F&D Business December 2011

December 2011

Moy Park moves up the pecking order

Food & Drink Business Website:

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C o n t e n t s

- 35 M EAT P ROCESSING

- 3 M ERGERS & A CQUISITIONS

Callan Bacon continues its winning streak.

Coverage of British and international deals.

P AGE 17 PAGE 3

Michael Clarke, ceo, Premier Foods.

- 7 C OVER S TORY Moy Park moves up the pecking order.

- 45 T RADE FAIR ProSweets Cologne 2012 _ 29th January1st February – Cologne Exhibition Centre.

Irene Rosenfeld, chairman & ceo, Kraft Foods.

R EGULARS

- 17 -

PAGE 25

C ONFECTIONERY

Processing & Manufacturing . . . . 20, 38-43

Kraft Foods to reshape UK confectionery operations.

Top players in the global confectionery market.

PAGE 4

Quality & Safety . . . . . . . . . . . . . . 24 & 33

Graham Mackay, ceo, SABMiller.

Bottling & Packaging . . . . . . . . . . . . 29-32 Energy & Environment. . . . . . . . . . . . . . 44

- 22 M ARKET F OCUS

Materials & Ingredients . . . . . . . . . . . 47-48

Top four donimate €46 billion European confectionery market.

Top 100 confectionery manufacturers in Western Europe.

PAGE 7

Nigel Dunlop, ceo, Moy Park.

Joanne DenneyFinch, ceo, IGD.

PAGE 27

Simon Baldry, md, Coca-Cola Enterprises GB.

Managing Director: Colin Murphy Editor: Mike Rohan Sales Director: Ronan McGlade Advertising: Susan Doyle. Senior Sales Executive: Paul Lees Production Manager: Susan Doyle

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Discounters, convenience and online key drivers as UK grocery market set to rerach £184 billion by 2016.

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PAGE 9

- 27 S OFT D RINKS Coca-Cola Enterprises to invest £50 million to develop British business.

Ursula Lavery, director, quality & technical, Moy Park.

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FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

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M E E R R G G E E R R S S M Premier Foods Selling Brookes Avana to 2 Sisters For £30 Million Premier Foods has agreed to sell its loss-making Brookes Avana business comprising of RF Brookes chilled foods and Avana Bakeries to 2 Sisters Food Group for £30 million in cash. The move represents an important step in streamlining Premier’s portfolio following its announcement in October that it will focus investment behind eight ‘power brands’ and dispose of selected businesses further enabling it to deleverage the business.

Employing just over 2,000 people, Brookes Avana operates from three sites at Newport (RF Brookes and Avana Bakeries) and Leicester (RF Brookes). Brookes Avana supplies chilled convenience products, including ready meals, accompaniments, chilled pizza and pies. Avana is one of the UK’s leading suppliers of high quality bakery, cake and dessert products.

Brookes Avana reported a trading loss of £0.1 million on a turnover of £203.6 million for the year ended 31 December 2010. The losses have deepened in the current financial year.

“The sale of Brookes Avana underlines our commitment to focus the business on growing a smaller number of brands,” explains Michael Clarke, chief executive of Premier Foods.

The net sale proceeds (after estimated disposal costs of £1.8 million) will be used by Premier to repay bank borrowings.

Michael Clarke, chief executive of Premier Foods.

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A C C Q Q U U II S S II T T II O O N N S S A

Tulip Expands in the UK Tulip has consolidated its position as the leading UK supplier of processed meat products following the acquisition of Parkam Foods for an undisclosed sum. The deal strengthens Tulip’s market standing by adding new products to its portfolio, while at the same time further increasing its sales to the biggest UK retail chains.

In addition to cooked meats, sandwiches and sausages, Parkam Foods also produces a number of highquality products based on beef, turkey and chicken. This will add a new and valuable dimension to Tulip’s business.

Parkam Foods consists of four companies: Parkam Foods, Tranfoods, Trophy Foods and Freshway. The companies have a total of 750 employees, with expected revenue for the current financial year in the region of £100-115 million.

Tulip is part of Danish Crown, Europe´s biggest pig slaughtering business and the world’s largest exporter of pork. The UK is Danish Crown’s largest market.

Baxters Acquires Fray Bentos Baxters Food Group, the Scottish soup and preserves manufacturer, has bought Fray Bentos for an undisclosed sum from Princes Group, which is owned by Mitsubishi Corporation. Princes was ordered by the UK Office of Fair Trading to dispose of Fray Bentos, which produces a range of canned pies and puddings as well as corned beef and meatballs, as a condition of its purchase of Premier Foods’ canned grocery operations for £182 million last July.

“Like Baxters, Fray Bentos is a heritage brand and is known the length and breadth of the country holding a special place in the hearts of British consumers both young and old,” says Audrey Baxter, chairman of Baxters Food Group. “We have many exiting ideas to revitalise the brand as we aim

to secure a strong foothold in the canned meat market.”

Production from the Fray Bentos site at Long Sutton in East Anglia will be transferred to the Baxters headquarters at Fochabers in Moray, Scotland, over the next twelve months.

Nestle Strengthens Food Service Business in Scandinavia and Finland Nestle Professional, the Nestle business that supplies the food service out-of-home industry, is strengthening its portfolio with a new acquisition in Scan-dinavia and Finland. The purchase of the stocks and sauces business Oscar from the Paulig Group will boost Nestle Professional’s presence in the ‘culinary flavours’ sector.

Oscar produces its stocks and sauces at factories in Denmark and Finland. The acquisition of this premium stocks and sauces operation gives Nestle Professional an opportunity to expand its outof-home food business in Denmark and Finland where the Oscar brand is used widely, and further afield.

Globally, Nestle Professional is present in more than 90 countries – with over 10,000 employees, including a large number of skilled chefs.

Nestle Professional sources from 171 Nestle factories worldwide and operates 13 dedicated food service factories, a number of specialist culinary centres, and a Beverage Centre located in Switzerland.

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

Heineken Acquires UK Pub Business For £412 Million Heineken has acquired the Galaxy Pub Estate in the UK from The Royal Bank of Scotland for £412 million (Eur480 million) on a cashand-debt-free basis. A further £10 million has been paid to settle accrued amounts owed under an existing management agreement between RBS and Heineken.

Galaxy consists of 918 largely freehold pubs and has been managed by Scottish & Newcastle Pub Company, a Heineken subsidiary, since 1999 on behalf of RBS. Galaxy will be combined with Heineken UK’s existing portfolio of 462 outlets. Following this acquisition, Heineken will become one of the leading pub owners and operators in the UK. Heineken expects the acquisition to be earnings accretive from December 2011 and value enhancing in the first year after completion.

Didier Debrosse, regional president Western Europe for Heineken, comments: “The acquisition of Galaxy is consistent with our strategy of driving future value growth in Europe and represents another step in the successful turnaround of our UK business.

Our ownership of this estate strengthens our leading position in the UK beer and cider market, particularly in the valuable on-trade channel.”

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M E E R R G G E E R R S S M Sara Lee Strengthens European Coffee Business Sara Lee and its Norwegian joint venture partner, Kaffehuset Friele, have agreed to acquire the House of Coffee business, a leading food service provider of beverage solutions to offices and institutions in Norway and Denmark, from ISS for an undisclosed sum. Sara Lee owns approximately 45% of Kaffehuset Friele, the leading coffee company in Norway.

Through this joint venture, Sara Lee successfully commercialises products such as Senseo coffee pods and Cafitesse liquid coffee in the Norwegian market. In Denmark, Sara Lee owns Merrild, the country’s number-one coffee brand. The acquisition of House of Coffee will help Kaffehuset Friele and Sara Lee strengthen their positions across various out-of-home channels in both countries.

& &

A C C Q Q U U II S S II T T II O O N N S S A

for the private label market and also under the Durigon brand.

R&R plans to invest in the Durigon factory and grow sales as an integral part of its strategy to develop its private label business in Germany.

The Durigon brand will be retained and complements the existing portfolio of R&R brands. Werner Durigon will continue as managing director of Durigon.

Lion Capital Purchases Cumbrian Seafoods Private equity firm Lion Capital, which owns Young’s Seafood, has expanded its UK fish and seafood interests with

R&R Ice Cream Acquires German Business R&R Ice Cream is consolidating its position as Europe’s largest own label ice cream manufacturer with the acquisition of Durigon Gelato of Germany for an undisclosed sum, subject to clearance from the German competition authority. Based at Schwanewede-Brundorf near Bremen with 70 employees, the family-run Durigon, which

generated sales of Eur20 million in 2010, manufactures tubs in different sizes from 200ml to 5000ml, sandwiches and other ice cream products

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the acquisition of the customer contracts and equipment of Cumbrian Seafoods from the administrators.

Cumbrian Seafoods is the UK’s leading independent seafood company, employing 500 people. It has a state-ofthe-art plant at Seaham in County Durham, a smokery at Whitehaven in Cumbria and the Border Laird shellfish facility at Amble in Northumberland.

According to Lion Capital, future options for Cumbrian Seafoods, which could involve integration and servicing of customer contracts by Young's Seafood, will be explored over the coming weeks. Leendert den Hollander, chief executive of Young’s Seafood, says: “This is the beginning of a process and the teams involved will work hard to understand the business

and consider in detail how best to take the customer contracts forward. Our focus is on customers - on fulfilling their contracts - and consulting with new employees on possible options for the future.”

Kerry Group Completes $230 Million Acquisition Kerry, the global ingredients, flavours and consumer foods group, has completed the acquisition of Cargill’s global flavours business. Cargill Flavor Systems with annual revenues of approximately $200 million was acquired for a total consideration of $230 million. The acquisition strengthens Kerry’s capability to provide integrated customer solutions across all food and beverage end-use-markets.

Cargill Flavor Systems employs 700 people throughout its integrated flavour development and application centres in France, the UK, South Africa, India, Malaysia, China, the USA, Puerto Rico, Mexico and Brazil, supported by a network of sales representative offices in twelve other countries.

Greencore Offer Talks End Negotiations about a possible offer by US private equity firm Clayton Dubilier & Rice to buy Greencore, one of the leading convenience food processors in the UK, have

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

ended. Greencore announced the receipt of an approach on October 25th 2011. Given the Greencore board's view on the strong underlying value of the group and the current dislocation in global equity and debt capital markets, both parties have now agreed to end discussions.

SABMiller’s Acquisition of Foster’s Approved The Australian competition authority has approved SABMiller’s A$9.9 billion (US$9.6 billion) acquisition

Graham Mackay, chief executive of SABMiller.

of Foster’s Group, the Austrialian brewer, and the 50% of soft drinks business Pacific Beverages currently owned by Coca-Cola Amatil.

SABMiller has provided certain undertakings in relation to the Foster’s acquisition including keeping management of Foster's operations located in Australia, and not relocating any of Foster's existing brewing facilities offshore to produce beer for Australian domestic consumption.

The deal is in line with SABMiller's strategic priorities and will provide it with a leading position in the stable and profitable Australian beer industry along with the opportunity to apply SABMiller’s capabilities and scale to improve Foster's financial and operating performance.

COVER STORY

Moy Park Moves Up the Pecking Order From small scale beginnings in Northern Ireland, Moy Park has developed into a £1 billion turnover international food group.

O

perating 13 factories in three countries and employing 10,500 people, Moy Park is the leading poultry processor in the UK and also one of the largest in Europe. In addition to a full range of chicken and turkey products, Moy Park also supplies other convenience food products, such as onion rings, spring rolls, coated cheese, doughnuts and apple pies, to retailers and food service operators throughout the UK and mainland Europe.

Heavy investment over the past twenty-five years and a forward thinking and dynamic management team have helped transform Moy Park from a small, traditional agriculture-led commodity producer in Northern Ireland into a market-leading, pan European food processor, equipped with the latest technology and operating to the highest technical and quality standards.

Great Britain. As well as adding scale, the acquisitions enhanced the business both in respect of geographical coverage and customer base. Padley and Dove Valley provided a strong manufacturing presence in England to complement Moy Park’s plants in Northern Ireland and France. The acquisitions also enhanced Moy Park’s presence in the food service market to supplement its strength in retail markets across Europe.

Scale is vital within the UK poultry market, where more than 75% of sales are split between just four retailers. The integration of Padley and Dove Valley has also benefited Moy Park in fostering closer partnerships with customers, which are a key to achieving product and recipe development, keen pricing and consistency of supply.

Vertically Integrated Moy Park is a vertically integrated poultry group encompassing parent/broiler hatcheries and primary and further processing factories. Moy Park processes over 200 million locally-produced chickens and 2 million turkeys per year throughout the UK. The company manufactures both branded and private label products. Indeed, the Moy Park brand is well known throughout Ireland.

Moy Park’s ethos is the production of ‘fresh, high quality, locally farmed poultry ’. Moy Park works with almost 600 poultry farmers in Northern Ireland who rear classic, higher welfare, free range and organic poultry to the most exacting standards. These are supplied to the company’s primary processing sites at Dungannon, which has the

Nigel Dunlop, Chief Executive of Moy Park.

Development Moy Park has grown organically and by acquisition. The Northern Ireland-based company first established a manufacturing presence in Europe in 1991 through the construction of a new factory at Henin Beaumont near Lille under a joint venture with French poultry group Bour-goin. The position in France was further enhanced with the acquisition of the former Cuisine de Licques plant in Marquise in 1998.

In 2004, Moy Park completed two acquisitions which effectively doubled its size, as sales rose to over £700 million, and considerably strengthened its standing in both the British and European poultry industry. The acquisitions of two family-owned English businesses - Derbyshire-based Dove Valley and GW Padley Poultry in the East of Moy Park is now operating a new £21 million England - substantially turkey processing facility at Ballymena. The extended Moy Pa-rk’s 100,000 square feet factory gives Moy Park the primary and further capacity to produce over one million fresh turkeys processed poultry profor the Christmas period. duction capability in

Moy Park is the leading player within the £2.8 billion fresh retail chicken market in the UK.

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

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Due to its versatility, chicken has a wide consumer appeal, with 95% of UK households buying chicken during the year.

Pioneer Moy Park has pioneered a number of poultry industry firsts, particularly at its original and now flagship primary processing plant at Dungannon. Initially built in 1975 but continually expanded and upgraded since, Dungannon was the first fully integrated poultry facility in the UK, undertaking killing, portioning, packing and dispatch on one site.

Another pioneering innovation has been the automated unloading of live birds arriving at the site from Moy Park farms. A custom designed hydraulic system unloads the trucks in batches of 6,000 birds. This process, which was previously carried out by forklift trucks, allows the birds to remain completely relaxed.

The use of electrical stunning of birds was another UK first for the Dungannon site. At the start of 2011, Moy Park also installed an anoxic gas stunning system, widely acknowledged as the most welfare friendly standard in the world, whereby the birds are killed humanely before being moved onto the processing line.

Moy Park also pioneered its now patented electrical stimulation process at the Dungannon site. This allows birds to enter rigor mortis very quickly. Following two-stage chilling, the birds can be ‘oven

capacity to handle 1.3 million birds per week, and Ballymena, where a further 600,000 chickens are processed. Further processing takes place at Moy Park’s factory in Craigavon, where ‘ready to eat’ (cooked) and breaded products are produced.

