OCTOBER 2019
Future Food Trends Why it’s important to listen to the market
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haron Natoli makes a good point – not knowing food trends can be a costly exercise. Just ask Yoplait, who was the number one yoghurt brand in the US up until 2015. Then Chobani realised that consumers loved their yoghurt but wanted healthier options available to them – lower fat and less sugar. Over the next few years, Yoplait lost up to 33 per cent of its marketshare. An expensive lesson, but one that other food and beverage manufacturers can learn from, Natoli explained at a St.George food event held at the urban farm – Cultivate in Sydney’s CBD. Natoli makes a living writing books and giving speeches on the food and beverage industry, and she offered quite a few insights into the future of our industry. She said there are three main planks companies should follow when thinking of the future – what they should keep, what they need to keep up with, and what they need to create. In our three-page feature article, she expands on
all three points, as well as giving the low-down on 3D printed food. Also, in this issue, we have a feature about a breakfast event where supply chain was the topic of discussion. A panel of experts looked at not only how we can adapt the food supply chain for the future, but they also covered off on sustainability and an aging population in the food and beverage space not being replaced. Why is that and what an be done about it? There were no exact answers, but there were some interesting ideas put forward. Finally, there’s an article for any food or beverage manufacturer thinking about expanding or building a new plant. Total Construction gives us the low-down on some of the roadblocks that could be in the way and how you can avoid excess red tape, and vicariously, shelling out money to fix unnecessary problems. Mike Wheeler
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4 NEWS
31 HYGIENE
44 SOFTWARE SOLUTIONS
16 FOOD TRENDS
32 CONSUMER FOCUS
47 SAFETY
21 THOUGHT LEADERSHIP
34 DIGITISATION
48 TRANSMITTERS
25 CRAFT BREWING
36 FOOD PROCESSING SOLUTIONS
50 CONVEYOR BELTS
28 STANDARDS & 38 SUSTAINABILITY REGULATIONS 30 AIP
51 INTERNET OF THINGS 52 NEW PRODUCTS
40 AUTOMATION
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www.foodmag.com.au | October 2019 | Food&Beverage Industry News 3
NEWS
German supermarket chain, Kaufland, arrives in Australia O ne of the world’s largest retailers, Kaufland, has broken ground to commence construction of its first South Australian supermarket in Prospect, the company’s first outside of Europe. It is one of three stores it will be building in Australia, with more to come. The multi-million-dollar development, on a 24,000sqm vacant site, will feature a Kaufland supermarket, food hall, outside dining area and support tenancies. The company has also secured planning approval for another Adelaide store on the former Le Cornu site on Anzac Highway at Forestville and has another development application currently being assessed. Premier Steven Marshall said it
was an exciting time for the state to have a company of Kaufland’s international standing build one of its first two Australian stores in Adelaide. “Not only will this project create an estimated 150 construction jobs and up to another 100 retail jobs upon completion, it will offer South Australian consumers more choice,” said Marshall. “Developments like this from major international companies show the confidence in the South Australian economy, reinforcing that we are heading in the right direction. “Kaufland’s expansion into South Australia presents significant opportunities for the state’s food producers, as the company has publicly stated its desire to stock local products on its shelves, which
is fantastic news. “We look forward to working with the company as they look to expand into further sites across Adelaide and the state.” Minister for Trade, Tourism and Investment, David Ridgway, said construction of Kaufland’s Prospect store and the subsequent projects in Forestville and across Adelaide will provide a number of important contract opportunities for local construction companies. “The company has already employed a local property development and construction management team in preparation for Kaufland’s expansion, which is a further indication of Kaufland’s strong commitment to South Australia and the local economy,’’ Ridgway said.
“To have a global brand like Kaufland invest in property is a great reflection of South Australia’s global standing, and I’m confident this partnership will generate further trade advantages in the future particularly with Europe where Kaufland has almost 1,300 stores across the continent.” Kaufland Australia’s managing director, Julia Kern, said it is committed to investing in South Australia for the long term, and its celebration at Prospect is a tremendous and exciting milestone for Kaufland Australia. The Prospect store will initially operate as a testing facility to train staff, practise processes and trial proposed concepts. Construction of the Prospect store is due to be completed in late 2020.
Image credit: Karolis Kavolelis / Shutterstock.com
Will Kaufland become the fourth big player in the Australian supermarket space?
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NEWS
Growth in premium livestock feeds spurs by-product demand L
ivestock feed company, Castlegate James Australasia, is seeking to purchase greater volumes of byproducts from food manufacturers, and establish new suppliers, due to strong growth in demand for its high-performance products. The company has been working alongside the Australian food industry since 1923, buying
growth potential for re-purposing or upcycling food industry “by-product” into high-performance livestock feed is both on-trend and exponential. Importantly, demand for improved on-farm performance, animal welfare and feed reliability are driving interest in, and sales of, the company’s unique product offer on both sides of the Tasman. “Each year across Australia and
purchased for the company’s unique feed rations include packaged bread, biscuits, dough, yeast, vegetables and fruits, brewers’ grains, food grains and nuts, flour, dairy powders and even confectionery. These ingredients are then formulated by the company to make a unique balanced ration depending on the livestock application and farm productivity goal.
Castlegate James is looking for new suppliers to help with increasing stock for its feed business. by-products from large FMCG food and beverage companies and converting these organic ingredients into highly sought-after premium livestock feeds. The company supports many of Australia and New Zealand’s most respected food industry suppliers and large-scale livestock producers, converting what some may see as surplus into nutritionally balanced, performance-based feeds for the dairy, cattle and sheep markets. Castlegate James Australasia’s Group CEO, Steven Chaur, is a 30-year veteran of the Australian consumer food industry and said the
New Zealand, we will convert over 700,000 tonnes of consumer food by-product into quality livestock feeds that would otherwise not be consumed,” said Chaur. “The ingredients include high-quality materials generated as part of a food production process such as production line trimmings or grade-outs, out of specification, over production or unused raw materials. It’s all perfectly good quality and safe but it can’t be used for consumer product and there is increasing pressure on food companies not to add to landfill.” Many of the ingredients
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“Our nutritionally balanced feed is produced from high-quality, consumer-grade food product inputs and because it’s been already fully or partially processed, the ingredient digestibility and calorific value tends to be superior for livestock, relative to a conventional grains based stockfeed, delivering better energy, protein and fibre in a way that increases weight gain, marbling scores or improved milk production. It’s a joy to see livestock chasing the feed wagon. Even cattle like confectionery, in moderation, or the sweet smell of brewers grain.” Castlegate James operates 10
high-volume production facilities across Australia and New Zealand, servicing both suppliers and customers through fast lead times and unique processes that can efficiently de-package retail-ready or bulk-packaged foods. The company is planning production investment in both Australia and New Zealand over the coming three years to meet increasing livestock customer demand, as well as pursing innovative new high-value markets. “Because a large amount of the by-product that we purchase is branded perishable food, our production sites tend to be state based close to both the customer and supplier,” said Chaur. “This ensures we can handle significant volumes reliably and operate a fast turnaround to ensure the best quality feed is delivered to our large-scale farm customers, who demand reliability and consistency. Critically, we ensure our suppliers can operate efficiently by providing a professionally managed and timely on-site collection service, as well as confidentiality in dealing with branded packaging materials.” Demand is growing rapidly for the company as it continues to explore new sources of by-product supply from food manufacturers, food retailers and QSR franchise operators. “Importantly, we are not a site services company so we don’t manage general waste. We are every bit a premium food manufacturing company, we just feed livestock instead of consumers. We pay a premium for the consumer foodgrade ingredients used in our livestock feeds and so we have high expectations on suppliers for reliable supply and quality. In turn, we provide a consistent commercial service to our ingredient suppliers. It is a win-win relationship and we’re delighted to play a key role in helping to make a unique contribution to food industry sustainability and support an important livestock value chain,” Chaur said.
