for empty co ee cans, a pressureless com biner to keep those cans from being crushed during production surges, and more. “With Precision’s help, we were able to come up with a really good design that met our needs,” says Vincent Tagliaferro, direc tor of co ee operations at Melitta North America. “Really e ective and an amazing project in terms of e ciency and productivity along the way, setting us up for where we are today.”
Melitta is a global producer of household and foodservice co ee products, and also has a robust business in co-packing for other high-profile brands.
While productivity along that line improved dramatically over the ensuing decade, new chal lenges arose as Melitta’s business grew rapidly during that time, particularly with bottlenecks caused by an outdated palletizer that couldn’t keep pace. “We reached out to Precision first and foremost to help us solve that problem,” says Tagliaferro. “We realized at that point we were beyond the ability of speeding up or shortening the time of the existing palletizer and needed to
s
Precision Automation helped Melitta choose and install this Columbia palletizer, which alleviated bottlenecks on the back end of its production line. The speedier palletizer also allowed Melitta to move existing labor from hand palletizing to quality control positions.
invest in a new unit to eliminate that bottleneck on the back end of the line.”
In 2020, Precision Automation created a plan to alleviate those bottlenecks through new equipment strategically placed in lagging areas along the line, beyond just replacing the palletizer. First, an accu mulation table was installed to handle overflow when product backups occurred, allowing produc tion to continue on other parts of the line. “The table gave us a 15% reduction in downtime by allowing the line to continue running on the front-end producing and filling cans,” remembers Tagliaferro, “while the back-end issues were dealt with. It gave us the abili ty to have that surge in production and catch up.”
In 2021, the first of two new labelers was installed, using a faster side labeling mechanism compared to the previous machine. “We removed a lot of the motion that occurs when you’re apply ing the label with arms and pistons that come out,” Tagliaferro explains. “Now it’s basically just a side apply, which has been really e ective and e cient.”
Next on Precision Automation’s upgrade list was a new conveyor that allows for 10 minutes of accumula tion feeding into a speedy new tray packer. After that, a new top sheet applicator was installed, along with the second labeler, and a conveyor with zero-pressure accumulation that feeds into the palletizer.
In April this year, the original source of the bot tlenecks was addressed when a new palletizer was installed. “The pandemic hit during the course of this whole project and slowed everything down in terms of supply chain, skilled labor to produce, and everything else,” says Tagliaferro. Up to that point, the old palletizer couldn’t handle the accelerated rate of Melitta’s production line, so the company had two to three people hand palletizing to help keep things moving.
With Precision’s recommendation, Melitta picked a palletizer made by Columbia, which only took a few days to install. “We utilized Precision from an engineering and layout perspective,” Tagliaferro
The addition of this accumulation table helped Melitta keep their co ee production line going even when bottlenecks occurred on the back end, resulting in a 15% reduction in downtime.
says. “They designed the best process available and actually participated in the direct installation.”
Some of the initial ROI from the new palletizer includes “increased outputs on the canning line and higher e ciency. We’ve also had a reduction in labor and eliminated some repetitive motion activities,” notes Tagliaferro, adding that workers who used to palletize by hand on the back end have been moved into quality control positions requiring more skill.
“If you look at the capital request for this project, we initially called it ‘replace the palletizer’ to remove the bottleneck on the line. The beauty of the project though, ultimately, is it addressed a couple of di er ent needs along the way,” Tagliaferro says. “The sign of a very successful project is when you tackle your main thing, but you’re able to eliminate a couple other smaller issues too. Our line is fairly well loaded now and constantly supplying our customers with product. This project has given us more confidence to be able to meet that demand.”
Columbia www.palletizing.com
Precision Automation www.precisionautomationinc.com
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Awards to be presented at
Each year, ProFood World recognizes outstanding food and beverage processing and packaging innovation projects via the Sustainability Excellence in Manufacturing Awards competition. Multiple awards will be named for projects such as: Reduction in water and energy Waste conservation Pollution prevention Packaging reductions
View a past winner’s video at pfwgo.to/meat
Join past winners such as Campbell Soup, Land O’Lakes, McCormick, Smithfield, Conagra Brands, Hormel, Hiland Dairy, Big Heart Pet Brands, Bob’s Red Mill Natural Products, Li ey Meats, and Graphic Packaging International. View past winning entries and learn more at pfwgo.to/sema
Entries are
March
2023.