Moy Park’s primary processing sites at Anwick and Ashbourne in England respectively process 1.6 million and 750,000 birds a week.

These are complemented by further processing sites at Grantham, where breaded products are made, and Wisbech, which specialises in ready to eat poultry products as well as corned beef.

All the birds for the company’s four primary processing facilities in Northern Ireland and England are sourced within an average of 30 miles radius of each plant.

The two French sites at Marquise and Henin both produce ready to eat products. Henin also manufactures coated poultry and some bacon products.

Non-meat Business Moy Park has a non-meat element to its business through subsidiary Kitchen Range Foods, which has two factories at Peterborough and Huntingdon in the UK, and Netherlands-based Albert van Zoonen.

Kitchen Range Foods, part of Moy Park’s Foodservice division, produces a range of sweet and savoury products and is a major supplier to McDonald’s.

Financial Performance Helped by the acquisition of O’Kane Poultry, a Northern Ireland chicken and turkey processor, Moy Park reported a positive financial performance in its annual results for the year ending 31st Dec-ember 2010 but has warned of the challenge to overcome feed price and energy inflation beyond this period. Moy Park achieved an uplift in sales revenue of 18% to £921.1m, resulting in a pre-tax profit of £27.8m representing 3% of sales.

After losses in 2007 and 2008, Moy Park returned to profitability in 2009 with pretax profits of £18.3 million on sales of £780.5 million. Over 95% of Moy Park’s sales are generated Ursula Lavery, Director of Quality and Technical, outside Northern Moy Park.

Ireland.

Operating 13 factories in three countries and employing 10,500 people, Moy Park is one of the largest poultry processors in Europe.

ready’ within 2.5 hours, whereas historically this process lasted between 6 and 12 hours.

Other key features of the Dungannon site include camera grading of the birds – the system handles 10,000 birds an hour – and MAP (Modified Atmosphere Packaging) of all portions. In addition to producing whole birds and portions for the retail and food service markets, the Dun-gannon site also supplies product to Moy Park’s further processing facilities in Craigavon, Great Britain and France.

The Dungannon site incorporates a Category 3 rendering facility to process the waste from the cutting lines and from the de-feathering process, which is delivered via a closed-pipe system from the main factory. The main function of the rendering facility is to produce high quality pet food as the raw materials handled are extremely fresh

Moy Park processes over 200 million locallyproduced chickens and 2 million turkeys per year throughout the UK.

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

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due to being processed so rapidly. Some of these by-products are also converted into fertilizer.

Indeed, Dungannon has been used as a blueprint for developing Moy Park’s other primary processing operations throughout the UK. For instance, Moy Park’s site at Anwick is based on the same integrated plan as Dungannon and has been further enhanced with more recent technological developments.

Major Expansion The Dungannon complex underwent a major expansion in 2009 following investment of £13 million, which extended the site to over seven hectares. The factory is now capable of portioning over 500,000 birds a week. Dungannon is also the base for Moy Park’s agricultural management. Moy Park’s corporate head quarters is based at Craigavon.

“Since 1997 we have spent in the region of £45 million at Dungannon. Just to stand still, the site has to spend £2 million a year – that is without any process improvement or new technology,” says Gary Leslie, Director of Operations, Primary, Moy Park. Indeed, Moy Park invests heavily across all its production and processing sites. £37 Million Investment Programme Moy Park is currently midway through a £37 million investment programme at its site in Ballymena, to be phased over four years.

Supported by Invest Northern Ireland and the European Regional Development Fund, the programme was announced in May 2010 and aims to achieve external sales of £154 million by 2013.

The largest element of the programme has entailed the opening of a new £21 million turkey processing facility at Ballymena. The site at Ballymena has been part of Moy Park since its £26 million acquisition of O’Kane Poultry, a £132 million turnover chicken and turkey processing business, in May 2010. The deal has allowed Moy Park to expand its chicken rearing and processing business in Northern Ireland, add milling capacity and also provided entry into the turkey market for the first time.

Opened late last year, the 100,000 square feet factory gives Moy Park the capacity to produce over one million fresh turkeys for the Christmas period. “This expansion forms part of a wider investment programme across Moy Park factories and poultry farms which will give us the flexibility to grow our business and meet the future demands of the marketplace,” points out Nigel Dunlop, Chief Executive of Moy Park. “Notably, the agri-food sector is one of the only Moy Park breaded Irish chicken industries in Northern Ireland that chicken breast strips. has continued to thrive in recent times, and we believe that this joint investment is an excellent example of government and private industry working together to exploit growth opportunities for the industry and for Northern Ireland.”

Moy Park is unusual in that Nigel Dunlop, who assumed his present role in 2008, is only the second chief executive at the company in the last thirty years. Trefor Campbell, who joined the business in the early 1960s, headed Moy Park from 1982. Indeed, it is this continuity, through a period of dramatic growth domestically and internationally, and changes of ownership, which has been a key strength of Moy Park and central to its successful development.

Locally Farmed Poultry Moy Park’s agricultural operations are also well-invested. “Local farming is at the heart of Moy Park. We continue to invest in the local farming base both within Northern Ireland and GB,” points out Ursula Lavery, Director of Quality and Technical, Moy Park. “We have expanded production of local poultry by 20% in the last two

Moy Park has pioneered a number of poultry industry firsts, particularly at its original and now flagship primary processing plant at Dungannon.

years. We have been able to do this by supporting local farming to increase the number of poultry houses we have on the ground.”

According to Moy Park, only 8% of the housing within the UK poultry industry is less than ten years old. “At Moy Park, 45% of our houses are less than ten years old. This shows that we have continually invested in the agricultural side of the business, whereas many others have invested, possibly in their manufacturing, but have not necessarily kept their agricultural business up to date at the same time.”

She continues: “Moy Park’s assets are both geographically and functionally complementary. The Northern Ireland sites mirror the GB operations with agriculture, fresh and convenience capabilities.

This structure ensures security of supply, which provides both a point of difference and considerable reassurance to our customers that we can deliver quality, locally sourced poultry to the highest standard.”

Market Trends Moy Park is the leading player within the £2.8 billion fresh retail chicken market in the UK. Indeed, the UK is the largest market for retail chicken in Europe and is approximately 20% larger than the second largest market, France. Due to its versatility, chicken has a wide consumer appeal, with 95% of UK households buying chicken during the year.

“Chicken is a versatile, healthy and convenient meat and is also breast portions and breaded Irish good value for money, which is why it has always remained popular and tends to grow in popularity in times of recession. Chicken caters to a range of consumer types and budgets, with breast fillets growing very strongly, along with dark meat sales, fuelled in part by a growing ‘foodie’ trend amongst consumers,” explains Ursula Lavery. “We have also noticed people are starting to buy bigger birds as they provide good value for money and can see

“Chicken is a versatile, healthy and convenient meat and is also good value for money, which is why it has always remained popular and tends to grow in popularity in times of recession.

Chicken caters to a range of consumer types and budgets.”

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

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households through more than one or two meals.”

To meet the breadth of consumer demand and price points, Moy Park produces a full range of poultry from classic birds right through to higher welfare, free range and organic at the top of the scale. For example, Moy Park produces all the chicken for the Duchy Originals From Waitrose range.

Moy Park has recently launched a new range of breaded and fresh chicken products as well as ready to cook meals. “We are always looking at ways to adapt and grow in line with consumer trends and in Northern Ireland and the Republic of Ireland there is a strong preference for locally sourced food. We also recognise that consumers are demanding healthy food that is quick to cook to complement today’s busy lifestyles, which is why we have developed both fresh and convenience products under the Moy Park brand,” she adds.

Capital Investment Moy Park is committed to pursuing a major capital investment strategy across all aspects of its vertically integrated operations. Last year Moy Park reinvested £32 million in developing and strengthening the business to meet the needs of customers and consumers.

“We also support our farmers in investing in the agricultural infrastructure which will help drive forward the development of the poultry industry,” says Ursula Lavery. The poultry sector in Northern Ireland is a key part of the agri food industry, which is crucial to rebuilding the local economy. As Northern Ireland’s largest food processing company, Moy Park will play a pivotal role in this process.

“Our future development strategy will see us continue to invest in the business, focusing on future sustainability and looking at new product development opportunities in line with consumer demands,” she remarks.

International Ownership Moy Park has operated as a highly autonomous part of a large multinational food group since 1996, when it was acquired by OSI Group, a US-based business specialising in supplying a wide range of products including beef, poultry, pork, pizza, seafood and vegetable products, to the retail and food service channels, including McDonald’s internationally.

Pictured at the official opening of Moy Park’s £21 million turkey processing plant in Ballymena were (l-r): Tony O’Neill, Executive Director of Moy Park Ballymena; Arlene Foster MLA, Minister for Enterprise, Trade and investment; and Nigel Dunop, Chief Executive of Moy Park.

Moy Park is now part of Marfrig of Brazil, one of the world’s largest food companies with interests in beef, pork, poultry and fish, and operations in 22 countries spanning five continents. Employing 90,000 people globally and with sales in more than 140 countries, Marfrig generated a turnover of 20.6 billion Brazilian reals (Eur8.6 billion) in 2010. Moy Park along with OSI businesses in Europe and Brazil, (with combined annual sales of almost $2 billion), were sold to Marfrig in 2008 in a deal worth up to $900 million. J

Moy Park is now part of Marfrig of Brazil, one of the world’s largest food companies with interests in beef, pork, poultry and fish, and operations in 22 countries spanning five continents.

Innovative Solutions From JBT FoodTech s a partner of Moy Park for many years, A JBT FoodTech knows only too well the challenges faced when a company grows and develops to become an industry leader.

JBT FoodTech’s Stein coating, frying and cooking equipment was originally installed in Padleys, which Moy Park acquired in 2004, along with Frigoscandia Freezers.

Throughout the years, processed chicken and poultry products have been the company’s staple products, but demand for more choice and convenience has been the driving force behind JBT FoodTech and Moy Park working in partnership to develop a broader, more innovative product range while retaining quality and consistency.

The Moy Park sites now boast equipment from across the JBT FoodTech portfolio including DSI slicing and portioning and Stein Ultra V™ coating equipment, together with frying and cooking, a Double D Searer/Grill Marker and the company’s 12

leading brand of Frigoscandia GYRoCOMPACT® Spiral Freezers.

Moy Park bought their first Revorack multi-purpose cooker from what was then Double D Food Engineering (which was acquired by JBT FoodTech in 2009) in 1987 for the plant in Portadown. Since then, several more have been installed at their factories in Northern Ireland, England and France.

Then in 1999, Moy Park approached Double D to manufacture a completely new

product – a searer/grill-marker. Since then, Double D has gone on to sell almost 100 of these units which are now installed all over the world.

This range of multi-phase equipment has enabled JBT FoodTech to integrate any combination of processes to produce exactly the required taste, texture and appearance of finished product.

“Multi-phase cooking allows us to authentically emulate the different processes involved in cooking at home in a factory environment,” comments Barry Jackson, JBT FoodTech’s regional sales manager for the UK. “For example, chicken might be coated or marinated, then seared before being cooked or roasted to provide a particular flavour or appearance. We can provide all of these processes so that the finished product exactly meets our customers’ requirements.” For further information on JBT FoodTech visit www.jbtfoodtech.com. J

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I CONFECTIONERY

Kraft Foods to Reshape UK Confectionery Operations Kraft Foods plans to invest £50 million across its confectionery factories in the UK while cutting the workforce by 200 people. he 200 jobs will be shed at the former Cadbury sites at Bournville in Birmingham, Chirk in Wrexham, north Wales, and Marlbrook in Herefordshire. The cuts will be made through redeployment and voluntary redundancies over two years from March 2012.

The US-based global food and beverages giant will invest £44 million in a range of projects to upgrade infrastructure, speed up production, reduce waste and improve energy efficiency at its three chocolate confectionery manufacturing sites over the next two years. This includes £13.5 million at Bournville, £3.4 million at Chirk and £2.6 million at Marlbrook.

According to Neil Chapman, Kraft's manufacturing director for UK chocolate, the investment programme in conjunction with the £217 million invested since 2006 is designed to increase productivity and transform the business. “The ambition is for Bournville, Chirk and Marlbrook to remain at the centre of British food manufacturing and of the Kraft Foods network,” he says. “We continue to invest in our people and facilities, so we can increase productivity and transform our business.”

He adds: “Kraft Foods has already designated Bournville its R&D Centre of Excellence for chocolate. The announcement signals Kraft Foods’ plans for growth across the manufacturing network.”

T

Kraft Foods will invest £6 million in a new biscuits line at its site in Sheffield to facilitate the manufacture of Oreo and BelVita biscuits in the UK for the first time.

Cadbury production at Bournville.

Move into Biscuits Production Kraft Foods will invest £6 million in a new biscuits line at its site in Sheffield, which produces sugar confectionery products such as Trebor, Maynards and Bassetts, to facilitate the manufacture of Oreo and BelVita biscuits in the UK for the first time. BelVita biscuits are currently manufactured in France while Oreos are made in Spain. The start of biscuit production at Sheffield will create 20 jobs.

Ian Dearn, head of manufacturing at the Sheffield plant, comments: “It is great that Kraft Foods recognises the strength of the UK as a manufacturing centre. We are proud to have been selected to bring the manufacture of BelVita and worldfamous Oreo cookies to the UK for the first time. We are also excited about the opportunity to create new partnerships with local farmers.”

Kraft Foods’ UK chocolate manufacturing business currently employs 1,400 people, while its total UK operation has a workforce of 5,500 employees.

Confectionery Leader Of course, Kraft Foods has been the world’s largest confectionery manufacturer since completing its $19.5 billion acquisition of Cadbury in 2010 (see Table) to overtake Mars, which had occupied top spot after purchasing Wrigley in 2008. The Cadbury deal also gave Kraft Foods leadership of the UK and Irish confectionery markets, where its share is about 30% in each market.

Kraft Foods is also now the leading confectionery company in Western Europe with a market share of 16.8% (see ‘Four

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

Top Players in the Global Confectionery Market Company Market Share 1 Kraft Foods 2 Mars 3 Nestle 4 Hershey 5 Ferrero 6 Perfetti 7 Lindt

14.9% 14.5% 7.9% 4.6% 4.5% 3.0% 2.0%

Source: Nestle

15

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Panel One: R&R Ice Cream Links With Kraft Foods R&R Ice Cream, Europe’s largest own label ice cream manufacturer, is joining forces with Kraft Foods to bring confectionery innovation to ice cream markets across mainland Europe. In cooperation with Kraft Foods, R&R will initially develop, manufacture and distribute an indulgent ice cream range of five iconic Kraft brands - Milka, Toblerone, Daim, Oreo and Philadelphia - across ten European markets - Germany, Austria, Switzerland, France, Italy, Spain, Portugal, Netherlands, Belgium and Luxembourg. The first products will hit the shelves in Spring 2012 and are likely to appear in an individual serve ice cream format similar to R&R's

Nestle Potz range, which has proved so successful in the UK. “We believe this venture could achieve additional sales of some Eur100 million for Kraft branded products within five years,” says James Lambert, chief executive and executive chairman of R&R Ice Cream.