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NEWS
David Jones expands into food convenience with BP D avid Jones and BP have announced a partnership to create all-new centres of convenience and shape the way Australian consumers shop for food. The partnership combines David Jones Food’s exclusive, high-quality product range with BP’s global
expertise in convenience retailing and national footprint, giving customers access to locally sourced, ready-made meals and other fresh, quality offers at selected BP sites throughout the country. Over the next six months, 10 sites strategically positioned around
major arterials and key suburban regions of Melbourne and Sydney, will be transformed to showcase the new offer that has been designed with busy, urban, health-conscious customers in mind. The new range will see more than 350 products on offer, including
“food-for-now” and “food-for-later “options, as well as a diverse range of fresh items such as sandwiches, sushi and David Jones Food’s freerange rotisserie chicken. They will also be adding pre-prepared meals and long-life groceries to the list of available products.
UberEats rival arrives in Australia D oorDash, the largest ondemand food platform for door-to-door delivery in the US, announced its official launch in Australia, beginning with Melbourne. This marks the company’s first market expansion beyond North America. Australia’s “foodie capital” will be the first to experience what DoorDash will bring to the food market. Thousands of restaurants will be available for delivery through DoorDash – in addition to hundreds for pick up – across the CBD and inner suburbs, with plans to expand to the outer suburbs in the coming weeks. DoorDash’s launch taps into Melbourne’s love of food and food delivery apps. At launch, customers can order from well-known brands such as Nando’s, Betty’s Burgers and Salsa’s Fresh Mex Grill, as well as local independent restaurants including misschu, Bay City Burrito and exclusive partners Cedar Bakery and Il Gusto. Melbourne isn’t alone in its enthusiasm for on-demand access to food from favourite local restaurants, with the rest of the country continuing to embrace the ease and convenience of food delivery. In fact, almost two million Australians aged 14+ (9.8 per cent) use meal delivery services in an average three-month period. “We are excited Australia is our first international expansion outside of North America,” said DoorDash general manager, Australia, Thomas Stephens.
DoorDash has arrived on Australian shores to take on the likes of UberEats and Deliveroo. “We dove deep into the Australian market and quickly realised two things; restaurants want more from their delivery partners, and not all Melburnians have access to the selection that they should expect. “We’ve built a lot of product and expertise to solve these problems in North America. Combining that experience with a tailored approach just for Melbourne, we’re excited to
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grow the market here. We’ve built a service for Australian eating habits with a simple focus: provide more access to Melburnian’s favourite foods,” Stephens said. Along with a wide selection of Melbourne’s finest eateries, DoorDash offers a delivery and pick-up function allowing users to collect their meals on the go in addition to group ordering for
big groups. “Working collaboratively with restaurant owners of all business sizes, customers and Dashers, our priority is accessibility to a delightful food delivery experience for all. From Melbourne, we aim to continue our expansion efforts throughout Victoria and Australia through the remainder of 2019 and into 2020,” Stephens added.
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NEWS
Improving oversight of live animal exports
The appointment of an inspector-general of Live Animal Exports is designed to improve regulator performance.
A
n independent inspectorgeneral of Live Animal Exports to oversee regulation of the industry is a step closer with a bill to establish the
position as a statutory appointment passing the Senate. Agriculture Minister, Bridget McKenzie said the community deserved greater assurance that
animal welfare outcomes for export livestock were being met and monitored. She said that Australia’s livestock export industry is an important contributor to Australia’s rural and regional communities and to the national economy valued at $1.7 billion and supporting thousands of jobs. “It’s a legitimate trade, however, it won’t be conducted at the expense of animal welfare standards. “This legislation is proof of this government’s continued commitment to improving the trade – making sure the trade is well regulated and above board. “Support for the inspectorgeneral of Live Animal Exports
Bill 2019 means there will be an entrenched independent check on the Department of Agriculture’s application of the regulations and its exercise of power. “Our livestock export system is already world class and the inspector-general will only enhance that. I am confident that the Bill will pass the House of Representatives and become law. “Once it does, I will appoint a suitably qualified person to make sure the system is operating as it should – driving positive change in the industry, improving regulator performance and providing greater confidence to the general community about livestock exports.”
First pea genome to help improve crops of the future A global team including scientists from The University of Western Australia has assembled the first genome of the field pea, which provides insight into how the legume evolved and will help aid future improvements of the crop. The study, published recently in Nature Genetics, has important implications for global nutrition and the sustainability of crops, with field peas providing an important plantbased protein source for human food and animal feed. Professors David Edwards and Jacqueline Batley from UWA’s School of Biological Sciences and UWA’s Institute of Agriculture were co-investigators in the research and said that the field pea had a much larger and more complex genome compared to other legumes. “The pea genome assembly spans about 4.45 thousand million letters,” Edwards said. “But it’s only
with relatively recent technological innovations that we’ve been able to sequence and assemble such large genomes.” Batley said the research built on pioneering concepts of inheritance developed by Gregor Mendel, a 19th century monk. “With the pea genome sequenced,
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we can now start to understand the basis for the variation which has evolved,” Batley said. “Mendel analysed the inheritance of different pea traits such as wrinkled peas, and he demonstrated that these traits were passed on from one generation to the next, a foundation for Darwin’s later discoveries in evolution.
“More than 150 years later, we’ve now assembled the pea genome, which means we can start to understand the DNA basis of the inheritance observed by Mendel.” This research was supported by the Australian Grains Research and Development Corporation and by the Australian Research Council.
The first genome of the field pea has been assembled, which will have implications for the sustainability of crops.
NEWS
Global Table Conference: Smarter agriculture needed to feed growing population T he former US secretary of state, John Kerry, warned that feeding a rapidly growing world population would be one of the greatest
Former US presidential candidate, John Kerry.
challenges of climate change. The amount of food wasted was not sustainable with the impact of climate change and the world’s population set to rise from 7 billion to 9 billion in the next 35 years, said Kerry, in his opening keynote address at the Global Table conference at Melbourne Showgrounds held in September. The three-day food innovation and agribusiness summit brought together global industry leaders and innovators from the Asia-Pacific, America, Europe and the Middle East, to discuss the future of food. While a third of all food went to waste in wealthy countries, nearly half of the 8,000 child deaths each day globally were caused by lack of food, said Kerry, who succeeded
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Hillary Clinton as secretary of state for the last four years of the Obama administration. “Right now, today, every one in nine people wakes up in the morning with hunger pains and they go to bed with an empty stomach,” Kerry said. “We have to increase food production by 60 per cent between now and 2050 just to keep pace.” Growing more food was only part of the challenge, said the former Democrat Party presidential nominee. “We have to become better stewards of the land. The truth is we are not smart enough that way,” Kerry said. He also called for improvements to food storage, transport and distribution. Switching to renewable energy sources was an urgent priority to
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address climate change, Kerry said. “Anybody who persists in putting before people the notion that you have to make a choice: you either get to have jobs and prosperity or you can protect the environment and the future, that’s a lie,” he said. Reducing emissions and choosing renewable energy remained the best solution to combat climate change. “The solution to climate change is staring us in the face. It’s not some pie-in-the-sky thing. Basically it’s called energy policy. “That’s the solution to climate change: energy policy. “The choices of how we produce electricity, how we transport ourselves from place to place, how we do industry without polluting,” said Kerry.