Admix, Inc 23 www.admix.com
Air Products 57 www.airproducts.com/IQ
Ampco Pumps Company 45 www.ampcopumps.com
Anritsu Product Inspection 20 www.anritsu.com/infivis
Assured Automation 61 www.assuredautomation.com
Axiflow Technologies, Inc. 51 www.AXiflowtechnologies.com
Avure Technologies 47 www.jbtc.com
Bunting Magnetics 8 www.buntingmagnetics.com
Central States Industrial 42 www.csidesigns.com
Cleveland Gear Company 64 www.clevelandgear.com
Columbia Machine, Inc. 59 www.palletizing.com
Coperion K-Tron 36a www.coperion.com/food-extruders • www.coperion.com/foodtransfer
CRB 33 www.crbgroup.com
Deville Technologies Inc. 67 www.devilletechnologies.com
Domino Amjet Inc. 4 www.domino-na.com
Douglas Machines Corp. 48 www.DougMac.com
Emerson Automation Solutions (TX) 56 www. Emerson.com/FoodandBeverageIIoT
Eriez Magnetics 38 www.PurityEriez.com
ESI Group USA 12a www.esigroupusa.com/about-esi/events
Flexicon Corporation C-2 www.flexicon.com
Frain Industries 18 www.frain.com
GEA North America 1 www.gea.com/packaging
Gorman-Rupp 49 www.grpumps.com
Graphite Metallizing Corp. 62 www.graphalloy.com
Hapman 31 www.hapman.com
Haskell 40 www.haskell.com
Hiperbaric - High Pressure Technologies 22, 60 www.hiperbaric.com
Industrial Magnetics, Inc. 41 www.magnetics.com
Klockner Pentaplast, Food Packaging 5 www.kpfilms.com
Linde 39 www.Lindefood.com/innovations
Lubriplate Lubricants 35 www.lubriplate.com
M&M Carnot 29 mmrefrigeration.com • carnotrefrigeration.com
Miura America Co., Ltd. 68 www.miuraboiler.com
Munson Machinery Co. Inc. 7 www.munsonmachinery.com
PAXTON, An ITW Air Management Company 62 www.paxtonproducts.com
ProFood World Manufacturing Innovation Awards 2023 66 www.pfwgo.to/mia
ProFood World Sustainability Excellence in Manufacturing Awards 74 www.pfwgo.to/sema
PACK EXPO Xpress C-3 www.packexpo.com
Radar Process, S. L. 63 www.radarprocess.com
Refrigerating Engineers & Technicians Association (RETA) 11 https://reta.com/page/2022-conference-home
Ross Mixers 15 www.mixers.com/web-app
Ryson International Inc. 50 www.ryson.com
SEW Eurodrive, Inc. C-4 www.seweurodrive.com
Shick Esteve 2 www.shickesteve.com
Stolle Machinery Company 62 www.stollemachinery.com
The Austin Company 27 www.theaustin.com
ThermOmegaTech, Inc. 10 www.ThermOmegaTech.com/LinesMoving
Tippmann Group 65 www.tippmanngroup.com
Triangle Package Machinery Company 69 www.trianglepackage.com
Uhde High Pressure Technologies GmbH 52 www.uhde-hpp.com
Uline 64 www.uline.com
Urschel Laboratories, Inc. 19 www.urschel.com
VDG C-1 https://www.vandergraaf.com/PFW
WIPOTEC-OCS, Inc. 55 www.wipotec-ocs.com
Wire Belt Company of America 17 www.wirebelt.com
Yaskawa America, Inc. 58 www.yaskawa.com
Kinetic’s Reflex devices help employees decrease repetitive motion injuries.
(IIoT) expands, it’s not just smart instruments, conveyors, and robots that are being outfitted with data-gathering intelligent sensors. Increasingly, they’re finding their way onto workers themselves. Wearable technologies are being put to a variety of uses, including enabling remote assistance via augmented reality (AR) headsets, measuring labor e ciency to reward workers for e ciency, and mon itoring the postures of employees with the goal of im proving workplace ergonomics and reducing injuries.
A case study from Frito-Lay demonstrates this latter application. Beginning in the summer of 2020, the company outfitted workers in 34 of its North American manufacturing and distribution cen ters with Kinetic’s Reflex devices. The devices are belt-mounted sensors that detect when a worker is assuming high-risk postures such as bending, over reaching, or twisting that could lead to repetitive strain injuries on the job. From here, the actions taken are twofold. First, workers receive real-time feedback via a gentle vibration, encouraging them to adjust their behavior. Then the data is sent to a cloud-based dashboard that provides management with insights
on how to improve workplace ergonomics.
Not only does this help to improve the health of workers by preventing injuries, but it saves FritoLay money by reducing worker compensation costs related to repetitive strain and other workplace-re lated impairments. According to Frito-Lay, the initia tive has resulted in a 19% reduction in Occupational Safety and Health Administration (OSHA) record able injuries, and 67% less work-time lost—a critical improvement amid continuing labor shortages.
In the past, Frito-Lay sought to reduce the num ber of high-risk postures workers assume by bring ing in athletic trainers to educate them on how to perform physical tasks more safely. However, this approach has been largely ine ective, as the infor mation communicated during these one-time train ing sessions is seldom retained. The company has also found that employees have been more willing to make changes to their behavior when they are receiving and acting on data insights themselves, rather than merely taking instructions from supervi sors. To further motivate them, the Reflex software sets quantitative benchmarks for workers to pursue and allows them to compete against each other.
Frito-Lay workers wearing Kinetic’s Reflex devices—which monitor highrisk postures in repetitive motion jobs— has resulted in a 19% reduction in recordable injuries, and 67% less worktime lost, according to Frito-Lay.
“We’ve always done all the traditional ergonomic work, but there has been something missing,” says Cormac Gilligan, vice president of global environ ment for health and safety at PepsiCo, Frito-Lay’s parent company. “We weren’t able to tap into that behavioral element to create a sense of ownership in the individual employee and help them behave posturally in a di erent way.”
The data gathered can also be used to rede sign the spatial arrangement of facilities, making them easier to navigate. Frito-Lay’s Kern plant in California was able to identify when and where the most high-risk postures were occurring. The com pany discovered that workstation space limitations during ingredient changeover were forcing employ ees to twist and bend in a dangerous way.
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