“It gives us a world-leading food brand across much of Western Europe and further enhances our reputation as a one-stop shop for both branded and own label ice cream products. I fully expect the Kraft deal to transform the European business in much the same way as the 2001 acquisition of the Nestle Ice Cream business changed our UK operations.”

Players Dominate ?46 Billion European Confectionery Market’ on page 22 in this issue).

Investment in Ireland Kraft Foods has also been transforming its former Cadbury business in Ireland. More than Eur100 million has been invested in the Cadbury’s chocolate manufacturing

facilities in Ireland during the past four years in introducing the latest production technology and improving competitiveness in order to ensure the survival of a business, which exports over 80% of its output.

The Eur100 million investment programme has involved the installation of new plants for the production of Flake, Twirl and Boost bars. Kraft Foods also invested Eur20 million during 2011 in a new moulded plant for the Cadbury Dairy Milk range. The new moulded chocolate plant will complete the current investment

programme and the business will then return to its normal level of capital expenditure of about Eur6 million per annum.

Confectionery Category The former Cadbury operations in the UK and Ireland are now part of Kraft Foods’ confectionery category. Confectionery is Kraft’s biggest category, generating 28% of group sales, ahead of biscuits on 22%. The group’s other categories are grocery, convenient meals, cheese and beverages.

The acquisition of Cadbury has increased Kraft Foods’ number of mega

Panel Two: Irene Rosenfeld to Lead Kraft’s Global Snacks Company In the next step toward dividing into two public companies, Kraft Foods has announced the appointments of the heads of the future global snacks and North American grocery businesses. Irene Rosenfeld, currently chairman and chief executive of Kraft Foods, will be chairman and chief executive of the global snacks company, which will have $31 billion in estimated revenue and a significant presence in numerous fast-growing, international markets.

Anthony Vernon, currently executive vice president and president of Kraft Foods North America, will become

chief executive of the $17 billion North American grocery company. Kraft Foods expects to complete the spinoff by the end of 2012.

As chief executive of Kraft Foods since 2006 and chairman since 2007, Irene Rosenfeld has led Kraft Foods’ transformation. She has thirty years of accomplishments in the food and beverage industry. These include integrating Nabisco; leading Kraft Foods through its spin-off from Altria to emerge as a strong, independent company; and devising strategies that included the transformative LU and Cadbury acquisitions.

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

Irene Rosenfeld will be chairman and chief executive of the global snacks company.

17

PPS’s Returnable Packaging Is Introduced Into Europe PS is a returnable packaging rental company that works with

Pbusinesses to reduce or eliminate their single trip packaging

costs. They have two box and crate washing sites, one in the Midlands and another in Lincolnshire, and have worked with food manufacturing companies for over 10 years.

Recently they have grown their business by supplying Icelandic fish producers with returnable fillet boxes and plastic pallets for their fresh fish delivery to Sealord, the dedicated white fish processor of Waitrose. PPS’s Icelandic agents are based in Reykjavik and supply returnable boxes and pallets to fish producers throughout Iceland to enable a simple change over to a more environmentally friendly option.

Speaking on behalf of PPS, Kate Williamson reports, “There is a growing trend from many UK & European food processors to seriously investigate alternatives to single trip packaging. Retailers are now looking at waste in their whole supply chain, and the best option from both a cost and an environmental perspective is to change to a returnable packaging solution. As part of this initiative we are providing our returnable equipment to the Icelandic source to ensure that the cost saving and environmental impact comes into play at the very start of the supply chain.

Our experience over the years is that on more than 90% of the projects on which we work, the returnable packaging option is a more cost effective solution than the existing single trip packaging.”

18

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FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

confectionery brands, those with sales of 1$ billion-plus, to three with Cadbury and Trident joining Milka. Kraft Foods has twelve mega brands in total. The other nine are Jacobs, Kraft, LU, Maxwell House, Nabisco, Oreo, Oscar Mayer, Philadelphia and Tang.

Kraft Foods’ European confectionery portfolio also includes Toblerone, Cote d’Or, Belgium’s favorite chocolate, and Freia and Marabou, the preferred choco-

late brands in Scandinavia. However, there is a major difference in the taste and composition of chocolate that is sold in the UK and Ireland and that which is popular in continental Europe. Kraft’s main brand in mainland Europe is Milka, which is very different to the Cadbury’s chocolate enjoyed by UK and Irish consumers.

Ice Cream Move Meanwhile, Kraft Foods has joined forces with R&R Ice Cream, Europe’s third largest ice cream manufacturer, to launch a range of Milka and Toblerone ice creams in ten European countries. Kraft Foods’ Daim, Oreo and Philadelphia brands are also being extended into the ice cream cat-

egory under the deal with R&R Ice Cream (see Panel One).

Creation of a Global Snacks Company The UK and Irish operations will soon become part of Kraft Foods’ global snacks business when the group is divided into two public companies next year. In addition to a global snacks company with revenues of about $31 billion, Kraft Foods will spin-off its domestic operations into a North American grocery company with sales of $17 billion. Irene Rosenfeld, chairman and chief executive of Kraft Foods, has been chosen to lead the new global snacks company (see Panel Two). J

Bournville Keeps Production Sweet With Lanner he Bournville plant has eliminated T waste, reduced cardboard and boosted productivity through using Lanner’s WITNESS simulation software. Bournville manufactures products including Cadbury Dairy Milk, Creme Egg, Wispa and Roses.

The Bournville site maintains a buffer stock of wrapped but unpackaged product for its Cadbury Roses and Heroes lines of assorted chocolate selections. This ‘buffer’ stock continually updates as it becomes the input for the subsequent production run.

The individual types of chocolates (or units) that make up these assortments had traditionally been stored separately in cardboard boxes. These boxes would then be emptied by hand for the purposes of packing into the finished Heroes or Roses product.

Because these boxes were emptied by hand, the health and safety regulations for maximum weight handling meant that units had to be stored in a large number of small boxes, rather than ‘polypans’ – industrial sized, specifically designed containers that move chocolates around automated parts of the factory.

This created an excessive use of cardboard boxes to store the individual units.

With ten types of chocolates in Roses and seven in Heroes, and a maximum weight of 7kg per box, the buffer stock needed some 170,000 boxes at any one time.

The Solution In order to automate the process and

eliminate cardboard box storage, Bournville began looking at the use of robots to feed in the different types of chocolates. Because the robots would be able to handle the polypans directly, the storage and unpacking of the boxes would be eliminated entirely.

However, it soon became apparent that the use of robots would mean very sophisticated control systems. In addition, the robots represented a very large investment of both time and money, so the confectionery manufacturer turned to WITNESS software from Lanner to simulate the processes that would be involved. A model was developed by the Bournville plant’s engineers to fully test and validate the options proposed.

Lanner’s WITNESS solution is a proven simulation system used by thousands of organisations to improve business process performance. WITNESS visually represents real world processes in a dynamic animated computer-generated

model. The model then enables experimentation with alternative ‘what-if’ scenarios to identify the best solutions.

WITNESS excels at the quick modelling of large new manufacturing facilities. In this project the modelling of the initial design was completed quickly including a range of complex control logic. At that stage the real investigation began and the model was used heavily over a number of months to refine robot timing and sequences, conveyor delivery and full operational control.

The Results The use of WITNESS at Bournville has been a great success. The new robot introduction has eliminated wasteful manual processes. Beccy Smith, associate principal scientist at Cadbury explains: “We have gone from multiple cases of manual unloading of boxes to the single automatic tipping of polypans that carry 5.5 kg of chocolate. We have also reduced our cardboard usage and transport requirement enormously supporting our ‘Purple Goes Green’ policy.”

“Many businesses in the food and beverage industry are recognising the benefits and savings that simulation, modelling and process optimisation can bring,” comments David Jones, chief executive of Lanner Group. “They understand that to stay ahead in business, analysis and simulation are crucial.” For more information visit www.lanner.com. J

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

19

I CONFECTIONERY

Looking to the Future in the Chocolate Industry

By Thomas Bischof of Buhler ooking into the future of chocolate proL duction one could easily argue that the industry will look completely different in ten years. Since this prediction is not very difficult to make the question to be asked is rather “What are the aspects which will drive these changes?”

Definitely, the taste of a chocolate creation is currently one of the most important factors - and will be in the future.

Without great taste nobody will buy the product. But at which step during processing is the taste developed and what will this process look like in the future?

Flavour Development

The taste and flow properties of a chocolate mass are not developed solely in the conching and liquefaction process. They are significantly influenced in the refining process, during size reduction and homogenization. This positive change in taste occurs above all with the use of crystalline saccharose.

During two-stage refining, the crystallized sugar from the mixer is calibrated in the prerefiner gap to the optimum initial fineness for refining, and at the same time as a result of the high shearing capacity, it is wetted with the released fat and flavoured.

The homogenized prerefined mass then undergoes size reduction to the required

Two stage refining process.

final fineness in the five-roll refiner, again as a result of high shearing force, with further flavour development of the resulting sugar surface taking place in each gap.

Ultimately, minimum energy expense leads to a high proportion of amorphous sugar, which produces a balanced chocolate flavour.

In addition to size reduction, setting and flavour development of the particles is crucial for the unique fineness of the products refined on the FinerTM. Up to 80% of the energy introduced into the roll gap is applied for this purpose.

After refining the conching process takes place. In this process step the flavour developing continues. During conching the chocolate achieves its final taste.

The latest development by Buhler now combines both process steps in one machine. With the All In One Refining machine, short ALIOR, Buhler will met its customers wishes towards flexible and efficient machines.

industry also faces a great challenge to meet all of today’s requirements. Among these are precision, compliance with hygienic standards, flexibility and corresponding output rates.

In order to meet these requests Buhler provides a.o. a volumetric depositing system: The PowerShot™ depositor is operated with the well-proven but permanently improved piston deposit system including a user-friendly software and a state-of-the-art servo drive technology. During the deposit process pistons of a precisely defined diameter are guided through piston bores also precisely defined in their diameter.

Given that the piston creates an underpressure in the bore when being pulled back, mass will be sucked in. The piston route can be fully electronically adjusted via user software. Considering the piston route covered and the according channel volumes including mass density, deposit weights can be determined. Rotary valves are used to transfer the mass flow during the sucking and extrusion process. When the pistons move backwards the rotary valve opens for mass supply and during extrusion of the mass the rotary valve turns in the direction of the nozzle plate thus enabling product deposit. This system allows a flexible adaptation to the individual mass characteristics.

Innovative and Efficient Moulding

Stamps in the CoolCore™ stamping unit.

20

As the producers’ demand for innovations in chocolate moulding constantly grows and the variety of complex products steadily increases, the mechanical engineering FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

The PowerShot™.

CoolCore™ depositing.

CoolCore™ Method

Another process which complies to requirements on precision is the CoolCore™ method. This is a shell forming method allowing production of abstract shell geometries with precise deposit weights. For the manufacture of CoolCore™ shells a precise weight of tempered chocolate is deposited into the mould cavities. A precooled stamp of -20 C is immersed into the mould and forms the shell by backward extrusion.

Depending on the shell thickness, the

stamp remains in the chocolate for a few seconds. To avoid chocolate mass sticking to the stamp, the stamp has to be kept free from ice, which is achieved by use of dry air circulation around the stamp in a closed housing. While using dry air, the temperature around the stamp will not fall below dew point and thus prevents freezing.

When immersing the cold stamp into the tempered chocolate, the inner side of the shell solidifies. The inner side will be solid enough to provide stability for the shell without having a negative impact on the crystal structures in the tempered chocolate.

Similar to conventional shell forming, a crystal grid will only be formed after appropriate cooling. The weight of the stamped shell will remain constant at steady mass density which is defined in its design by the distance between mould and stamp. Thus the CoolCore™ stamping process enables consistent shell weights.

Both, the PowerShot™ and the CoolCore™, are part of the new moulding line ChocoStar™ Compact which is based on established technologies and developed

by Buhler Bindler. The ChocoStar™ Compact moulding line is a completely flexible moulding line - based on established technologies - with efficient through-

put for both emerging and established markets.

In the beginning of this article there was the question about the aspects in the chocolate manufacturing industry that will change in the future.

Hygienic, efficient and flexible machines - these are the aspects which will impact industry in the future. The equipment for manufacturing chocolate has to be highly efficient in energy consumption, designed and manufactured according to latest hygienic design standards and flexible in their application.

For further information contact Thomas Bischof of Buhler at e-mail: thomas.bischof@buhlergroup.com. J

PowerShot™ point depositing.

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21

I MARKET FOCUS

Top Four Dominate €46 Billion European Confectionery Market Four manufacturers control about half of the Eur46 billion confectionery market in Western Europe. ollowing its $19.5 billion acquisition of Cadbury in 2010, Kraft Foods is the market leader in Western Europe (15 West European Community members plus Norway and Switzerland). With a current market share of 16.8% it has overtaken Mars (on 13.8%) and Nestle (10.9%). Italian confectionery company Ferrero ranks fourth with a market share of 8.4%, almost double that of fifth ranked Leaf, which has been owned by private equity firm CVC Capital since 2005. According to international food and drink consultancy Food For Thought, the top ten Western European confectionery manufacturers account for 68% of the market, while the top twenty companies hold about 78% (see Table).

Germany is the largest confectionery market in Western Europe, accounting for a quarter of total sales, followed by the UK (19%) and

F

Following its acquisition of Cadbury, Kraft Foods is the confectioney market leader in Western Europe.

France and Italy, both on 12%. Spain and Sweden are the next largest country markets. Indeed, the five largest country markets generate 72% of the total West European confectionery sales and account for 77% of the region’s population. The remaining 12 countries have a combined share of about 28%.

Market Segments The confectionery market is divided into three distinct segments – chocolate, gum and sugar confectionery (candy). Chocolate confectionery (including countlines) is by far the largest segment within the Eur46 billion Western European confectionery market with 62% of sales, worth Eur19 billion. With sales of about Eur13.3 billion, sugar confectionery has a market share of 29%. Chewing gum accounts for the remaining 9%.

In contrast to many other food markets, which are dominated by the supermarket multiples, confectionery is characterised by a relatively low level of penetration by private label products and a high proportion of sales through other types of retail outlets. Smaller shops and other convenience outlets, where confectionery is bought by consumers on impulse rather than as part of a planned shopping trip, still accounts for a significant portion of sales. However, although manufacturers’ branded products still account for 87.6% of the total confectionery market in Western Europe, retailers’ own label products have been making inroads and held a share of 11.7% in 2010.