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NEWS
FFH new manufacturing plant starts production F ine Food Holdings (FFH), a division of the Gourmet Food Group, has commenced operation from its new customdesigned manufacturing facility, which is based in Dandenong South, Melbourne. Representing an investment in excess of $10 million, the new premises more than doubles the company’s previous Keysborough capacity, enabling FFH to manufacture a large and diverse range of premium crackers products under one roof. Following the success of MaxFoods and its Ocean Blue seafood brand – an importing food business launched in 2009 – the company owners identified an opportunity to diversify from the arena of seafood entertaining to the “entertaining” deli cracker market. From the outset, FFH sought to manufacture not only premium quality deli crackers but ones that
led through innovation, creativity and flavour. Production began in Keysborough in early 2015 with its brand, OB Finest soon becoming popular. Today, the products of FFH, like that of MaxFoods, are acknowledged as market leaders across several product categories and geographical markets. Furthermore, FFH recently gained recognition as Top Ranked Supplier 2018 in the Australian Grocery Deli Category of the Advantage Report, a 360˚ survey that sets the supplier performance benchmark across the retail sector. CEO, Todd Wilson, attributes the company’s success to its strong focus on building retail partnerships and understanding the demands of consumers. The premium OB Finest range is now established in Australia in the entertaining deli cracker category. The brand has many quality products
from a selection of wafer crackers to various varieties of specialty crackers such as cranberry and pumpkin seed, as well as fig and almond. OB Finest recently added Parmesan Crisps and 3 Seed Crisps to its line up. Other new OB Finest products will be released in October. Further creative cracker innovations will be easily facilitated at the bespoke Dandenong South manufacturing plant. The move from nearby Keysborough has been a seamless one as it meant easy relocation of FFH’s current 250-strong workforce, as Wilson explained. “As an Australian food manufacturer, we at FFH are proud of our current achievements and excited about our future. “The larger capacity and flexibility of our new premises are the cornerstones of our vision to
create a scalable Gourmet Food Group. “This we will actualise through the development of additional products while pursuing entry into new entertaining categories via acquisition and tapping into new markets,” Wilson said. The Australian and New Zealand markets have been well-established and continue to grow. Already, the company has several distribution deals relating to its products. Countries involved in these distribution deals include the US, UK, Chile and South Korea, and there are also commitments in Canada, Hong Kong, Ireland and Singapore. “Just as the opening of Dandenong South manufacturing facilities brings assured optimism around future growth and success, the Gourmet Food Group mantle enables a more expansive strategic focus,” said Wilson.
FFH invested $10 million in its new factory in Dandenong South, Melbourne. www.foodmag.com.au | October 2019 | Food&Beverage Industry News 13
NEWS
Carlton Breweries acquires Riot Wine
Riot Wine has now become part of Carlton and United Breweries’ expanding beverage portfolio.
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he keg and canned wine revolution led by Adelaidebased Riot Wine Co is gathering pace, with Carlton & United Breweries (CUB) acquiring the company. Riot Wine is the only company in Australia that sells wine in kegs and cans. Its innovative and disruptive model is said to give wine lovers a superior and more sustainable product. This has seen it land in hundreds of venues and
retail stores nationwide despite only launching in 2016. “We are excited to be joining Carlton & United Breweries. Their investment, expertise and customer relationships will help us continue our rapid expansion,” said Riot co-founder and chief winemaker Tom O’Donnell. “We launched Riot Wine to start a wine revolution in Australia by getting venues and consumers to switch from
bottles to steel kegs and aluminium cans,” said Riot co-founder and general manager Joe Cook. “Wine drank this way is fresher and easier plus it’s more sustainable because one keg saves roughly 23,000 bottles from entering the environment. Our kegs prevent wine oxidising and our wine has a fun and fresh taste profile, with less sulphur, making it cleaner than traditional wine.” Riot produces wine from South Australian grapes, supporting local producers in premium wine regions. The new investment by CUB will also see Riot’s urban cellar door upgraded in the Adelaide suburb of Brompton, creating a revamped hospitality space where wine lovers can sample and enjoy Riot products and food. The partnership continues CUB’s investment into SA and follows the building of a new Pirate Life brewery in Port Adelaide last year. “We are committed to being the
best beverage company in Australia and expanding our portfolio to meet the evolving needs of Australian drinkers,” said CUB sales vice president – Australia and NZ, Rose Scott. “Riot Wine will help us do that. It’s a truly innovative company and CUB shares its commitment to quality and sustainability. Its rapid expansion in just three years shows venues and retailers agree that it can deliver great things for consumers. “We plan to accelerate the expansion of this growing business through our large on-tap network and more than 100 years of draught experience. The Riot Wine Co team won’t change and management will stay on to ensure the elements that have helped drive the business’ success – a focus on quality wine from grape to glass, disruption and innovation, and the quality of its people and outstanding customer relationships – remain in place.”
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NEWS
Plant-based proteins such as lentils and beans are growing in popularity among consumers.
Plant-based protein worth $25 billion by 2030 P lant-based protein, foods for health and wellbeing, premium products and other emerging food trends could be worth $25 billion by 2030, new analysis by Australia’s national science agency, CSIRO predicts. Economists in CSIRO’s strategic advisory arm, CSIRO Futures, have released an economic valuation of the full range of opportunities identified in the 2017 CSIRO Food and Agribusiness Roadmap that was released two years ago. Senior economic advisor at CSIRO Futures, Dr Katherine Wynn, said that if Australia harnessed these opportunities, the food and
agribusiness sector could successfully become a growth orientated, de-commoditised, value-adding and differentiated sector. “Achieving this growth will depend on continued innovation and investment by all players in the food industry,” Wynn said. “As consumer demand for healthy foods and foods with added health benefits increases, foods such as enriched yoghurt and fortified breakfast cereals are likely to claim a much larger chunk of the $25 billion pie.” Global consumer trends for sustainable, ethical and healthy food products combined with
growing demand from export markets buying into Australia’s reputation for clean and green products are driving this growth. Wynn, whose team drew on extensive research, consultations and economic analysis, said the health and wellness, sustainable solutions, and premium segments will see higher growth (3.6 per cent per annum, in real terms) compared to the food and agribusiness industry as a whole (2.4 per cent per annum). The goal to grow Australia’s share of emerging food markets complements the National Farmers’ Federation strategic target to reach $100 bn by 2030, with a growth rate
of approximately four per cent per annum expected in farm gate output. Key opportunities fuelling this growth include the meat alternatives market – such as plant proteins and insect-based ingredients – as well as demand from export markets with large vegetarian populations such as India. It was also recognised that the meat alternatives market also has the potential to reduce greenhouse gas emissions and water use. The research also shows that consumers are more willing to pay a premium for sustainable brands, which could see greater economic as well as environmental benefits.
www.foodmag.com.au | October 2019 | Food&Beverage Industry News 15
FOOD TRENDS
How a 1960s cartoon predicted the future of food The 1960s cartoon, The Jetsons, introduced the world to 3D printed meals, now they might become a reality. Food & Beverage Industry News explains how.
The St.George Bank event was held at urban farm, Cultivate.
S
haron Natoli loves food. Which is just as well when she makes her living as an author and speaker specialising in the food and beverage industry. At a recent event held by St.George Bank at urban farm, Cultivate, which is based in the Sydney CBD, Natoli spoke about the future of food and some of the challenges processors, retailers and manufacturers face. Her first point was that the future – in general – is coming faster and faster. The Human Knowledge Curve has shown that in 1900 humanity’s knowledge was doubling every 100 years. In 1945, the rate was doubling every 25 years. By 1982 it was down to approximately one year. Today, it is estimated that what humans
know is doubling every day, while deep learning platform IBM Watson predicts that our knowledge will double every 12 hours by 2020. What is driving this alarming rate of change? “It is around data collection,” said Natoli. “The fact is that every day that we use our laptop, our phone, we buy things, and we click purchase things online. We use our credit cards, that’s data that is being collected all the time. Wearables, sensors – so much technology around us, and so much data to collect. The key is keeping up with the rate of knowledge that is happening in terms at which it is doubling.” And with all these changes starting to occur, it is important that
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food and beverage businesses don’t get caught ‘sheep walking’ – a term that Natoli said is similar to sleep walking, except people are wandering around with their eyes open. “We have our eyes open and we are conscious, but it is hard to see the future coming at us because we are surrounded by the status quo,” she said. “If we get caught sheep walking, then it is harder for us to innovate and keep up.” She gives the example of French yoghurt manufacturer Yoplait, who up until 2015 was the number one brand in the United States. Over a few years it lost 33 per cent of its market share, with 23 per cent of that coming within one year. The equated to about $500 million in revenue. What happened?
A rival read the future. “Chobani came along with a better tasting yoghurt, a lower sugar yoghurt – the kind of things consumers were looking for at that time, and so they took a large chunk of that market share away.” However, one topic that Natoli covered could have consequences for food processors – 3D printing. Back in the 1960s the cartoon television series The Jetsons had the Foodarackacycle, a device that, with the press of a button, would produce food for the family. Fifty years later, similar technology is coming to fruition with the Foodini. “Foodini is a 3D printer that enables us to serve food, freshly printed,” said Natoli. “It is a smart
FOOD TRENDS
Food will be able to be printed to order in the near future. kitchen appliance using 3D printing technology that enables us to personalise our food. Not only the amount, but a personalised nutritional profile of the food, and we can personalise the way that it looks. “It is also attractive to healthconscious people because it puts food production in the hands of the consumer. You can print things like crackers, wraps and pizza bases – some of the things you would usually buy prepared from the supermarket.” With the future fast approaching, it would be easy to put your head in the sand and say “it’s all too much”, especially as Natoli has already stated, our knowledge is almost doubling every day. However, she also said there are three “plates that need spinning” if the food and beverage manufacturers are going to keep ahead of the knowledge curve. They are: what do you need to keep? What are things that these companies need to keep up with? What do they want to create? When she talks about what companies need to keep, it is more about their legacy, their history – it is about a company’s culture, both past, present and looking to the future. Probably the most important of the three “spinning plates”, is keeping up with trends, something that could be argued Yoplait failed to do when it lost its market share in the US. There are lots of trends and different businesses need to keep up with them, said Natoli. She said there are three areas of macro trends that will be relevant to the food and beverage industry. “The first is this rising rebellion,”
she said. “What we are finding is that we have the means and the motivation more than ever to stand up for the things we believe in. We are seeing a power shift from organisations and institutions through to individuals. And this is being shown a Colmar Brunton’s Millennium Monitor. What they monitor is Australia’s changing social sentiment. What they have found, is we are moving from an era of conformity where we had trust in institutions and organisations, through to this rebellious era. What we are valuing is empowerment and individual responsibility and taking on change ourselves.”
This is leading some food and beverage brands to adopt a rebellious approach, such as the likes of Soul Fresh, which owns the brand The Milk Thief. “They’re saying, ‘we’re a movement, not a corporation’. They are saying they are a disruptor of the status quo versus doing what we’ve always done,” said Natoli. “They’re focussed on creating healthier and better foods for consumers instead of focussing on delivering foods and beverages at the lowest cost possible.” The second macro trend is the idea of getting more from less. This is around the intersection between disquiet about the state of the environment, combined with consumers concern about their personal health. It’s about growing things with less impact on the environment but also being healthy. She cites the example of Mike Lee from US-based Alpha Food Labs, who is looking at the biodiversity of the supermarket shelf. Natoli said he has flipped things on its head. Usually, when it comes to new product ideas, it is marketing or product development people who come up with new concepts and go out and tell the farmers, or the suppliers, to grow this or produce that. “What Alpha Labs is doing is turning that around and going out to the farmers and saying, ‘what are you growing? What is good for the
soil? What is in season?’ and then the company takes that and makes a product from it. It is the opposite of what we would usually do from a food production perspective,” she said. “They want people to see that these products are not just made from wheat, rice and oats, but they are made from things like lentils, fava beans and moringa powder, millet – all kinds of different grains and that is a way to introduce biodiversity into the food chain.” The final part in the macro trend equation is the expectations that people have when it comes to what they are consuming. Natoli said they have high expectations of food producers as well as high expectations from their food. “This is where transparency and knowing where your food comes from – who made it, what’s in it – comes in,” she said. “Also the use of technology in terms of things like augmented reality, where you can scan a barcode of a product and find out the story behind it. Also around health and wellbeing and how we can really improve it through what we eat. “Companies like Habitoir, which is a US company that takes some of the insights around genetic testing, and develops personalised nutrition plans that meet peoples’ expectations around how food can deliver better health to them.” Natoli also believes that even
Sharon Natoli said food processors and manufacturers need to keep up with consumer trends. www.foodmag.com.au | October 2019 | Food&Beverage Industry News 17
FOOD TRENDS
“The future is coming at us quite quickly and we don’t want to get caught sheep walking.” – Sharon Natoli.
WHY ST.GEORGE IS EXCITED ABOUT THE GROWTH IN THE FOOD AND BEVERAGE INDUSTRY Food & Beverage Industry News spoke to St.George Bank’s Mark Burgess on why he sees good times ahead for the food and beverage sector. With interest rates at an all-time low – and some industry pundits stating they might go lower – this opens up opportunities for growth, especially for a developing industry like food and beverage. Mark Burgess is the experienced and affable relationship director – consumer goods leader at St.George Bank. His portfolio of customers are in the food and beverage arena and he sees solid opportunities within the industry over the next 12-18 months. It is one of the bank’s growth sectors, mainly propelled by the domestic and global demand for quality Australian produce. He’s also a good gauge of what other factors are propelling the market at the moment, and Burgess cites new technologies and food trends as being market drivers. At a recent St.George Signature Food Event, Burgess talked of not only how the food and beverage sectors are looking healthy, but how the role of banks has changed over the past decade. “I think within the last few years – the banks have shifted away from being what I would call ‘order takers’ – like at McDonald’s – to that of being more trusted business advisors. That is one of the reasons St.George moved to an industry model four years ago because we wanted to have industry experts to not just be there to take orders from customers, but also have
insightful discussions with them about their industry as well as their growth plans and where they see themselves going. Then talking to them about how we can support them to grow and prosper. It’s really about that. It is one of the reasons I joined the bank.” Having been a director at Ernst and Young and a senior corporate advisor, Burgess likes helping businesses grow. It’s another reason he likes the food and beverage industry. “While we are seeing growth with our customers who are the larger players in the market, as a bank we also focus on family businesses and the middle marketplace, too,” he said. Why? Burgess sees them as lean, hungry and leading the charge when it comes to some of the newer market sectors within food and beverage. “Those companies are really nimble, and quite dynamic and they are looking at new areas that they can diversity in,” he said. “For example, a lot of my customers look to supply Coles and Woolworths, and it is those customers who are leading the charge in the healthy alternatives market. Then there is a push for the vegan movement, as well as alternative substitutes for meats and other core products. “Some of those businesses are ahead of the curve and have a huge focus on innovation within their organisations. I’ve got one customer who is a traditional meat supplier and they are now getting into non-meat products.” Although Burgess is excited about the market and where it is headed, this doesn’t mean the bank has a laissez-faire attitude
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though there is a lot of automation, robotics, artificial intelligence and augmented reality creeping into the food processing and manufacturing space, there is still room for human interaction. Some companies even make it part of their marketing plan. “Harris Farm, they often put themselves forward – like one of the brothers Tristan Harris – as commentators,” she said. “They put a face to the brand. It gives it that human element.” And getting back to her point about the rebellious disruption going on, The Havas Media Group recently completed a survey that involved 300,000 consumer and 1,500 brands across 33 countries. What it found was that brands that are more meaningful outperform the stock market by double over a 10-year period. Being meaningful meant contributing to the
towards doing business. There are still systems that have to be followed. A large portion of food and beverage businesses involve the manufacture of perishable items, not exactly great assets to put in the ledger when talking to your bank. So what does a company have to do with regard to getting a loan if they need to recapitalise, or more often than not, expand their business? “If we’re doing cash flow lending as opposed to bricks and mortar property lending in the food space, we look at your working capital cycle. We are relying on your debtor book to fund your business,” he said. “We look at the strength of your relationships and what your terms are like with those debtors. We then look at how efficient your supply chain is. It’s also about the experience of the management of the company, too.” And how does the bank find the attitude of the big players like Woolworths and Coles when it comes to helping out not just those who are regular brands on their shelves, but those new to the market? Burgess works closely with them and said they are very supportive of entrepreneurs because they want to see new products on their shelves. “They want to get onboard because an entrepreneur could produce a new product that might fly off the shelves, and that product might also be a reason why consumers go to a Woolworths store instead of Coles or vice versa,” he said. New technologies are also a driver for the industry, and Burgess and his team are seeing those innovations first-hand from their customers. “I was talking with a customer today who
collective well-being of society. “Overall the future is coming at us quite rapidly and we don’t want to get caught sheep walking. We have to be really future ready. If we can spin those three plates together at the same time, then that is going to help us navigate in this decade of disruption. Many a false move was made by standing still, so whatever you do, just don’t stand still. “It is really great for food businesses to have the opportunity to come together, to network, and connect, particularly over a meal. To create those social connections over food and to share their ideas and learnings. “I think the way of the future is really about collaboration and so an event like this that St.George has put on is really beneficial for helping to do that.” F
St.George Bank’s Mark Burgess.
specialises in ready-made meals, and he has been flat out” said Burgess. “His product had a shelf life of three to four days, but because a packaging specialist brought out a new technology, his product now has a shelf life of 7-10 days. Something as simple as that has made a huge impact on his business in terms of wastage and time savings from deliveries.” Burgess loves the industry, not just because he’s a foodie, but because it is dynamic, ever changing. He is very excited about the future of banking in the sector, and the industry itself. “The thing I love about this role is that it is all about seeing the customers grow and prosper and supporting them in their growth plans,” he said. “Given my corporate advisory background, I can provide meaningful insights around business strategy and direction. The food and beverage space is a rapidly changing environment and it’s exciting.”