22

Top 100 Confectionery Manufacturers in Western Europe, 2011 Market Share Rank Company Western Europe Cumulative 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

Kraft Foods Mars Nestlé Ferrero CVC Capital Fazer Konfektyr Lindt & Sprüngli Perfetti Haribo Ritter Storck Toms Cantalou Barry Callebaut Migros Katjes Fassin Mederer Tangerine Confectionery Hosta Orkla CFP Brands Thorntons Hero Elah Dufour Krüger Ricola Bahlsen Süßwaren Imhoff Packbond Holdings P&G

16.78% 13.77% 10.92% 8.42% 4.30% 3.07% 2.96% 2.88% 2.75% 2.43% 1.77% 1.33% 1.24% 1.10% 1.09% 0.73% 0.63% 0.62% 0.57% 0.57% 0.57% 0.53% 0.48% 0.48% 0.47% 0.41% 0.37% 0.36% 0.33% 0.33%

16.78% 30.55% 41.46% 49.89% 54.18% 57.25% 60.20% 63.08% 65.83% 68.26% 70.03% 71.36% 72.61% 73.71% 74.80% 75.52% 76.15% 76.78% 77.35% 77.92% 78.48% 79.01% 79.49% 79.97% 80.44% 80.84% 81.21% 81.57% 81.90% 82.23%

Source: Food For Thought.

Outlook Food For Thought forecasts that the total West European Confectionery Market, which was worth Eur46.0 billion in 2010, will grow at an average annual real 0.80% during the 2010-2013 period.

Innovation has been key to driving market growth in developed markets where premium and ‘better-for-you’ products have been growing in popularity. Despite the recessionary economic environment, confectionery is still regarded as an affordable treat or luxury. However, manufacturers have been faced with sharp rises in raw materials costs, particularly for cocoa and sugar, and falling volume sales in many markets. Finnish group Fazer is the sixth largest confectionery Indeed, the value producer in Western Europe by market share.

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

Top 100 Confectionery Manufacturers in Western Europe, 2011

Swiss chocolate confectionery group Lindt & Sprungli ranks seventh in the Western European confectionery market.

increase in most markets is a reflection of commodity price inflation.

Manufacturers have had to rely on new product development and promotional activity to protect market share.

Eastern Expansion Many of the major manufacturers in Western Europe have expanded into Central and Eastern Europe by establishing manufacturing facilities to exploit these emerging markets. Local players are also investing in growth. For instance, as part of its expansion strategy to increase turnover to $100 million by 2012, CJSC Landrin, one of the largest chocolate confectionery manufacturers in Russia, is to invest in the region of Eur20 million in upgrading and expanding its production capacity. The company will modernise its production facility in Saint Petersburg and also plans to construct a confectionery factory in Ukraine.

Roshen, the Ukrainian confectionery manufacturer, is investing $250 million in building a new production complex in the Lipetsk region of Russia. Due to be finished in 2016, it will be Roshen’s third factory in Russia.

Having only entered the European food market following its purchase of the Wedel branded chocolate and sugar confectionery operations in Poland from Kraft Foods, Tokyo-based Lotte Group is planning to invest in the region of Eur200 million to expand and diversify its newly acquired business. The expansion programme entails the construction of five new factories.

Global Market The top three players in the confectionery market in Western Europe are also the leaders in global terms but are joined by Hershey in fourth place by virtue of its strength in the large North American confectionery market. The acquisition of Cadbury has allowed Kraft Foods to overtake Mars to become the global confectionery market leader, with number one positions in both the chocolate and sugar confectionery segments and a strong number two in the high growth gum segment, still headed by Wrigley, which became part of Mars in 2008.

Hershey is stepping up its growth in Europe as part of its strategy to reduce its reliance on its domestic market by developing internationally, especially in emerging markets such as Asia and Latin America. The North American confectionery group has now established a European subsidiary, located in London. Last year, only 14% of Hershey’s total turnover of $5.3 billion was generated outside of North America.

Chocolate is the largest market segment, accounting for about 55% of all global confectionery sales. The top four players – Kraft, Mars, Nestle and Hershey - control about half of all global chocolate sales.

However, chocolate is a regionalised business with local tastes determining consumer preferences.

Generating 14% of global confectionery sales, gum is the fastest growing segment of the market. It is also the most consolidated and internationalised with the top two players, Wrigley and Kraft Foods, controlling over 60% of the market between them. Sales growth in gum is being driven by innovation and marketing.

Sugar confectionery (candy) is the most fragmented segment, featuring a plethora of local brands and manufacturers with the top four players only holding a combined 24% market share. J

Rank

Company

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

66.

67.

68.

69.

70.

71.

72.

73.

74.

75.

76.

77.

78.

79.

80.

81.

82.

83.

84.

85.

86.

87.

88.

89.

90.

91.

92.

93.

94.

95.

96.

97.

98.

99.

100.

Karlsruher Süßwaren Coop Schweiz Manner Finalrealm Glisten Verquin Leonidas Groder Swizzels Matlow Tengelmann De Aviateur OEP LSH Neuhaus Lacasa Natra Zaini Douglas Holding Danone Averna Yildiz Sorini Jack Chia Vidal Zentis Lotte Delaviuda Northern Foods Van Houten Ion SanchisM. Ashbury Citterio Baronie Sanchez Cano Illycaffé The Sugar Company EuroDelight Baugur G.E.I. Vivil A. Müller Camille Bloch Daintee Elite Industries STI Iberica Blue Bird Unilever Noi Sirius Frederik Chocolatier Astra Sweets Valora Icam Duncans Riegelein Hanseatische Chocolade Big Bear Wawi Dagrofa Haas Loacker Parmalat Andros Accent/EQT Regina Kanold Müller Imperial Productos MB Funds Balconi Brynildsen Fabrikker

Market Share Western Europe Cumulative 0.32% 0.31% 0.26% 0.26% 0.26% 0.24% 0.24% 0.24% 0.23% 0.23% 0.22% 0.21% 0.19% 0.19% 0.19% 0.18% 0.18% 0.18% 0.17% 0.17% 0.17% 0.17% 0.16% 0.16% 0.16% 0.16% 0.14% 0.13% 0.13% 0.13% 0.12% 0.12% 0.11% 0.10% 0.10% 0.10% 0.10% 0.10% 0.09% 0.09% 0.09% 0.09% 0.09% 0.09% 0.09% 0.09% 0.08% 0.08% 0.08% 0.08% 0.08% 0.07% 0.07% 0.07% 0.07% 0.07% 0.07% 0.07% 0.07% 0.07% 0.07% 0.07% 0.07% 0.07% 0.06% 0.06% 0.06% 0.06% 0.06% 0.06%

82.55% 82.86% 83.12% 83.38% 83.64% 83.89% 84.13% 84.36% 84.59% 84.81% 85.03% 85.25% 85.44% 85.63% 85.82% 86.00% 86.18% 86.35% 86.53% 86.70% 86.86% 87.03% 87.20% 87.36% 87.52% 87.68% 87.82% 87.95% 88.08% 88.21% 88.33% 88.45% 88.56% 88.67% 88.77% 88.87% 88.97% 89.07% 89.16% 89.26% 89.35% 89.44% 89.53% 89.62% 89.71% 89.79% 89.88% 89.96% 90.03% 90.11% 90.19% 90.26% 90.33% 90.40% 90.47% 90.54% 90.61% 90.68% 90.75% 90.81% 90.88% 90.95% 91.01% 91.08% 91.14% 91.21% 91.27% 91.33% 91.39% 91.45%

Source: Food For Thought.

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

23

QUALITY

& HYGIENE

New Touch-Screen Food Texture Analyzer ood Technology Corporation (FTC) has F launched its new texture analyzer, the TMS-Touch. The TMS-Touch allows fast and easy texture evaluation to reduce off spec production costs and product waste.

Since consumers judge the quality of foods through texture evaluation, it is vital to maintain consistent texture standards through a routine system of objective monitoring.

Easy to operate, Food Technology Corporation’s TMS-Touch texture analyzer is an affordable, stand-alone system designed specifically for quick and easy food texture testing by unskilled operators.

Controlled by an easy-to-use LCD Touch Screen, The TMS-Touch requires minimal operator training and doesn’t require a PC for testing. Tests are performed at the push of a button and regularly used tests can be saved as “Favorites” for instant test recall and setup, plus there’s password protection to safeguard the data and test setups.

The TMS-Touch can determine the textural properties of almost any food product,

including baked goods, confectionery items, dairy products, fruits, vegetables and meats. Test methods such as breaking,

snapping, tension, shearing, bulk analysis, compression, penetration and extrusion tests are all easily performed.

The president of FTC, Shirl Lakeway Jr, coments: “For an all-in-one, routine, food texture measurement system, the TMSTouch offers the ideal solution without the complexity of a fully featured, research instrument. It is flexible, easy to program, simple to use and very affordable.”

The full range of test cells, probes and fixtures offered by FTC are available for use with this system. You can create and store multiple test programs and there are five favorite buttons for direct access to frequently used programs. The 10 ranges of intelligent load cells are changeable in seconds.

If your requirements change, an upgrade path is available to enable the Advanced Test program mode. This gives you the full functionality of FTC’s research model, The TL-Pro texture system software.

For more information about the TMSTouch, e-mail info@foodtechcorp.com or visit www.foodtechcorp.com. J

Thermocode Provides Prefect Pouch Printing Solution D Foods, based in St Leonards-on-Sea in Sussex, has taken delivery of a B Thermocode 107M thermal transfer printer from Open Date Equipment, to print specific product information onto pouches containing its range of chutneys, sauces, dressings and soups. The Thermocode, which is mounted on a new pouch filling line, was acquired to replace an existing printer, bought in 2010, which was proving unreliable. BD Foods is expanding rapidly so needed continuity of production.

Open Date, which already supplies the company with thermal transfer ribbons for all printers used on-site, responded by lending BD a Thermocode machine to help maintain supplies for customers in the food service wholesale, restaurant, pub, hotel and airline catering sectors. This trial proved so successful the company purchased a new model.

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Chief Engineer at BD Foods, Mike Beresford explains, “Our pouches are generic in colour, style and brand. They need product information, such as ingredients, allergy and storage advice, barcodes, date and batch codes printed on them prior to filling. They are all hot filled, but can also be frozen later, so the printing needs to withstand extremes of temperature. “ He adds: “To date the Thermocode has proved capable of meeting all our requirements and has been very reliable. In addition it has been easy to train our operators to use both the hardware and software supplied. Any minor problems have been sorted out via the telephone technical back-up service, which has proved spot on.”

The printer’s ability to generate ‘best before’ dates, batch codes and Julian codes has virtually eliminated human error when inputting data, according to the company.

The Thermocode 107M has a maximum print area of 106.6mm x 106.6mm.

It can print variable data to 300dpi quality at 450 cycles per minute or 400mm per second. The ribbon length is 500m. For further information contact Open Date on Tel +44 (0)20 8655 4999, Email sales@opendate.co.uk or visit www.opendate.co.uk. J

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

I RETAIL MARKET

Discounters, Convenience and Online Key Drivers as UK Grocery Market Set to Reach £184 Billion by 2016 he UK food and grocery market is set to T be worth £184 billion by 2016, compared to £156.8 billion in 2011, according to the latest research published by IGD Retail Analysis. Discount retailers will be one of the key drivers of this expansion, hitting over £10 billion for the first time: Discounters will grow at an average annual rate of 10.1% and are forecast to be worth £11.4 billion by 2016 (up from £7 billion in 2011).

The convenience sector will grow by 4.7% and is set to be worth £42.2 billion by 2016 (up from £33.6 billion in 2011). Online will be the fastest growing channel with an annual average growth rate of 13.7%. It is set to almost double in value in the next five years to reach £11.2 billion (up from £5.9 billion in 2011).

Joanne Denney-Finch, chief executive of IGD, says: “Despite the extraordinary economic climate and the ongoing uncertainty caused by the euro zone crisis, there are a number of exceptional events in 2012 that could provide opportunities for growth: the Queen’s Jubilee celebrations, the Euro2012 football championship and the London Olympics. During this year’s Royal wedding, for example, our ShopperTrack

Discounters will grow at an average annual rate of 10.1% and are forecast to be worth £11.4 billion by 2016 (up from £7 billion in 2011).

research found there was a spike in shoppers’ interest in food with a local or British theme.

“We still buy most of our groceries at supermarkets and hypermarkets but we are also using different types of stores more often, such as online and convenience. And leading retailers are building their presence in these areas.”

Another growth area is discounters and with people increasingly experiencing a squeeze in incomes, this format will benefit despite counting for a small share of the overall grocery market. “Our ShopperTrack data shows a doubling in shoppers using food dis-

counters for their main source of grocery shopping: 6% of them say they now use this outlet as their main grocery channel, compared to 3% last September,” she points out.

Technology will be another key feature in driving growth in the various food and grocery sectors, according to IGD. This includes, for example, proximity marketing where customers who sign-up to the service receive a text when they are near their local store about specific offers or virtual reality services which allows people with an online camera to get a 3D view of a product without needing to be in a store. J

Sainsbury’s to Double Purchase of British Food ainsbury’s plans to double the amount S of British food it sells by 2020 as part of the UK supermarket group’s 20 by 20

According to Justin King, chief executive of Sainsbury’s, the UK food industry can grow for the future with confidence, Sustainability Plan. Sainsbury’s is already despite the current economic climate, by an industry leader in the sale of British pro- taking advantage of increasing customer duce, spending over £4 billion each year demand for home-grown food. “This prewith its UK suppliers. sents a great opportunity for British farmers, as Sainsbury’s customers increasingly ask for more quality, British food. Now all we need is the industry to work together to create sustainable supply chains for the future,” he comments. “In these tough economic times our country needs action to boost sustainability and create secure supply chains, so our long term commitment and investment will provide security and help the food indusSainsbury’s is already an industry leader in the sale of British try plan and grow food for the produce, spending over £4 billion each year with its UK suppliers. future with confidence.”

Sainsbury’s farmers and growers have already benefited from working with the supermarket group to improve productivity and efficiency. Dairy farmers alone have saved over £10 million in the last five years thanks to improvements in animal welfare and savings in energy bills.

Justin King adds: “We’re going further than any other retailer to support farmers in the Sainsbury’s development groups by creating sustainable, resilient supply chains.

So far we’ve invested over £30 million which includes funding for vet visits, environmental assessments, advice and new IT equipment. We will keep investing in British farming to support the economy and boost farm productivity, creating significant savings on our sustainability journey to 2020.”

Sainsbury’s has now established development groups across beef, lamb, pork, eggs, chicken, milk, cheese, grain and produce. J

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

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Sismatico is a leading independent supplier of Air Conveyor Systems & Can Rinsing Systems for the Beverage market sector

Ionised Air Can Rinsing By Sismatico UK Ltd

PET Bottle Handling Empty Can Handling Can Rinsing Systems Line Control Systems Service and Maintenance

Sismatico was formed in 1995 and is today very proud to have 18 years of success to our name.

Our systems are supplied to the top beverage producers and many key OEM equipment suppliers to compliment their packages.

Sismatico has grown into one of the market leaders supplying & installing extremely successful, low maintenance & efficient lines.We offer our customers excellent service, support and innovative solutions for the major Beverage market sectors.

From our Head Office in Doncaster we offer worldwide assistance & support to our international customer base.