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THOUGHT LEADERSHIP
Preparing for the future: sustainability, digitisation, and an aging workforce Pollen Consulting Group held a discussion panel that covered supply chain, factories of the future and the aging manufacturing population. Food & Beverage Industry News was there.
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upply chain, factories of the future, Industry 4.0, and an aging manufacturing workforce – all subjects that recently have started to have an impact on the food and beverage industry. It’s no longer enough to go after market share; processors and manufacturers in this space have to play the long game and ask themselves some questions about where they are heading, such as: What does the future hold in the supply chain space? Do we need to adopt an Industry 4.0/Internet of Things (IoT) strategy? Does it even affect my business? What is a factory of the future? Pollen Consulting Group is a company that specialises in value chain transformations in the fast moving consumer goods (FMCG) sector. It recently hosted a networking event where a panel consisting of some of the brightest minds in the
digitisation area came together to discuss some the issues that both multinationals and SMEs are facing within the sector. Facilitated by Pollen’s managing director, Paul Eastwood, the event showcased insights into the aforementioned issues. Linda Crowe, head of supply chain at wines and spirits producer Diageo, knows that the company has to get onboard with sustainability initiatives –but at what cost? “We had our global supply and procurement director out recently and we talked about sustainability,” she said. “And the biggest message he landed was that we don’t have a choice anymore, but we need to find a way to be sustainable without impacting costs. Or, if it’s going to be more costly, then we have to pull it out of the profit and loss (P&L) somewhere else. We definitely
"We don’t have a choice anymore, but we need to find a way to be sustainable without impacting costs. Or, if it’s going to be more costly, then we have to pull it out of the profit and loss (P&L) somewhere else. We definitely need to start looking within to get ahead of the trends and do it in an intelligent way.” need to start looking within to get ahead of the trends and do it in an intelligent way.” And while some talk the talk, as James Magee, CEO of Operations Feedback Systems (OFS), explained, when it comes to walking the walk, some baulk. “From my time working in Visy’s recycling department, there were many brand owners and organisations that came in and said they wanted to go down the path of sustainability,”
he said. “They wanted to promote it, but of course it came at a higher cost. When that resolve was tested, in many cases, neither the brand or consumers, despite outwardly promoting it and testing at shelf, decided they would go for the cheaper option. It’s interesting to hear Diageo’s approach. That is a breath of fresh air because a lot of companies will chase profits over sustainability.” And while it is easy to be cynical about costs over profit, at least
Food supply chains need to become more sustainable and transparent as consumers become more opinionated about where their food comes from. www.foodmag.com.au | October 2019 | Food&Beverage Industry News 21
THOUGHT LEADERSHIP
one person on the panel was not willing to compromise when it came to making sure her company was minimising its impact on the environment, even if it affects the bottom line. Diem Fuggersberger is the CEO of Berger Ingredients and food company Coco & Lucas, and her values in her home life cross over into her professional life. “I have certain values in my personal life, so I have to make sure those things are the same in my business,” she said. “When I started Coco & Lucas I wanted sustainability, but it has hurt my profitability by at least $250,000 a year. All the packaging used in Coco & Lucas is biodegradable. Instead of paying $0.12 for a plastic food tray, I’m
paying $0.28 for a biodegradable one. Initially my family wondered why I was paying all this extra money but I was determined to be the first national brand that doesn’t have plastic going into the earth. I felt it was my responsibility for me to have a biodegradable tray.” The executive general manager at CHEP Australia, Lis Mannes, brought up the issue of waste in the food and beverage industry. Mannes was involved in companies that have had a large sustainability arm, yet the infrastructure within some of them has not been mature enough to handle the amounts of waste being created. “We are in a lag position where we do not have, as a country, the infrastructure to handle the amount of
WHAT IS A DIGITAL TWIN AND DO I NEED ONE? You’ve decided to add a new piece of inventory to your food production line. However, you have no idea how it will impact on your current supply chain set up. Will it affect deliveries? How will the changeover on the production line from one SKU to another affect the bottom line? Will the new product require the conveyor belts to be washed down before putting in the next SKU, and how much time will that take? These and other considerations need to be taken into account. Other than physically implementing the process, how can these parameters be measured? Because, even if you put a comprehensive plan together, issues can arise. Enter the digital twin. Championed by the likes of Pollen Consulting Group, the digital twin is a virtual replica of a factory’s supply chain, which will take all the interlinking processes into consideration – all of the complexities and viabilities that exist within a factory and supply chain. A supporter behind the concept at Pollen is technology director Oliver North. At a recent breakfast event held at the company’s headquarters on Sydney’s North Shore, North gave an outline of how a digital twin can be a practical solution to those thinking of expanding their product offerings. “We can have lines set up for huge product runs whereby we now need to service 25 different SKUs over a certain period of time but we’re stuck with the equipment we’ve got,” he said. “So it is becoming more difficult for our planning teams to understand, ‘what is the optimum solution for me based on all the complexities that come in?’ This is
Pollen Technology’s Oliver North. where the digital twin comes in. “You can map a supply chain or factory by a process map. It might be a pretty long and complicated process map, but you can map it in logic,” said North. “What you are doing is building that logic into a software, which takes all of it into account.” For example, he said, if a person tweaks an input at a certain point, what impact is that going to have across the rest of the supply chain? And where Pollen sits is, this is the brain upgrade that is going to become required for any business. “As the complexities come through and as the ability to throw capital at automation and equipment starts to dry up, we’re really going to have to start looking at how we are going to adopt a cleverer way of thinking,” said North. “A digital twin will allow you to replicate your supply chain in a digital environment with real complexities and variabilities – all the independencies that will allow you to make optimum decisions.”
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waste we create,” she said. To take it one step further, not only do companies have to think about what side effects waste will have on the environment, but there is a generation of younger workers coming through that are interested in their employer’s stance on the environment. “I did an induction recently for some new employees, and one of my slides goes, ‘Why CHEP?’” said Mannes. “As I went around the room I asked people why they joined us. I would say over half of the room actually cited [the company’s attitude towards] sustainability as one of the core reasons that they joined the company. I don’t think I would have had that answer 10 years ago.” Another point up for discussion was the role of technology in the supply chain, something that manufacturers and distributors in the food and beverage space need to take into consideration as digitisation starts to take hold. There were duelling trains of thought with this aspect of business in general – digitise completely now, or do it gradually. Pollen Technology director, Oliver North believed that because technology is ever changing, there is a conundrum, which is that nobody knows what these changes will entail when it comes to supply chain. “Nobody can predict what is going to happen,” said North. “The only thing we know is that it is going to change. The question being asked was, ‘How do we as a business adopt these changes?’ And when it comes to technology the first thing you should be looking at is where the pain points are in your supply chain. “You need to look internally at a business and understand the areas where we have a problem, and where we can use technology to solve it. Then you look at the market and understand what technologies can help us there, and what technologies will fix that need.” Mannes also delved into a few issues that need addressing within the Australian food and beverage industry – distance that products need to travel; legacy plant and machinery that needs upgrading; the need to diversify outputs during production; and an aging manufacturing workforce. “When I look around the infrastructure in the food and beverage industry in Australia, there is a lot of legacy assets that
exist, and one of the challenges of our economy is the distances versus the population that we are trying to service,” she said. Mannes also touched on Australia being in a unique situation whereby the nature of the country – its size and the supply chain distances travelled – creates natural constraints that have to be considered. According to Mannes, some start-ups are often scared off by the scale of economies that exist in the country and the possibility of making a business work where they are servicing so many locations. “To establish a fresh sandwich factory in Sydney, and to service the country, you just can’t do it, because you can’t get it with a three-day shelflife to Perth,” she said. Then there is the issue of the condition of the some of the plant and machinery in some factories, as well as the aging population of workers in the food and beverage processing and manufacturing industries. “We have factories in many of our food industries that have these legacy assets that are looking tired,” she said. “Then, you have the generation of workers coming through who don’t want to work in them. I’m sure I’m not the only one who has been in endless discussions about aging employment and aging workforces and what that is going to do the economy, because we have a generation of people coming through who don’t want to work with our aged assets. But we have an economy that makes it really hard to have a business case to keep industry here. I don’t know what the solution for that is. Generationally, as we start to adopt Industry 4.0 in the appropriate places, we will gradually get a younger segment coming though that do want to work in those kinds of environments.” Eastwood then touched on workforce issues and how automation would affect factories of the future. In 2018, a Swiss think tank, The World Economic Forum, released a statement that stipulated that half the work force could be replaced by robots by 2025. However, it also said that robots could create twice as many jobs as currently exist now. “I think the main problem is going to be a race between technology and education and which one is going to win,” said Eastwood. “I think if technology is going to win, you are going to have people without skills; if education wins then we might be
THOUGHT LEADERSHIP
okay. At the moment, technology is winning.” This was backed up by productivity expert Ishan Galapathy who said we should be working smarter, not harder. “If we can build the capability of our frontlines leaders to problem solve, they will be using the skills that won’t go away – like empathy and courage,” he said. The next topic on the agenda was about working in a factory of the future from an employee’s point of view. They would be ripe for the gig economy, said Magee, with gig referring to independent workers who contract their services out for short-term jobs. “I would say that in the future an opportunity exists for manufacturing employees to share in the gig economy,” he said. “Why couldn’t there be a star rating where I’m an employee, or a hired gun, who can work in any factory. If you only need me for five hours, you don’t have to pay me to sweep the floor to fill out the contract if I finish early. I’ll walk across the road and go and work at another place for few more hours.” A similar scenario could be played out for excess factory floor space. Diageo already thought ahead before
The event covered new technologies and an aging manufacturing workforce. it built its new distribution centre, according to Crowe. It intentionally built the factory bigger than it needed because it was taking into account the growth of the company. For about four months of the year it runs at full capacity, while in the other months it runs at about 50 to 60 per cent. It can rent out the extra space to, as Crowe
puts it, “sweat the asset to make it profitable”. The final point of the discussion, made by Eastwood, was about food and beverage processors and manufacturers taking on digitisation – don’t rush into it, he said. “I don’t think you have to worry too much about being left behind
because it takes time,” he said. “You won’t change the world tomorrow, but you do need to start thinking about it, because some companies are clearly starting to nudge ahead. There is no one that is miles ahead at the moment. Think about it. Take your time. And get it right. It doesn’t cost millions.” F
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www.foodmag.com.au | October 2019 | Food&Beverage Industry News 23
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CRAFT BREWING
Gas the key to fledging microbrewing industry Air Liquide sees a lot of potential in the micro-brewing industry and plans to be leading the way in supporting its growth. Food & Beverage Industry News explains. Gases are the unsung hero of a good brew.
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raft brewing has taken off in Australia over the past five years. Driven by consumer demand for something a little different outside the main brands. These usually one- or two-person bands are making inroads into traditional markets right across the country. From Perth to Sydney, Adelaide to Brisbane, micro-breweries aren’t just putting down roots in the main cities, regional Australia is getting its fair share of beer aficionados, too. Some craft breweries are driven by wanting to be in an industry they love, others believe their unique blend of hops, barley, yeast and malt offer an exquisite taste to a discerning public, while yet others are hoping one of the big breweries will buy them out. According to a 2018 report by
"We offer cost-effective, safe solutions and are able to provide the right product, at the right time and the right price. We’ve got fantastic aftersales service and logistics solutions to provide any type of gas delivery – whether it be in cylinders, skid tanks, mini-bulk or bulk vessels." IBIS World, the craft brewery market in Australia is worth about $520 million and is growing at a rate of about six per cent a year. Not only are the brewers themselves excited about the market’s potential, but those providing products and services can also see that the sector offers lucrative opportunities. As well as the four basic ingredients, there are peripheral – but just as important – constituents
that need to be taken into consideration, such as packaging, distribution and gases. Gases are the unseen heroes of a good brew, something that Air Liquide’s Western Australian sales representative, Gavin Lee, is all too aware of. Having a background working at brewing giant Lion, has helped Lee gain momentum in supplying a variety of gases to the large number of micro-breweries
popping up on the west coast. And it’s only going to get bigger, according to Lee. “The micro brewing industry in Western Australia is going gangbusters at the moment,” he said. “There are more than 60 microbreweries in Western Australia – ranging from Exmouth down to Albany. The majority are in the Perth area.” Like wine-making, gas plays an important role, from the brewing of the amber fluid, through to it being dispensed at the tap. Oxygen is both the friend and enemy of the brewer. The only time it is necessary is when there is the oxygenation of the wort, which is the liquid extracted from the mashing process that occurs during the brewing of beer. Wort contains the sugars that will be fermented by
www.foodmag.com.au | October 2019 | Food&Beverage Industry News 25
CRAFT BREWING
CO2 is used in the bottling process. the brewing yeast to produce alcohol. “Oxygen and light are the two things brewers don’t like. Dissolved oxygen in beer ruins the taste and flavour,” said Lee. If gas was a workhorse its name would be carbon dioxide (CO2). It is used extensively to move beer around from one vessel to another, as well as during the bottling process. It has a multitude of uses, and because it is an inert gas it
has no effect on the end product. Nitrogen can also be used but CO2 is the preferred option among most brewmasters. CO2 is mainly used in the carbonation process, giving the beer its fizz at the point of bottling, canning or kegging. “When using it in the bottling process there is tank inerting,” said Lee. “Currently, if the brewer has the brew in the tank and there is a bit of head space in that vessel,
Gases are involved in the brewing process from beginning to end.
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they can pump CO2 on top of that beer so it blankets the surface, and that provides a protective layer for the beer, or they can use nitrogen.” And when it comes to setting up the delivery mechanisms for the gases, Air Liquide has that covered, too. There are two main options. “Typically we like to use copper piping because it won’t leak and it won’t corrode and can last for a very long time,” said Lee. “Or you can use food-grade nylon, which is a cheaper option, but over time it does have a tendency to spring a leak because it is under pressure. “We have engineers and an installation team that are very experienced. We swapped out a vessel, down at Little Creatures in Freemantle, which had been there for the past 18 years. “We swapped out to a 10-tonne vessel and within a couple of hours they were back in full operation without any down time.” Another growing part of the company’s business is providing mixed gases for the dispensing of beverages in hotels and pubs throughout the state.
“It is often a mixed combination of CO2 and nitrogen,” said Lee. “It is the gas that pumps the beer through to the glass. As with the brewing process, it is inert so doesn’t affect the quality or the taste of the beer.” Another reason Lee believes Air Liquide is making inroads into the market is that it supports the industry in other ways other than just providing gases. “Air Liquide supports WABA – the Western Australian Brewing Association,” he said. “We try and support a lot of the brewers who start a business. Although some would argue gas is a small part of the process, it is a very important part. We offer costeffective safe solutions and are able to provide the right product, at the right time and the right price,” he said. “We’ve got fantastic aftersales service and logistics solutions to provide any type of gas delivery – whether it be in cylinders, skid tanks, mini-bulk or bulk vessels. All ALIGAL products we supply to breweries and wineries are of food-grade quality and our CO2 is FSSC 22000-certified, guaranteeing maximum quality and food safety.” F
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STANDARDS AND REGULATIONS
Don’t let regulations bring you down Capital investment when building or renovating a plant can be expensive. Even more so if you don’t follow council and building regulations. Food & Beverage Industry News explains.