Within the team at Sismatico there are many years of industry experience and ability to go forward with new designs and Sismatico (UK) Ltd developments to assist our Plumtree Farm, customers.

Industrial Estate Our specialized air conveyor Bircotes, Doncaster systems for EMPTY CANS & South Yorkshire PET BOTTLES Plus our CAN United Kingdom RINSNG SYSTEMS are all DN11 8EW manufactured from our UK Tel. +44 (0) 1302 719738 production facility in Fax. +44 (0) 1302 719222 info@sismatico-uk.com Doncaster.

I SOFT DRINKS

Coca-Cola Enterprises to Invest £50 Million to Develop British Business Coca-Cola Enterprises, the UK’s largest soft drinks producer, is investing £50 million across three of its manufacturing sites in Great Britain. he investment at its sites at Wakefield and Sidcup in England, and East Kilbride in Scotland forms a crucial part of Coca-Cola Enterprises’ strategy to grow its business whilst reducing the impact of its operations on the environment, with sustainable innovation at the heart of the £50 million programme.

Coca-Cola Enterprises currently employs around 4,500 people across England, Scotland and Wales at manufacturing sites, regional offices and depots. Simon Baldry, managing director of Coca-Cola Enterprises in GB, says: “We are committed to manufacturing in this country and are proud that 95% of what we sell is made in Great Britain. The £50 million investment is crucial to developing our business in line with our fundamental objective to grow more, while minimising our impact on the environment.

T

£30 Million Investment at Wakefield Approximately £30 million is being invested in a new automated warehouse at Wakefield, which is the largest and most environmentally efficient bottling plant of its kind in Europe. Since 2009, the site has sent zero waste to landfill and has recently been certified to the new international energy management standard, ISO 50001

by SGS United Kingdom. The new facility will increase Wakefield’s storage capacity by 102%, which means that products manufactured at the site will be delivered to customers directly, rather than via external warehouses, saving approximately 500,000 road miles per year.

Since opening in 1989 with four production lines and 120 staff, the Wakefield site has been continually expanded and now operates ten lines, em- Coca-Cola Enterprises is the UK’s largest soft drinks producer. ploys more than 500 people and produces over 100 mil- line will raise the site’s capacity by an addilion cases of product a year. Wakefield is tional 20 million cases of product per year. the company’s largest soft drinks plant in Innovations in the technology used on the Europe, producing 40% of GB volume. It new canning line mean that it will use 20% operates 24 hours a day, seven days a week. less water, and it will help reduce the site’s Since 2007 Coca-Cola Enterprises has carbon footprint by 610 tonnes in 2012. invested around £50 million to make Coca-Cola Enterprises is also investing Wakefield one of the fastest, most efficient £5.4 million in a number of projects at its and sustainable producers of soft drinks in East Kilbride site. These include the introthe world. duction of a new energy-efficient bottle Part of the new blowing facility that will produce lighttwo year con- weight PET bottles, reducing the amount struction pro- of PET required, and a state-of-the-art gramme at Wa- packaging machine that removes the need kefield will entail to use cardboard in the packaging of multimaking improve- pack products. ments to a local wildlife area as European Business well as imple- Coca Cola Enterprises is the world’s third menting a noise largest independent Coca Cola bottler. In reduction plan to ensure minimum disrup- addition to Great Britain, it is also the sole tion to neighbouring residents and businesses. “We are committed to manufacturing in this country, and are proud of the ongoing investment in the Wakefield site,” comments Ian Johnson, site operations director of Coca-Cola Enterprises Wakefield. “Sustainability is in our DNA, and is at the heart of our business decisions.”

Expansion at Sidcup and East Kilbride An investment of £15 million is boosting production capabilities at Coca-Cola Enterprises’ Sidcup site - a new canning FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

Simon Baldry, managing director of Coca-Cola Enterprises in GB.

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licensed bottler for products of The and are proud of our significant sustainCoca-Cola Company in Belgium, contiability progress,” says John Brock, chairnental France, Luxembourg, Monaco, the man and chief executive of Coca-Cola Netherlands, Norway, and Sweden.

Enterprises. “We recognise this is an onCoca-Cola Enterprises has been going journey and believe that partnering focused on its Europe since selling its with our stakeholders is the only way to bottling operations in North America to determine how to shape our CRS comThe Coca-Cola Company in October mitments so we continue to be a viable 2010. Coca-Cola Enterprises retained its part of the solution to environmental and European operations and also acquired social challenges.” the Coca-Cola bottling operations in Coca-Cola Enterprises has invested in both Norway and Sweden. In addition, carbon reduction projects, focusing on its Coca-Cola Enterprises has the right to cold drink equipment and improving effiacquire Coca-Cola’s German bottling ciencies in manufacturing and distribuoperations. tion. Through the group’s internal recyWith annual sales of $7.3 billion (£4.7 cling infrastructure in its facilities, the billion), Coca-Cola Enterprises currently company achieved a 99.5% waste recovery employs 13,500 people and operates 17 rate across its territories. manufacturing facilities across Western John Brock (left), chairman and chief executive of CocaIn March 2011, Coca-Cola Enterprises Europe, where the company distributes a Cola Enterprises, with Muhtar Kent, chairman and chief announced a £5 million investment in a wide range of beverages including regular, executive of The Coca-Cola Company. joint venture with ECO Plastics to develno- and low-calorie sparkling, energy and op one of the biggest plastic reprocessing sports drinks, waters, juices and juice 4% and its water use ratio by 6% while facilities in Western Europe. When operadrinks, coffees and teas. growing business volume by 4% in 2010. tional, the facility is expected to make a The company recently released its sixth step change in the plastics reprocessing Environmental Performance company-wide Corporate Responsibility industry in Great Britain by producing Coca-Cola Enterprises is committed to and Sustainability (CRS) Report - 25,000 tons of recycled PET (rPET) annuminimising the environmental impact of its ‘Committed to 2020: Shaping a ally, more than doubling the amount of products and operations, with a particular Sustainable Future in Europe’. high quality rPET produced in the country focus on sustainable packaging and recy“CRS is core to our business and at the at present. The facility will supply Cocacling, water stewardship, and energy and forefront of our company’s priorities. We Cola Enterprises with enough high quality climate protection. The soft drinks produc- are committed to being the CRS leader in rPET to include 25%t rPET in all its plaser reduced its overall carbon footprint by the food and beverage industry in Europe tic packaging in Great Britain by 2012. J

High Speed Empty Can Handling and Ionised Air Rinsing ismatico UK has built up a high quality S reputation for supplying high speed empty can handling lines and Ionised Air empty Can Rinsing Systems to CCE and many other key beverage producers.

Sismatico UK’s equipment uses the original ‘Jetstream’ principle with a series of low pressure fan units and a combination of special shaped deck louvers and vented top covers to give a continuous high speed supply of empty cans to the upstream filling process.

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Systems are capable of handling can sizes from 150ml to 568ml at speeds from 1000cpm to 2300cpm incorporating either Manual or Automated top cover operation.

Systems consist of a VTU assembly to eliminate any fallen cans, mass air conveyor deck to feed multi lane, twin or single lane rinsers. Systems can be supplied with ‘Water’ or market leading ‘Ionised air’ rinsing packages as installed at the CC Sidcup and Wakefield facilities.

For customers requiring the added feature of ‘empty can inspection’ within the process a special single lane or twin lane vacuum conveyor assembly, depending on line speeds, can be integrated between two buffering zones to ensure high operating efficiencies.

Sismatico UK’s latest proven feature installed at CCE Sidcup, is Can Coding Before Rinsing as this has added benefits for the customer: • Moves Sensitive Coding Equipment

away from Wet areas • Removes Change Part Full Can Drop Twists • Significantly Reduces Full Can Buffering after filling.

The Sismatico overhead vacuum solution provides a position for the chosen coding company to install its equipment. All systems are designed, built and assembled within Sismatico’s UK facility near Doncaster. Contact Sismatico UK on info@sismatico-uk.com for further information. J

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

Mecmesin Launches New Versatile Torque Tester – The Vortex-xt he new touch-screen controlled tester, T the Vortex-xt, brings quality control measurement straight to the point of manufacture. The Vortex-xt is an easy-to-use modern torque tester which has been designed to cut costs by improving production line efficiency and reducing wastage.

It can quickly measure stripping torque and release torque. It is able to identify bridge breaks and can help to avoid spinners. It can also be adapted to test childresistant closures and Mecmesin is able to offer bespoke fittings to match individual containers.

The machine’s simple set-up means manufacturers can test clockwise and counterclockwise torques of packaging components, such as the application and release torque of screw closures, with merely two clicks of the touch screen interface.

Utilising colour-coded results, the large, clear display enables very easy identification of pass/fail sample conformance.

The Vortex-xt is designed to make routine measurements quick, whilst still providing users with detailed results data, as well as reporting capabilities, if required.

Users have the choice of viewing a graphical ‘live’ display of the test for observational purposes, or multiple test results in tabulat-

ed form, to begin making comparisons and, subsequently, to evaluate them in more depth with a choice of calculations. The data collected can then be easily exported to statistical process control software.

Up to 5 frequently used tests can be stored for quick access and initiation by different users, without the need for a high level of technical or test application knowledge.

Password protection allows ‘administrators’ to alter test set-up and template design, thereby avoiding any accidental changes to programmable functions.

Rated to 10N.m, the Vortex-xt completes Mecmesin’s range of 3 motorised torque testing systems, which includes the basic Vortex-d and the top-of-the-range Vortex-i computer-controlled test system.

The managing director of Mecmesin, John Page, says: “Our goal is to make routine sample checks as easy as possible. We realise manufacturers want to make instant, time expedient checks on their products before shipment, therefore the Vortex-xt ensures reliable, user-friendly performance

for production staff with minimal set-up time and training requirements. Adding versatility, this motorised torque tester can also be programmed, for those occasions where special one-off test routines are needed.”

For more information, e-mail info@mecmesin.com or phone + 44 (0)1403 799 979 or visit www. mecmesin.com. J

Glass Packaging Growth Sheds Light on Bright Future lass packaging production G volumes in Europe grew by 4.7% in the first half 2011, according to data just published by the European Container Glass Federation (FEVE). The growth builds on increased production already recorded in 2010. In the first six months, the European industry produced 10.6 Mtonnes of glass compared to 10.2 Mtonnes in the first half 2010. Major EU countries like France were up 7.2% in production volumes, Germany up 7.1%, Italy up 6.4%, and Turkey recorded a dazzling growth of 15% - all signals to a recovered confidence from customers and consumers.

“The industry has generally seen a recov-

ery from the crisis,” says FEVE president Niall Wall. “This means glass packaging remains one of the reference materials for brands and retailers to deliver high quality food and drinks to both domestic and export markets because glass brings great added value while remaining at a competitive price. Such signals reinforce our confidence in the fact that consumers simply

trust glass because of its environmental, health and taste preservation qualities.”

While glass remains the leading choice for some markets like wine, beer or spirits, for other products like milk, yoghurts, baby food or mineral waters, a recent consumer survey showed that the strong consumer demand for glass packaging is not being met due to the lack of choice on supermarket shelves. The glass industry is committed to working with brands and retailers to enlarge their product ranges in glass to meet this expressed demand. J

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

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Mecury Packaging Keeps it Flexible For the Frozen Food Sector ercury Packaging, one of Europe’s leading suppliers of plain, printed, laminated M and converted flexible packaging products, has implemented an aggressive sales drive aimed at significantly growing its presence within the frozen food sector over the next 12 months. As part of the exciting new initiative, BRC-accredited Mercury Packaging has become a member of the British Frozen Food Federation and installed a cutting edge UTECO ‘Eclipse’ Solventless Digital Laminating System for high specification pack designs.

Investment in high performance conversion, laminating and printing technology together with an in-house design department enables Mercury Packaging to deliver lightweight yet robust plastics packs and film-onthe-reel which have been specially designed to achieve maximum brand awareness, shelf life

and protection.

Tony Stanger, Mercury Packaging’s managing director, comments: “Our high quality laminates provide excellent barrier properties

for frozen food products and can be customised to include special features and finishes such as gas barrier, odour barrier, UV absorber, etc. Designed to suit individual customer requirements, these films offer excellent protection for packaged goods and substantial enhancement in shelf life – reducing wastage for the packer and consumer.”

Mercury Packaging has vast experience in providing highly efficient film-on-the-reel for all kinds of horizontal and vertical form fill and seal applications, as well as for flow-wrapping or lidding. Bags and pouches can be supplied in a variety of styles and options: with or without gusset, tear-off perforations, punched handles, ventilation perforations, re-sealable tapes, captive flap and blockheaded. For further information contact Mercury Packaging on Tel +44 (0)1623 759600 or visit www.mercurypackaging.com. J

Sustainable Success For Kliklok ealthy food company Nature H Delivered has chosen Kliklok again to supply two more JR carton forming machines for its plant in Feltham, having already installed three. As part of its move to reduce its packaging by using thinner, 100% biodegradable and recycled carton board, Nature Delivered initially asked Kliklok to supply a cartoning machine to ease the transition from hand erecting to automatic carton forming. The products

are portions of dried fruit, nuts & seeds that sit inside compartments in a specially formed top load carton. As well as erecting the cartons, Kliklok is pre-breaking the three lid flaps, as they are tucked inside the carton once the product has been manually inserted. The package is then mailed to homes and workplaces as a healthy alternative for lunches and snacks.

For further information visit www.kliklok-int.com. J

National Flexible ISO:n Board ational Flexible have recently passed a N routine ISO audit with an exemplary performance, demonstrating their commitment to delivering excellent supplier performance. As part of their continuous improvement programme, National

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Flexible have continued to invest in the processes and systems that help them to maintain their performance and which have allowed them to build a reputation as a company that differentiates through quality, reliability, consistency, technical expertise and the level of service they provide.

National Flexible were only recently acknowledged by Nestle for their performance as an ‘outstanding supplier’ when they were among only a handful to be granted the prestigious Green Light supplier award in recognition of the way they have helped them to reduce costs and added value to Nestle’s operations over the years they have worked with them.

“We have always operated to a high

standard and pride ourselves on being a business that is driven by the needs of our customers,” says National Flexible’s chief executive Barry Twigg. “The importance we place on our ISO and BRC operating frameworks cannot be understated.”

National Flexible operate from a state-ofthe-art facility on the outskirts of Bradford, servicing customers with flexible packaging in the food, confectionery, bakery, snack, contract packing and pharmaceutical industries. The factory was purpose built to be compliant with the latest BRC and ISO global standards for food-grade flexible packaging materials and is the UK’s largest BOPP conversion facility. For any further information contact National Flexible on Tel +44 (0)1274 685566 or visit www.nationalflexible.co.uk. J

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

I PACKAGING DESIGN

Mimosa Pack Wins Top Retail Ready Award or the second year running, DS Smith F Packaging has won the prestigious Retail Ready Pack of the Year accolade at

integral dividers. The structure uses the characteristics of corrugated board with crumple zone areas to absorb energy impact and minimise damage. The pack creates an eye-catching display that looks good on-shelf and is easy to find back of store.

The one-piece 100% recyclable pack allows faster assembly and 'in-line' product packing (no gluing for the customer to do). It is printed in four colours to complement the primary pack. The contents are highly visible to consumers and the pack makes it easier to manage the shelf, as individual bottles do not have to be decanted. J

the UK Packaging Awards. In the 2011 event, DS Smith Packaging’s retail ready entries were so strong that they were selected for all three short listed places.

The judges opted for Mimosa Market’s Rape Seed Oil pack describing it as a “good, clean pack” giving the brand a “great impact” in-store and solving the problem of protecting a fragile product “without over-packaging.”

The corrugated pack was designed by DS Smith Packaging Louth to protect six bottles of oil in a one-piece unit using

Reinvigorated Packaging For Seven Seas S Smith Speciality Packaging, Belper, D has designed new, high quality retail ready packaging for the Seven Seas range of Liquid Pure Cod Liver Oil. The different bottles had been previously packed in a variety of B-flute open fronted trays with shrink-wrap. All these have been replaced with a single material.

Using PackRight, DS Smith Packaging was able to specify another space saving material with an ideal print surface, Cartonflute, to optimise the packaging’s performance in the supply chain and its appearance in store. ImageRight enabled an exact match of the brand colours, so that primary and secondary packaging work in

perfect harmony.

High quality flexo print has been applied on both the outside and inside liners to cre-

ate greater impact on shelf. What is more, these attractive packs incorporate clean perforations that add greatly to the visual presentation of the Seven Seas range.

Each pack has an Imagelase panel containing data such as product descriptors, pack weights and barcodes. This has resulted in reductions in packaging inventories, fewer changeovers on the packing line and the total elimination of consumables such as labels or ink-jetting.

It all goes to show how working with DS Smith Packaging enables customers to improve supply chain efficiency whilst driving out costs and carbon and boosting sales in store. J

Chocolate Bar Breaks Record S Smith Packaging has been D delighted to support Thorntons, its long-time and highly valued customer, by creating replica packaging for the world’s biggest chocolate bar.

Thorntons celebrated its 100th anniversary by producing the massive, nearly six tonne bar, thereby entering the Guinness Book of World Records.

After months of top-secret planning, Thorntons made the bar in its iconic Continental 90gm chocolate block design.

DS Smith Packaging’s replica packaging was produced through a truly collaborative effort, showing how well the different capabilities of the business can work together to a customer’s benefit.

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

DS Smith Packaging’s Clay Cross design team managed the specification and manufacture of the pack; its Monmouth site, home to Tri-Wall, supplied the board; DS Smith Multigraphics printed the vinyl graphics.

Steven Rose, managing director at Clay Cross explains: “This was a fantastic opportunity to support Thorntons and a real challenge to produce an exact replica of the packaging.

We relied on each site’s skills set to make this idea happen. Everyone was very happy with the result.”

Emma Tag of Thorntons comments: “The carton looked totally amazing and really made the record chocolate bar stand out.” J 31

Astra Plastique Launches Picasso Flip-Top Translucent Sports Cap stra Plastique has developed Picasso, a high tech custom tri-colour flip-top sports closure A with a translucent polypropylene body incorporating an innovative integral tamper evident band, which remains within the closure after opening. Nestle has chosen Picasso for its European water brands.

Nestle is highlighting the progressive design features and benefits of the Picasso closure on the product labeling and on the brand support websites. Astra Plastique has patented the integral tamper evident band which is completely inaccessible and therefore inviolable, even with an external tool. The translucent material for the closure body and flip-top allows a clear view of the colour-contrasted tamper evident band; when the flip-top is pushed open for the first time the band’s bridges break automatically, the lower section then drops to the base of the spout and is retained there as permanent evidence of opening.

A significant benefit of this tamper evident design is that no separate strip of plastic is thrown away, a concept in line with the environmental policies of GCS and Nestle.

Picasso also features a double hinge, which enables the flip-top to open easily to 180 degrees, holding it in that position for a more comfortable drinking experience. The flip-top closes with a positive click to ensure a full seal.

Picasso is produced both with and without a silicone valve for maximum versatility, a concept mastered by the GCS Group in the beverage and other markets. With the valved flip-top open, the bottle can be safely tipped upside down without spills or leaks making it ideal for the playground, at work or on the move and the silicone valve provides the cleanest, easiest and most convenient drinking facility of all sports caps. For further information contact GCS on Tel +44 (0) 1784 415209 or visit www.gcs.com. J

Thermocode Provides Pouch Printing Solution based in Sussex, England, has BDtakenFoods, delivery of a Thermocode 107M

thermal transfer printer from Open Date Equipment, to print specific product information onto pouches containing its range of chutneys, sauces, dressings and soups.

The Thermocode, which is mounted on a new pouch filling line, was acquired to replace an existing printer, bought in 2010, which was proving unreliable. BD Foods is expanding rapidly so needed continuity of production.

Chief engineer at BD Foods, Mike Beresford explains: “Our pouches are generic in colour, style and brand. They

need product information, such as ingredients, allergy and storage advice, barcodes, date and batch codes printed on them prior to filling. They are all hot filled, but can also be frozen later, so the printing needs to withstand extremes of temperature.” The printer’s ability to generate ‘best before’ dates, batch codes and Julian codes has virtually eliminated human error when inputting data, according to BD Foods. For further information contact Open Date Equipment on Tel +44 (0)20 8655 4999 or visit www.opendate.co.uk. J

G Mondini-Ulma Launches Tray Skin Solution For Tray Sealing Mondini-Ulma has introduced a tray G skin solution for use with its EVO and Trave range of machines, which it hopes will revolutionise the sealing of meat, poultry, fish and ready meals. The system produces a high visibility vacuum pack on a pre-formed tray providing additional shelf life, better meat quality and reduced packaging on a low profile tray. Traditionally vacuum packed products have been produced on a thermoformer, but the Mondini system offers total flexibility on the types of materials which can be used and gives an added value appearance to vacuum packed 32

products.

The latest range of Mondini machines offer unique multi format opportunities.

The same machine can be used for MAP tray sealing, tray skin packing, Super protruding skin packing and more. These high speed machines offer producers flexibility and future proofing against change in customer demands Initially, G Mondini-Ulma will be offering customers three solutions, 'standard skin' which is ideal for low profile items such as cuts of meat and small fish, 'protruding skin' for ready meals, steaks, meat

portions and whole fish, and Super protruding for large meat joints, turkey crowns etc. A key benefit for meat applications is that meat joints can continue maturing in the pack, therefore adding further product value. J

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

QUALITY

& HYGIENE

US Food Safety Hazard: Cantaloupe Caused Listeria Food Poisoning n October 19, 2011 the US Food and O Drug Administration (FDA) confirmed the presence of strains of listeria in cantaloupe samples taken from Jensen Farms.

Currently, there are 33 additional illnesses and 29 deaths reported to be linked to the ongoing outbreak of listeria food poisoning from Colorado-grown cantaloupes.

The bacterium that causes listeriosis, L. monocytogenes, produces varying symptoms depending on a person's risk factors.

Listeriosis normally starts with diarrhea followed by fever and muscle aches, similar to the symptoms of flu. If pregnant women develop the flu-like symptoms they may also endure complications including miscarriage, stillbirth, premature delivery or a fatal infection of the newborn infant. Elderly people with defective immune systems and young children can develop headaches, stiff neck, mental confusion, loss of balance and convulsions and can result in fatal meningitis or encephalitis. The onset of symptoms can occur anytime between three days to two months after infection occurs.

The Colorado Department of Public Health and Environment reported it had nine cases of listeriosis including two deaths on September 2, 2011 prompting the US Food and Drug Administration and US Centers for Disease Control to commence an urgent investigation of the multiple state outbreak in which cantaloupe was the suspected infection vehicle.

On September 10, 2011 the FDA and Colorado state officials visited cantaloupe producer Jensen Farms to collect multiple

samples. Of the 30 swabs taken, 13 were confirmed positive for L. monocytogenes with pulsed-field gel electrophoresis (PFGE) pattern combinations matching three of the four outbreak strains. In addition, cantaloupes from the firm's cold storage area confirmed positive for the bacteria with PFGE pattern combinations matching two of the four outbreak strains.

The FDA identified several factors that most likely caused the introduction, spread and growth of L. monocytogenes at Jensen Farms. The problem may have been stemmed from bacteria in the field where the cantaloupes were grown or through contamination of the packing facility by a truck that

hauled reject cantaloupes to a cattle operation. The bacteria may also have spread in water near the machinery and employee walkways, hard-to-clean floors and/or machinery in the packing facility, or from equipment previously used for other agricultural products. Bacteria growth is likely promoted by condensation, due to a missing pre-cooling step prior to cold storage.

The FDA concluded that if the facility had followed the non-binding recommendations for minimizing microbial food safety hazards in melons, as published by the FDA in July 2009, these problems might have been avoided. Obligatory standards will soon be enforced under the Food Safety Modernization Act of 2010, providing new authorities for the FDA. In all, four outbreak strains of L. monocytogenes were found in 26 US states, leading to 29 deaths and 33 additional illnesses.

Settlements to the families may cost $150 million.

SGS Food Safety Services

SGS, the global leader in third-party testing, provides food safety services to the whole food supply chain, from farm to fork, to help assure that your products are fit for consumption. SGS has testing labs throughout the world that can test food products for L. monocytogenes.

For more information on food safety and testing for L. monocytogenes, contact SGS Consumer Testing Services at email cts.media@sgs.com or visit www.foodsafety.sgs.com. J

LGC Standards Supports Food Labs With Range of Stevia Reference Standards preparation for the recent EU approval of Iblednsteviol glycosides, LGC Standards has assemthe largest and most up-to-date range of stevia reference standards in Europe, including an exclusive series of standards for the JECFA analytical method.

These standards provide laboratories that are undertaking the determination of steviol glycosides in food and beverages according to the JECFA (Joint FAO/WHO Expert Committee on Food Additives) method, with one complete kit containing all nine compounds required.

As a distributor for ChromaDexTM, LGC Standards’ range of highly characterised ana-

lytical reference standards for steviol glycosides are not only necessary for food and beverage manufacturers to ensure the consistency and quality of stevia-based products, but are important for public sector analysts checking for compliance with the EU limits.

Scientists in LGC’s Science & Technology division are also developing a robust and fully validated method for the simultaneous determination of sweeteners, both artificial and natural (including steviol glycosides) in various food products. This project is funded by the UK Food Standards Agency.

For further information on these stevia reference standards, contact your local LGC

Standards sales office, or email: askus@lgcstandards.com. Customers within the UK can place their order through the LGC webshop (www.shop.lgcstandards.com). J

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I MEAT PROCESSING

Callan Bacon Continues its Winning Streak Having doubled in size over the past five years to reach a turnover in excess of €40 million and now armed with new and expanded production facilities, Irish pork processor Callan Bacon is well placed to continue on its strong growth trajectory. ased at Callan in County Kilkenny, the family-owned company specialises in supplying consumer pork and bacon products, ranging from gammon joints and rashers to marinated pork in oven ready trays, to major retailers in Ireland and the UK. About 90% of products are sold under private label although Callan Bacon has developed its own brand, which is sold in selected Dunnes stores outlets in Ireland and Nisa Todays in the UK. The company’s distinctive bacon cure is also highly sort after by butchers and wholesalers.

Callan Bacon sources its specially selected raw materials from its supplier partners before traditionally curing for three to five days and then cutting into consumer packs for dispatch to customers.

Managing director John Walshe has headed the company since 1985. His family has run Callan Bacon for four generations, developing the company from its modest premises in pre-World War II Ireland into a state-of-the-art meat processing business.

luding oven ready pork along with pork chops and pork eye joints). The bacon joints range covers oven ready joints, streaky joints, eye loin joints and dry cured back bacon joints. Callan Bacon has also harnessed its experience and expertise in the fresh meat sector to develop a range of frozen products.

B

Modern Facility Originally established in 1924, the company has been operating from its present site since 1990 when it built a purpose

designed factory, which was upgraded and extended in July 2010. The expansion project has resulted in a 57,000 sq ft world class facility, which has the capacity to produce 45,000 tonnes per annum and provides Callan Bacon with a strong base to enable it to continue its growth in the UK and to launch into continental Europe. The company has also created thirty new jobs within the last year to increase its workforce to over 120 people.

“Our process lines are designed for high volume with the latest and most advanced technology available. Our computer systems give fully traceability from the back door to the retailers,” points out Paul Walshe, market development manager at Callan Bacon. “We are constantly re-investing in our facilities to continually bring more value to our consumers,” He adds: “Our facility and technology would be among the most modern in Europe and would be the most modern in Ireland.”

John Walshe (centre), managing director of Callan Bacon, receiving three awards - gold, silver and bronze - at the Blas na hEireann (National Irish Food awards) 2011.

Product Range Callan Bacon offers a comprehensive product range encompassing gammon joints, bacon joints, oven ready products (catering for modern taste and easy cooking), sliced bacon (including gammon steaks) and pork (inc-

Market Trends Callan Bacon is continuing to grow because of its ability to respond to the changing needs of modern consumers.

While value for money is now a priority, consumers are also seeking products which offer taste and convenience.

“Consumers are looking for products which are easy to cook in under thirty minutes but are also interesting and with some new taste flavours,” says Paul Walshe. “The Modern consumer is looking for higher quality products with less salt and more innovation. The present economic environment requires us to examine every single part of the business to ensure the consumer gets the value they require in these hard times.”

Innovation Callan Bacon’s New Product Development department has risen to the challenge. The company’s oven ready range has been highly successful and has shown significant growth during the past two years as well as winning some prestigious awards. The quality and innovation of Callan Bacon’s products have been recognised in the British Guild of Fine Food’s Great Taste Awards and The Grocer Awards in the UK. In the recent blas na hEireann (National Irish Food awards) 2011 competition, Callan Bacon won gold, silver and bronze in the intensely competitive ‘bacon’ category. The company’s Sweet Cured Pork Loin with a Mixed Pepper Crust and its Smoked Back Bacon Joint were awarded bronze and silver medals respectively. Callan also won gold as the overall category winner with its Smoked Bacon Eye Loin Sweet

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

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Immediate, quantifiable

bottom line savings Making every second count with Idhammar OEE Systems In the current economic climate, every second of production counts. Moreover, precision operation and reliable and accurate production information is fundamental to success in high pressure food and drink manufacturing.

Overall Equipment Effectiveness is a powerful industry standard measure that multiplies plant availability and performance with output quality, to identify all aspects of waste in your production process. While you can calculate OEE with a spreadsheet, OEE systems enable drill down analysis to quantify even the smallest opportunities to help you make every second count, steer operational improvement agendas, and ensure your resources are effectively deployed.

Idhammar OEE is already driving financial benefits to a wide range of leading manufacturers from Premier Foods, Chivas Brothers, and Accolade Wines, to Percy Dalton’s Peanuts and Aunt Bessie’s.