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ed tape, bureaucracy, standards and regulations – all can be a bugbear for any company thinking of building or expanding their food and beverage processing plant. Food and beverage processing factories especially have a range of rules that dictate what they can and can’t do due to food safety issues. Problems arise when the correct planning hasn’t been taken into account, or even ignorance of what is required when building a premises. However, the latter is never an excuse for putting up a building without consent, although that doesn’t stop it from happening. It’s not lost on Total Construction’s design operations team, who has have seen their fair share of projects go pear-shaped due to naivety, poor planning, or disregard for building and council regulations. As the name
"Here’s a bit of advice – if the council says you only need 15 carparks, only provide 15. The reason being? If you provide 20 and you are going to do more works in the future, those 20 carparks can become your baseline. It is part of the development control plans that have been in play with any development project with councils." implies, Total Construction specialises in total builds – from the ground up and that includes getting all the right approvals. Total cites a recent example with a client that wanted to expand its premises and had done so already without getting the correct building consents. They were told to dismantle the illegal structures. The company came to Total Construction for help. “The client had put an awning
structure out at the back of the property to protect their roller shutter opening when they were loading and unloading food products,” said Rob Blythman business development manager F&B. “And then they built another structure to store equipment that needed to be protected from bad weather. You can typically put up a small tool shed in your back yard, but when it comes to a commercial enterprise, you can’t do that without
the correct approvals. “We understood what the issues that were raised by council and by the owner – what they needed to achieve and what they wanted from a building point of view,” he said. “To do that, they needed to amend the building considerably and make about a 30 per cent increase in the building footprint.” The client used its own architects, who managed to get the necessary approvals. However, the client soon realised that it still wasn’t big enough for what they actually needed. The Total Construction team helped to get the amended development approval through. If the client had done it correctly the first time, they might have saved themselves the best part of $25,000, according to Blythman. But it just wasn’t the footprint of the upgraded facility that needed attention. There were other aspects A company can save a lot of money if they get everything right at the planning stage of a build.
28 Food&Beverage Industry News | October 2019 | www.foodmag.com.au
STANDARDS AND REGULATIONS
of the build that needed to be taken into consideration. For example, there needed to be enough room for trucks to turn around in while loading and unloading produce. That in itself holds a lesson for those looking at building or revamping a plant. “The number of carpark spots that the original architect put onsite was over and above what the council minimum requirements were,” said Blythman. “Here’s a bit of advice – if the council says you only need 15 carparks, only provide 15. The reason being? If you provide 20 and you are going to do more works in the future, those 20 carparks can become your baseline. It is part of the development control plans that have been in play with any development project with councils.” When a company decides to modify and carry out remedial works to buildings, they open themselves up to fire upgrades and compliance with current codes. The essential services for emergency requirements need to be upgraded as well. These are potential costs that clients may not be aware of that get triggered by council. Then there are the accessibility issues that able-bodied people forget about – planning authorities don’t.
“If there is an employee, employer or visitor in a wheelchair, you can’t discriminate against them according to the Disability Discrimination Act (DDA),” said Blythman. “If you walk down the street and you see a vacant shop, and you go, ‘that’s a nice shop. I might rent that shop out and make it a café’, and the front door requires you to step up, then you have considerations to think of. If you took on that lease, straight away the council would very likely invoke that you need to put accessible ramp in that building to allow accessibility for all persons wishing to enter that business.” Not to be overlooked, but often can be, are the issues of acoustic requirements for the reduction of noise transferring out of the factory to adjoining properties. Some industrial properties cut across residential boundaries. When such a factory has hours of operation that can potentially go on 24/7, the sensitive nature of the equipment and the noise needs to be able to be retained within the industrial boundary. It is not allowed to creep over and impact on the sleep of the nearby residents. “If you can imagine the amount of mechanical plant that’s needed
Getting the correct permits can take time but are a necessary part of renovating or building a new processing plant. to air-condition a large refrigerated space, then there is a lot of noise,” said Blythman. “There has to be acoustic screens specifically engineered by an acoustic engineer to make sure that the noise doesn’t leak out to disturb residents (i.e. sleep). “Clients have to understand the legislation framework that goes around all projects.” Blythman imparts a couple of pieces of advice to those that are thinking of upgrading or building a new facility. The very first port of call
if they are unsure about anything, is to go and talk to the local authority on what is possible for the site and speak to the local planner for that council. “You are a rate payer, so you are entitled to go and get help from your local authority,” he said. “Also, if you are unsure, or don’t know where to start, we can provide means to navigate you through all these issues. We can work in collaboration with a client’s architect or the clients can engage us directly and we can manage the process for them.” F
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www.foodmag.com.au | October 2019 | Food&Beverage Industry News 29
The role that resealable packaging plays in minimising food waste Author
Nerida Kelton MAIP, Executive Director, Australian Institute of Packaging (AIP)
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ith Australia producing 7.3 million tonnes of food waste across the supply and consumption chain, and a Federal Government National Food Waste Strategy to halve food waste that goes to landfill by 2030, now is the time for packaging technologists to review pack designs that could minimise food waste and losses. According to the National Food Waste Baseline, which was launched earlier this year, in 2016-17 (the base year) 2.5 million tonnes of food waste (34 per cent) was created in our homes, 2.3 million tonnes (31 per cent) in primary production and 1.8 million tonnes (25 per cent) in the manufacturing sector. Australians recycled 1.2 million tonnes of food waste, recovered 2.9 million tonnes through alternative uses for food waste and disposed of 3.2 million tonnes. So what role does packaging play in preventing and or minimising food waste? The primary purpose of packaging is to contain, protect, preserve, promote and communicate, handle and transport and provide convenience for a product – all the while ensuring the safe delivery of food to the consumer. Without adequate packaging design features,
and fit-for-purpose packaging, food can be wasted all the way through the supply chain to the consumer. By modifying packaging designs and ensuring that Save Food Packaging guidelines are followed, food waste and loss can be minimised. As a core participant of the newlyestablished Fight Food Waste CRC, the Australian Institute of Packaging (AIP) has been working on producing Save Food Packaging design criteria and communication material for the implementation into food packaging that will lead to better packaging design, material and format selection to assist retail, food service and consumers to minimise and prevent food waste.
Resealable packaging to minimise food waste An important Save Food Packaging criteria is resealable packaging. Under the umbrella of resealable packaging there are many intuitive technologies including resealable zippers, resealable lidding films, extrudable reseal adhesives, resealable packaging, sliders, resealable zipper tapes and labels, valves and more. Resealable packaging provides a myriad of benefits including extension
Resealable packaging can go a long way to reducing food waste. of shelf life, reduction in spillages, retention of nutritional value and freshness of product, ingress of flavours, prevention of further product contamination, consumer convenience, controlled dispensing and pouring, allowance for multiple uses of the same pack and easy storage. Through this packaging design consumers have the ability to retain the product in the original pack and not add additional plastic film, foil, bags or containers to maintain freshness and quality of the product. All of these benefits in turn ensure the prevention of unnecessary food waste and loss.
On-pack communication
Reseal versus reclose
Packaging technologists and designers also need to balance the 2025 National Packaging Targets against the 2030 National Food Waste targets when designing resealable packaging. The decision to move to resealable design must also include discussions about the recyclability of the packaging in the country in which the product is sold. Making the decision to move to packaging that minimises food waste, all the while meeting the 2025 National Packaging Targets, is the optimum solution and may require undertaking a Lifecycle Assessment to find the sweet spot. If every food manufacturer made a commitment to incorporate Save Food Packaging guidelines into their packaging development process, then this would be a considerable step in the right direction to minimise and/or prevent food waste in Australia. F
When selecting the best resealable technologies, it is important to ensure that the pack can in fact reseal and not simply reclose. There is a difference between intuitive resealable designs that guarantee seal integrity and a closure that could compromise the quality of the product. Choosing the wrong solution can potentially stand in the way of preventing food waste in the household and also damage consumer perceptions of your product.