Stuart Drysale, Manufacturing Director at Aunt Bessie’s, says, “The Idhammar OEE system highlights losses, drives our improvement agenda, and leads to improved effectiveness, a better working environment and big bottom line savings. Our minimum improvement last year was 14% and our best was 47%, so the system paid for itself in a couple of months.”

To achieve the full potential of your production processes, call Idhammar on +44 (0)117 920 9400 or visit www.idhammarsystems.com

Contact us today to find out what even a 1% OEE improvement could mean to your organisation. Idhammar will help put together a business case for implementing an OEE system, identify potential savings and calculate an accurate ROI.

Cure Bacon.

Future Prospects “Winning the entire categoEquipped with its expanded, ry was a real achievement for state-of-the-art production faciliall the team, and it’s a tribute ty, Callan Bacon is well prepared to the emphasis we place on to achieve further sales growth as quality and taste for every it develops new products and product,” Paul Walshe explores new market opportuniremarks. “Outstanding export ties. “We have doubled in size success has followed our excelover the past five years and lent performance in the expect to continue this trend over domestic market.” the next five years,” says Paul Callan Bacon has been Walshe. “Callan’s drive is to be a working to develop new prod- Callan Bacon operates a 57,000 sq ft world class facility, which has the capacity world class company in every ucts in a number of categories. to produce 45,000 tonnes per annum. facet of our business and we are Recognising that bacon is traundertaking several key initiates ditionally a product marketed to a more ucts in the frozen foods sector and is to reach this goal.” mature consumer, the company is aiming launching a range of premium options to The enterprising company is planning to its new ranges at the young and pre family grow this category. invest over Eur500,000 in the next two categories, where it believes real opportuni“With a department devoted to New years in product development alone plus ty exists.

Product Development, it is our ability to another Eur1 million during the next The NPD team is also convinced there is listen to channel partners and retailers and twelve months on new machinery. “In this room for more innovation in sliced bacon firmly react to trends that has seen us grow business you need to constantly upgrade and has been striving to offer new products business substantially in what is undoubt- your machinery to ensure the consumer and approaches. Callan Bacon is also keen edly a tough trading environment,” Paul gets the best value possible,” Paul Walshe to exploit further potential for new prod- Walshe points out. concludes. J

I MEAT PROCESSING

Rising Input Costs Impact Profits at Cranswick ranswick, one of the leading UK suppliers of pork products, has reported a 23% drop in operating profit to £19.0 million on revenue up 3% to £393.9 million for the six months ended 30th September 2011, compared to the corresponding period in the previous year. Operating margin at 4.8% of sales was also below the 6.4% achieved in the same period last year and for the last financial year as a whole.

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Operating margins were impacted by a sharp increase in input costs during the first quarter of the financial year.

Operating profit included £0.5 million in respect of the group’s 49% share of the post-tax losses of associate company Farmers Boy (Deeside). Pre-tax profit declined to £18.5 million from £23.8 million a year ago.

Volume Growth On a like-for-like basis Cranswick’s sales increased by 6%, reflecting strong volume growth across most categories. Fresh pork sales in the first six months rose by 14% to £143 million. Sausage sales were 6% ahead at £37 million. During the first half, bacon sales increased by 30% to £24 million, and underlying sales of cooked meats were up by 4% to £119 million.

Indeed, pigmeat products have gained an increased share of the UK retail protein market due to the versatility and low relative price of pork to other proteins.

Cranswick’s sandwich sales also increased in the period by 3% to £25 million. ”Current trading is good and much improved and the group is, with the exception of continental products, seeing growth across each of its categories. The company’s customer base continues to

grow and new products are constantly being developed, either in existing categories or in new areas,” points out Bernard Hoggarth, chief executive of Cranswick. £100 Million Invested He adds: “With over £100 million invested in the group’s infrastructure over the past five years, its facilities are class leading.

New product development teams which are the envy of the competition and a continued focus on customer service are key factors in the group continuing to be first choice supplier to its customers.” J

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High Quality Systems and Solutions From SF Engineering ased in County Sligo, Ireland, SF B Engineering specialises in providing highquality systems and solutions for the food processing industry both in Ireland and internationally. Building on strong partnerships with major food producers and other equipment manufacturers, SF supplies a full range of processing and packaging equipment from its own innovative conveyor systems to hightech multihead weighers, innovative 3D vision systems, x-ray quality control technology, and end of the line packing robots.

In 2009, SF acquired Opal FPS, a leading manufacturer of butchery systems to the meat industry. The acquisition has enabled SF to draw on 220 years of combined experience in bringing innovative engineering solutions to the food industry.

SF currently employs 80 people and has an annual turnover in excess of Eur12 million.

The company operates across three sites, maintaining production plants in Sligo and Cambridge and a base of project people in Prague.

Innovators and Integrators

SF emphasises innovation and the integration of tried and tested systems that meet the specific operational needs of customers with the aim of improving their production efficiency, yield, and product quality. Everything that SF does is about creating profitability for its Irish and global customer base.

Building on years of engineering and technical expertise, SF offers a wide variety of systems, each tailored to the specific needs of a

particular niche in food production. From butchery and cutting to weighing, grading, portioning, and deboning to packing, stacking, and dispatching, SF specialises in hightech applications that can be monitored with advanced software solutions that deliver the right production data into a customer’s ERP system.

SF has strategic partnerships with some of the major suppliers of equipment in the industry, including Ishida, Ceia and Key Technology. Indeed, SF is expert in integrating different pieces of equipment of different brands into full production lines.

Constant Investment

SF is committed to continuous investment in its business to maintain its innovation capability and its competitive edge, and to ensure that its products and services are of the quality expected by its growing customer base.

Despite the tough economic conditions, SF has invested heavily in new acquisitions and brand development, as well as research & development in the last few years.

The company has substantially expanded its production area, devoting a large proportion of the space to the fabrication of its Batch Distribution Systems (BDS) as well as housing the bead-blast finishing division.

A dedicated customer PDI area and a new R&D centre have also been added, both aimed at better serving SF’s increasing customer base.

In conjunction with the expansion of the production area SF has also invested heavily in the heart of the company – the design department. Employing the latest computer technology and a recent Solidworks 2011 upgrade, all the company’s designers have the best resources needed to produce high

quality design.

SF plans to expand its workforce by 25% over the coming 12 months as it benefits from the recent 40% increase in manufacturing capacity.

Expanding Overseas

With over 80% of the major food manufacturing companies in Ireland as customers, SF has managed to stay innovative and competitive, while building its business overseas.

Reflecting its success in winning new customers abroad, the enterprising company recently received the ‘Manufacturing Exporter Award 2011’ from the Irish Exporters Association. Sponsored by Enterprise Ireland, the award recognises the achievements of manufacturing companies in securing and building new export markets. SF is currently exporting to the UK, Russia, the Middle East, Poland, USA, Australia, Japan and Chili. J

SF Engineering at Callan Bacon Having established a strong working relationship with SF Engineering in the past, Callan Bacon contacted SF to assist with the development of a new layout and production design. Focusing on improving efficiency, throughput and yield, the team designed a smooth product flow, going from raw to finished product in one process. As a result of this streamlined production flow, product handling has been minimised, yield increased and overall efficiency improved significantly.

The packing end of the production is completely automated, requiring no operators.

What’s more, SF and Callan Bacon have easily achieved the line speeds required at the front end of the packing hall. Controlled by SF’s high

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speed conveyors, five packing lines converge into one via an automatic converger that delivers the product onto a single lane ready for labelling.

The Ishida Weigh Price Labeller applies labels simultaneously to both top and bottom of the pack at the rate of up to 60 packs per minute with minimum operating costs and label waste.

Product and labels changeovers are easy and cleaning is simple.

Data on every pack from the labeller is fed directly into Callan’s control system, providing valuable real time yield control. Label changes can also be done very quickly thanks to Ishida’s unique label cassettes.

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

I MIXING, BLENDING & SLICING

Bacon Slicing – Capacity Without Compromise volution is imperative in the continued E development of any business and bacon slicing is no exception. With the Weber range of slicers supplied by Interfood Technology, continual improvement is not just a nice slogan dreamed up by the marketing department, it is one of the cornerstones on which the company’s success has been built.

Back in the mid 00’s Weber entered the bacon market with its ever reliable 902 workhorse alongside its new scanning technology.

This combination set a new standard in yield recovery, offering unrivalled give-away control coupled with excellent levels of accept rate (portions produced in-weight, right first time): evolution had occurred and a new standard had been set.

The launch of the 904 brought a stepchange in machine technology, from which evolved the new Weber 804, introduced last year, to offer a new mid-range involute blade slicer. The 804 was designed to ultimately replace the 902, incorporating all of the technical advantages developed in this machine into a more compact, cost effective model – so what next?

Twin Log Slicing

Having made the advances in yield recovery, the next step has to be capacity, and with this in mind Weber have successfully launched twin log slicing of bacon primals on the 904.

Rob Unwin, director of Interfood’s Slicing

Division, comments: “The ability to produce greater capacity in today’s market is a major step forward; manufactures are under constant pressure to drive efficiency, cut manufacturing costs and improve profitability. But with the ever increasing cost of raw material and a technically demanding market place, capacity cannot be achieved at the expense of quality or yield – meat is money and customers buy with their eyes - they might be cliches but they have never been truer.

“We might now be slicing two primals simultaneously but with the evolution of multi-track scanning and independent controls and ever improving blade technology, we can truly offer capacity without compromise, increasing throughput, holding yield recovery and ensuring that the slice and pack quality is in no way affected.”

Specific Demands

He continues: “Bacon brings its own specific demands in terms of slicing and we have undertaken extensive trials before bringing

the dual log approach to the market. You only get one chance at making a first impression and we felt it was vital not to rush the technology to market prematurely.

“The technology for multi-track scanning has been available for some time and we had the throat capacity but we needed to make sure the control system in no way compromised performance when moving into twin log slicing. In slicing two bacon primals simultaneously, we deliver everything that we did when slicing just one and that was key for us in deciding to take this to our customers.

It’s always better to do your homework first as Weber have always been in it for the long haul.”

Loading Solutions

With higher in-line volumes, the requirement increases for loading solutions and Weber can offer a number of loading options, but most suited to bacon is Weber’s established, inhouse, pick and place technology. Portions are visually spotted prior to loading so regardless of whether the portion has twisted slightly or moved through transport, the picker picks the portion in its actual position and then delivers and loads to the fixed position of the packaging machine. The picker can also rotate the portion through 90° so that a packaging machine which has a pack orientation that differs to that of the slicer can still be loaded, a common occurrence in bacon slicing.

Rob Unwin concludes: “Weber has always been recognised for its innovative approach to slicing but it is an approach which has never sacrificed performance. We have worked with Weber for many years and we know it is all about understanding your market to ensure that any innovation only enhances a slicer’s capabilities and takes nothing away.”

For further information contact Interfood Technology on Tel +44 (0)1844 217676 or visit www.interfoodtechnology.com. J

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I MIXING, BLENDING & SLICING

New Silverson Verso – Streamline Scale-up With Pilot-scale In-Line Mixer oing from the lab to production scale G has always been a challenge. With the new Silverson Verso, it has become less of one. “The Verso reproduces what we can do on a production scale,” explains David Rothman, director of Silverson Machines. “It gives clients the ability to start scaling accurately with smaller volumes than they were able to previously.”

A bench top in-line mixer, the Verso is ideal for pilot-scale or laboratory applications. Controlled from a digital operating touch pad, it offers excellent reproducibility when scaling up, and with a tachometer, ammeter and programmable timer, it provides an accurate and easy method of forecasting the performance of larger in-line mixers under full-scale con-

ditions.

The Verso complements Silverson’s lab range of equipment, providing the next step in the scale-up process. The 1 hp machine has a self-pumping flow rate of 6.5 U.S. gallons per minute (depending

on product viscosity). “We developed the Verso as a direct response to customer requests. Our customers wanted an interim size machine that could allow them to streamline their scale-up process,” says David Rothman. “Our production scale UHS Series In-Line Mixers can be used with single or multistage rotor/stator configurations, so we have included that option with the Verso as well.”

A full range of interchangeable workheads is available for the Verso, allowing it to perform the widest range of mixing duties, including blending, emulsifying, homogenizing, solubilizing, suspending, dispersing, particle size reduction and reaction acceleration. For further information visit www.silverson.co.uk. J

1,500-Gallon Kettle and Mixing System is an Industry First S-based Lee Industries, which speU cialises in designing and manufacturing stainless steel process equipment, recently built a 1,500-gallon production vessel for a customer. The delivered product was the industry’s first-ever 1,500-gallon capacity hemispherical kettle. The unit also features Lee’s patented Tri-Mix Turbo-Shear, one of the most versatile, high performance mixing systems avail-

able today.

Greg Wharton, vice president of Lee Industries, comments: “This truly represents an unprecedented process systems blending of capacity, versatility and functionality. This product exemplifies the Lee Industries commitment to the success of our customers by providing world-class high quality stainless steel process equipment and service.”

He continues: “In the new lean manufacturing world, being able to fabricate larger vessels allows our customer to produce more product without having to use multiple vessels. The bottom line is that being able to produce product in a single larger vessel is more cost-efficient for our clients than multiple smaller kettles.” The company has subsequently built two 2,000 gallon Twin Action kettles. J

Major Developments at Newtech ewtech’s new workshop and assembly N area in its recently refurbished warehouse at Sharnbrook in Bedfordshire, England, is now fully functional. A mezzanine floor was built to provide an area for stores that is fit for purpose. This move frees up the previous area as office space for the company’s design team/demonstration area.

The relocation marks a milestone in the period of investment that Newtech is making in R&D. Almost £0.25 million has been invested in engineering staff and product development over recent years, as interest in Newtech’s ultrasonic cutting machines increases. With 12 years of expe-

rience in ultrasonic cutting, the company is a leader in this type of technology for the food industry and has recently expanded its customer installation base into France.

Newtech has recently expanded its product portfolio with the introduction of Titan Slicers, the market leader in Australia and New Zealand. The Titan range of industrial slicers is ideally suited for a wide range of meat, fish and dairy product slicing.

The Titan Slicer delivers precision performance despite huge variations in raw material properties and the need to process a wide range of different product on one

piece of equipment with the absolute minimum changeover time. Processor friendly benefits are incorporated into the design, including auto tilt loading, auto weighing, vision systems, on-board production performance data collection and packaging system interface. For further information visit www.newtech-ltd.co.uk. J

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

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‘Serious Service’ Improves CO2 Plant Performance Improved availability, lower maintenance and utility costs as well as instant hotline trouble shooting and strong operator skills are some of the benefits you can obtain by implementing the service programme - Serious Service - offered by Union Engineering. nion Engineering is the world leader withU in CO2 technology. Through the years more than 500 reference plants have been

designed to keep your CO2 plant performing at its best during the whole plant lifecycle. To meet the needs of all customers and plant sizes we have furthermore divided the programmes into three levels (basic, silver and gold packages), depending on individual needs.”

designed, engineered and installed worldwide.

The in depth insight and knowledge that the

“We have established a flexible range of service solutions designed to keep your CO2 plant performing at its best during the whole plant lifecycle. To meet the needs of all customers and plant sizes we have furthermore divided the programmes into three levels (basic, silver and gold packages), depending on individual needs.”

company has built up has also given an understanding of how to maintain the best performing CO2 plants, and how to avoid forced stoppages.

Henrik Hinz, General Sales Manager, Customer Service, explains: “Experience shows that plants monitored by true experts have a longer lifetime, lower maintenance costs and improved availability. Running a CO2 plant efficiently and achieving high onstream rate are critical to all CO2 plant owners. Lack of delivery can be very costly!”

Union Engineering has therefore developed a service programme consisting of five unique packages: • Remote monitoring is designed to provide proactive troubleshooting and long-term performance optimization through continuous monitoring from dedicated specialists.

• Data acquisition offers optimization of the plant based on continuously collected and available data and KPI’s.

• Preventive maintenance is about preventing problems before they occur, scheduling stops and carrying our recommended overhauls, emphasizing a maximum of availability.

• Training and consultancy helps to improve the skills and plant understanding of operators, maintenance personnel and management.

• 24/7/365 hotline agreement is the fastest access to a Union Engineering troubleshooting specialist who can access the plant instantly.

Henrik Hinz elaborates: “We have established a flexible range of service solutions

You can learn more about Serious Service by contacting the Union Engineering service department at service@union.dk or learn more on www.union.dk. Union Engineering, Snaremosevej 27, Dk-7000 Fredericia, Denmark. Tel +45 7620 7700. J

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

“Experience shows that plants monitored by true experts have a longer lifetime, lower maintenance costs and improved availability. Running a CO2 plant efficiently and achieving high on-stream rate are critical to all CO2 plant owners. Lack of delivery can be very costly!”

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UK Grocery Industry on Course to Meet Courtauld Commitment Targets rocery retailers and manufacturers in England, Northern Ireland, Scotland G and Wales, are making significant progress in meeting the ambitious waste and recycling targets set out in phase 2 of the Courtauld Commitment, according to WRAP, the waste prevention advisory body. The results, which highlight achievements for the first year of phase 2 of the voluntary agreement, show that signatories are already half way to achieving the packaging reduction target, and three quarters of the way to reaching the household food waste objectives.

These results indicate a strong collective performance given the ambitious nature of the three year targets and the increase in volume sales among signatories. The challenge now is for businesses to build upon this early success, through the implementation of more waste prevention and resource efficiency measures.

The supply chain impact is significantly less at only 0.4% against a 5% reduction

target. This is a new area for the Courtauld Commitment, and will be an area of additional focus going forward.

The grocery supply chain has performed well in diverting waste from landfill, with a 40% reduction over the reporting period - much of this waste has gone to renewable energy production using Anaerobic Digestion (AD). WRAP will be working closely with signatories to ensure that the supply chain and other targets are reached before the end of the Commitment.

The Courtauld Commitment is funded by all four UK governments, and is run by WRAP. The voluntary agreement, which began in 2005, supports businesses to improve their overall performance and reduce their environmental impact. Phase 2 began in March 2010 and is due to complete in December 2012.

“Following the success of Courtauld Commitment 1, Phase 2 has focused on encouraging resource efficiency and reducing waste in the supply chain and the home. The latest phase 2 figures show good initial progress towards these by the signatories,” comments Dr Richard Swannell, director, Design & Waste Prevention, WRAP. “The next step is to build on this good start, sharing best practice to encourage rapid change. This is particularly key around waste within the supply chain. We will continue to work with the sector to help ensure the Courtauld phase 2 targets are achieved.” J

Every Last Drop Campaign – Saving Water Along the Food Supply Chain he Food and Drink Federation (FDF) T has launched the 'Every Last Drop' campaign – a campaign to raise awareness amongst food and drink companies of the impact water stress could have on the longer term sustainability of the food and drink industry, and to provide practical, easily-accessible guidance on how businesses can be more water efficient.

The Every Last Drop guide provides a series of golden rules for food and drink

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manufacturing businesses – tailored for those with boardroom, supply chain and operational roles, to help them manage its use effectively along the supply chain, including as individuals at home.

Developed by FDF's Water Working Group, Every Last Drop is available to all food and drink businesses, including nonFDF members, and provides downloadable resources in support of the guide's key messages. A series of workshops and webinars are also planned for the New Year. It also includes a new dedicated water page on FDF's website giving further sources of help and information along with best practice case studies.

Andrew Kuyk, FDF's director of sustainability and competitiveness, comments: “Water is particularly important for the long term sustainability of the food and drink industry because of our reliance on a supply of water for both our raw material and processing needs. It is vital that we all

do what we can to conserve this precious resource and to alleviate water stress. Every Last Drop forms part of our Five-fold Environmental Ambition's wider work to improve environmental sustainability across the supply chain.”

“This simple guide provides a series of 'golden rules' for food and drink manufacturing businesses of all sizes,” says Inder Poonaji, chair of FDF's water group and head of safety, health and environmental sustainability at Nestle UK. “I am convinced that by taking on board these simple tips we can help make a difference to the protection of this precious resource and, in turn, contribute to the longer term sustainability of the food and drink industry. Please therefore keep this guide handy and share it with others in your organisation.” J

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011

I TRADE FAIR

ProSweets Cologne 2012 – 29th January-1st February – Cologne Exhibition Centre ProSweets Cologne 2012 will open its doors from 29th January to 1st February 2012. o far, more than 300 exhibiting companies from 32 countries have registered for the trade fair.

ProSweets Cologne will take place for the fifth time. The trade fair will present the entire range of products offered by suppliers for the production, processing and packaging of confectionery. This includes the product areas for Raw Materials and Other Ingredients, Confectionery Packaging and Packaging Technology, Machines and Plants for the confectionery industry, and secondary segments such as Food Safety and Quality Management. And in 2012 products for the production, processing and packaging of snack items will be exhibited at ProSweets Cologne for the first time.

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There are not only large numbers of returning exhibitors in all product segments, but also numerous companies that will be exhibiting for the first time. About three quarters of the exhibiting companies took part in the 2010 event, and around one fourth of the exhibitors will present their products and services in Cologne for the first time.

New Exhibitors The new exhibitors include the companies esarom, Denk Ingredients, Capol and Kahl in the ‘Ingredients’ segment; Sunino, Sirene and Tam Matbaacilik ve Ambalaj San. Tic. Sti. in the ‘Packaging and Packaging Materials’ segment; PFM, CAMA1 and

BluePrint Automation in the ‘Packaging Machines’ segment; and Comas and Yamato Scale in the ‘Process Technology’ segment. Over 58% of the exhibiting companies at ProSweets Cologne 2012 will be from abroad, making the event once again even more international (2010: 56%).

And in 2012 there will again be a modest increase in the overall exhibition space occupied by ProSweets Cologne.

NETZSCH-Feinmahltechnik, for example, has expanded its stand space from 15 square metres to 160 square metres and will demonstrate a complete chocolate production line at the stand with partners. The suppliers PAWI Verpackungen, Cavanna and Buhler also intend to significantly increase their stand spaces.

Raw Materials & Ingredients Growth has been recorded in particular in the ‘Raw Materials/Ingredients’ area at ProSweets Cologne 2012, where considerably more companies will exhibit, and on more space, than at the previous event. To make it easier for visitors to find what they are looking for, the product area will be centrally located and feature distinctive signs. In addition to the new exhibitors esarom, Denk Ingredients and Kahl, this

area will feature the companies Rum Albrecht, Chr. Hansen, Loders Croklaan, GNT Europa, Mantrose UK, HLR Praline, Curt Georgi, Cesarin and Roha Europe.

And the key players Norevo and Palsgaard will once again exhibit at the trade fair.

The ‘Raw Materials/Ingredients’ product area will be rounded out by the ProSweets Cologne Conference on Ingredients, which will be presented in co-operation with Herbertz Dairy Food Service. The conference will focus on the raw materials stevia and milk and dairy products, addressing the potential they offer for innovation in confectionery production.

ProSweets Cologne 2012 will occupy Hall 10.1 at the Cologne exhibition centre.

In combination with the International Sweets and Biscuits Fair (ISM), ProSweets Cologne presents the confectionery industry’s entire value chain at one location. J

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Soy is on Top as a High-Quality Plant Protein he importance of protein in the T human body is undeniable. However, the idea of what makes a protein a ‘quality protein’ has not been as easy to determine. A new study from the Journal of Agriculture and Food Chemistry takes a

closer look at the criteria for determining the quality of a protein.

Traditional methods for determining protein quality have shown animal proteins such as milk and eggs to be high in quality. However, those who are interested in a plant-based diet, or diversifying their proteins, have a more difficult time determining which of their choices are

high in quality. Testing methods have shown most plant proteins, such as pea protein, are lower in quality than animalbased proteins.

“Accurate methods for determining protein quality are key to helping people plan a healthful diet,” says Glenna Hughes, MS, research scientist at Solae.

“Due to the increasing interest in including plant-based proteins in the diet, accurate information on protein quality is needed in scientific literature to help educate consumers and healthcare professionals on this topic.”

The Food and Agriculture Organization (FAO) and the World Health Organization (WHO) recommend using the protein digestibility-corrected amino acid score (PDCAAS) as a simple and scientific procedure for assessing protein quality. The PDCAAS methodology focuses on three different parameters: the amount of each essential amino acid the protein contains, how easily the protein can be digested, and by taking both of those parameters into account, whether the protein meets the FAO/WHO's amino acid requirements set for children aged two to five years, as they have higher needs to support growth and development than adults.

According to this study, soy protein has a PDCAAS of 1.00, meaning it is a highquality protein that meets the needs of both children and adults. Eggs, dairy and

meat proteins also have a PDCAAS score of 1.0. However, soy protein is the only widely available high-quality plant-based protein that achieves this score.

“It’s important for people to understand that a plant-based diet is healthy, but that not all proteins are created equal,” says Connie Diekman, RD, LD, FADA. “If you are planning a vegetarian diet or want to incorporate plant-based proteins in your diet, understanding protein quality using the PDCAAS scale can allow you to select proteins that score higher, such as soy, to ensure that you are getting the essential amino acids you need.”

Solae is a world leader in developing soy-based ingredients. For more information, visit www.Solae.com. J

Airknives Help Clean-down Times and Increase Production Levels asteTech, a specialist manufacturer of T ‘controlled release’ flavourings and ingredients for applications in bakery, confectionery and chewing gum products, has recently increased production and cut machine clean-down times by employing airknives in a novel way. The airknives are employed in a cooling/drying vessel for powered products that have been encapsulated in specially compounded waxes and fats. Previously, after each product batch the vessel would have required scraping down followed by a cold rinse, a hot wash and then a cold rinse to ensure all product residue had been removed.

This cleaning process has been reduced

significantly thanks to the elimination of the scraping down and the first cold rinse since the installation of two blower-powered airknives and two medium flow fans from Air Control Industries (ACI). The airknives were supplied with a heat exchanger.

“The installation of the ACI airknives and fans has helped us increase our production levels and save time during the manufacturing cycles,” says Jason Ticktum, TasteTech’s factory manager. “ACI’s ability to incorporate a heat exchanger in the package and to facilitate the whole project for us has been a great benefit to TasteTech as a business.” J

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Volac Launches New Generation Whey Permeate olac, one of Europe’s leading manufacV turer of nutritional whey protein and lactose based ingredients, and Milk Link, the UK’s largest cheese manufacture, are utilising a unique combination of state-ofthe-art technologies to produce a new generation whey permeate at their brand new MVI (Milk Link Volac Ingredients) joint venture processing facility at the Taw Valley Creamery in Devon, England.

The new Volactose Taw Whey Permeate, launched at the recent Food Ingredients Europe, is made using a sophisticated manufacturing process which removes much of the minerals responsible for the salty taste usually associated with whey permeate,

whilst retaining more nutritionally valuable minerals such as calcium and magnesium.

The process also reduces other impurities such as glucose, galactose, and lactic acid resulting in a higher lactose content, good flavour and an ingredient with excellent physical quality characteristics.

Eamonn Drea, commercial director at Volac, comments: “Volactose Taw Whey Permeate is a great tasting economical source of milk solids and is suitable for a wide range of applications including bakery, confectionery, flavour and soups. Because of its unique flavour and physical characteristics it can also be relied on as a cost effective alternative to lactose and whey powder. Volactose

Taw Whey Permeate will be Vegetarian and non GM and importantly will be Kosher and Halal Mui approved which are real advantages in markets which demand such assurances.” For further information visit www.volac.com. J

IOI Loders Croklaan First to make Shea Supply Chain Transparent lobal edible oils firm IOI Loders G Croklaan has launched a campaign showing that their Shea nuts supply chain from West Africa is transparent and sustain-

able. As a first in the industry, IOI Loders Croklaan teamed up with the Rainforest Alliance and invited them to conduct a study into their Shea nuts supply chain.

“There are no major critical issues along the supply chain for Shea nuts with regards to sustainability standards,” says Olaf Paulsen, who executed the study for the Rainforest Alliance. Together with the report, IOI Loders Croklaan has published a magazine and a video to explain to customers and external stakeholders more about their responsible Shea nuts supply chain.

The specific qualities of Shea make it a popular ingredient for chocolate confectionery, cosmetics and other products. Shea nuts are a wild crop, picked in the fields by

women in rural communities in different countries in Africa, amongst others Burkina Faso, Ghana, Ivory Coast and Mali. Being a wild crop, the collection of the nuts could not be certified against any sustainable agricultural standard. “This assessment gives our customers the assurance they can responsibly use our Shea nuts in their products,” says Patrick Cobussen, business unit manager and commercially responsible for Shea containing products at IOI Loders Croklaan.

The study included visits to Shea processing facilities as well as to rural communities that depend on Shea harvesting. The report indicated a few areas for improvement that IOI Loders Croklaan commits to tackle. J

Beneo Presents New Sugar-free Sweetening Solutions ENEO, one of the leading manufacB turers in functional ingredients, is presenting new solutions in sweetening on Stand E78, Hall 10.2 at ISM, which is being stage in Cologne between 29th January to 1st February 2012, Cologne.

Attendees at the exhibition can look forward to herbal flavoured sugar-free candy samples using ISOMALT with Stevia, among the range of new confectionery ideas. By combining these two ingredients, BENEO has been able to achieve a product that has a rounded sugar-like taste and also provides nutritional and 48

health benefits.

ISOMALT is the only sugar-replacer derived from sugar-beet and thus has a similar sweetening profile. It offers manu-

facturers an alternative to sugar in both functionality and bulk. The combination of the two naturally-derived sweeteners supports a variety of subtle or strong flavours while successfully masking the undesired after-tastes of Stevia. Blending the two ingredients in candy recipes also helps achieve added benefits; the samples from BENEO are low in calories as well as being toothfriendly and low GI. Both dental health and blood glucose benefits of ISOMALT have been approved by EFSA. For further information visit: www.beneo.com J

FOOD & DRINK BUSINESS EUROPE, DECEMBER 2011