Undertaking trials
Packaging is designed to contain, protect, preserve and help transport product. 30 Food&Beverage Industry News | October 2019 | www.foodmag.com.au
Just like for any other style of packaging, trials need to be undertaken before the resealable packs are commercialised. This is to ensure that the design provides the required freshness, nutritional and food waste objectives for the product. Integrity of seals, freshness, shelf life and barrier, oxygen, contamination, leakage etc can be assessed during trials.
Developers of the packaging should consider incorporating on-pack communication that explains the key benefits of the resealable option to the consumer. Extension of shelf life, freshness, quality and the ability to minimise food waste in the home are important for consumers. Food manufacturers need to actively engage the consumers in the journey and to explain the important role that packaging plays in minimising food waste.
Balancing 2025 and 2030 targets
HYGIENE
Ride-on cleaning range has hands-on local support Cleanliness in food and beverage processing plants is paramount. A series of sweeper and scrubbers are designed to make the job easier. Food & Beverage Industry News explains.
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eeping a food and beverage processing plant clean is an important part of the manufacturing process. One company that specialises in this area is Tennant Australia, which offers an array of floor care solutions that it has been delivering to the food and beverage sector since 1976. As well as its range of floor scrubbers and sweepers, it has floor coatings systems and machine technologies to make sure plant and equipment meet Australian and New Zealand health and safety standards. This includes: • Ech2O NanoClean offers detergent-free cleaning that reduces water consumption by up to 70 per cent, as well as chemical usage. • IRIS Data Manager, which allows customers to use data to make
decisions and make sure their fleet is being utilised property. If a customer has fleets of units throughout the country, this allows them to remotely see the status of these machines, who’s using what machine (and when), monitoring machine performance and maintenance needs, and calculating the costs per machine. One of the benefits of dealing directly with a manufacturer is that companies can purchase, rent or lease directly from Tennant depending on their business needs. Another benefit is that Tennant offers a nationally backed Factory Direct service program – it has 40 plus technicians across the country that look after customer needs. Regular servicing reduces the
likelihood of unplanned downtime, identifies potential problems before they become major, and helps a facility’s machines perform optimally. All of these benefits can help reduce the ongoing cost of ownership. The company also has a national strategic account team at all of its locations across Australia and NZ to help customers with centralised pricing and servicing components. Tennant has a large rental fleet that starts with the smaller-sized T300 walk behind floor scrubber through to a large M30 sweeperscrubber combo machine that can cover over 10,500m 2 per hour. There is also a range of floor sweepers starting with a S10 walk behind sweeper to a larger Sentinel
industrial high-performance rider. The company recently won a national rental deal with one of Australia’s largest national bottlers of ready-to-drink beverages that is currently being rolled out. F
Tennant scrubbers and sweepers meet stringent Australian and New Zealand health and safety standards.
Your brand is your capital - we‘re here to help you Detectable plastic cable marker Contamination of food products with plastic objects presents a high risk for your manufacturing process. Weidmuller’s innovative detectable plastic cable markers can be recognised within the HACCP concept by both metal and X-ray detectors. These markers are embedded with a stainless steel metallic filler into the plastic which allows for both magnetic and X-ray detection, even small fragments can still be detected. Weidmuller - your partner in innovative solutions. www.weidmuller.com.au
www.foodmag.com.au | October 2019 | Food&Beverage Industry News 31
CONSUMER FOCUS
Opportunity for frozen vegetables in health-focussed diets Frozen vegetables have a role to play in healthy diets, according to Mintel’s global food and drink analyst Melanie Zanoza Bartelme. She tells Food & Beverage Industry News why.
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n Australia, producers of frozen vegetables are missing an opportunity to help consumers create high-quality, home-cooked healthy meals without sacrificing time. More Australians are starting to prioritise eating more healthily, and to do so, market research specialist Mintel has information
from its surveys that points to increasing fruit and vegetable intake. This is done by following a balanced diet, and cooking more at home, as key steps in this journey. At the same time, Australians want to make room in their lives for other priorities, such as cultivating strong personal relationships and enjoying social occasions – activities that they understand are important to their health in other ways. Currently, Australians tend to have frozen vegetables on hand for side dish emergencies. However, these products can actually be promoted to do more – frozen
vegetables can act as a shortcut for consumers who are trying to balance many things in their limited time, including eating well. Frozen vegetables provide a solution for time-strapped, yet health-focussed consumers, to create semi-scratch meals that contain lots of vegetables, while still eschewing the processed foods that they seek to avoid. Frozen vegetables are the solution to helping Australians achieve their goal to cook at home more often. While Mintel research shows that almost half of urban Australians say they like to cook, the time taken to prepare for cooking, especially when Vegetable producers need to communicate more about the benefits of freezing their products.
32 Food&Beverage Industry News | October 2019 | www.foodmag.com.au
using whole, fresh vegetables, could be better spent on other pursuits. Enter speed-scratch or “semihomemade” cooking. This concept, championed in the US by Food Network host Sandra Lee, instructs home cooks to use partially prepared foods to create dishes that feel like they are scratch-made. Frozen vegetables are suitable for this, especially as they are already washed, peeled and chopped, and often come without the need to be defrosted before being added to a recipe. Positioning frozen produce as a partially prepared ingredient offers consumers a way to prepare something convenient at home without relying on processed foods – something that over two-thirds of urban Australians say they are looking to avoid. Frozen vegetables can help home cooks in Australia create inspired, intentional meals that are rich in plant-based ingredients by clearly showing consumers the different ways that they can be used. Adding recipes and usage suggestions on pack is an approach that has worked well for the frozen fruit category. For instance, frozen fruit brands have included recipes and usage suggestions for smoothies on pack. These suggestions give consumers more ideas on how to use frozen produce, and they position frozen fruit as a product that consumers would purchase for this purpose. By taking on a similar strategy, frozen vegetable brands can encourage consumers to buy their products more often than just something to have at home as a backup or emergency side dish. In addition to helping consumers
CONSUMER FOCUS
see frozen vegetables as a speedscratch solution, brands need to overcome the perception that frozen is lower quality than fresh. This is especially true as Mintel research indicates the importance of freshness to Australians, with over half of them ranking it as the top attribute they seek in food. However, according to Mintel Purchase Intelligence, a tool that measures consumer reactions to and purchase intent of food and drink products, Australians are unconvinced by the freshness of frozen vegetables. This reflects how frozen vegetable brands are not telling a strong story that communicates the freshness that these products can offer. While many brands use snap-chilling, and do mention this on pack, most are not using their packaging to talk about the benefits of quick freezing in preserving the quality, flavour and nutrition of vegetables. Telling a more dynamic story about freshness and quality can raise the value perception of frozen vegetables, especially when combined with convenience messaging. Meanwhile, New Zealand’s Goodness Kitchen offers a good
Frozen vegetables provide a convenient solution for time-strapped consumers. example of how these types of vegetables can communicate freshness and quality. The product uses bright colours and a see-through cut-out that reveals the product inside, which are aspects that set this packaging apart from the many bags and boxes in the frozen aisle. In addition, it uses the back of the pack to tell a full and engaging story about the company
and its practices. Goodness Kitchen talks about organic farming, freshness, nutritional quality and how frozen veggies help to reduce food waste. In an aisle where low price drives purchase intent, communicating the added value one product offers over another could open consumers’ minds to the fact that price is just one element of the value equation.
Brands in Australia have not fully exploited the chance to communicate the freshness and quality of frozen vegetables. There is the potential for these brands to show consumers that frozen products can empower them to achieve their health goals by helping them eat more vegetables, avoid processed foods and cook at home more often with less effort. F
Dependable Food Conveying Solutions from Rexnord. The Rexnord® KleanTop® line of plastic modular belts are designed specifically for food processing and our experts are here to help you find the right product for your operation, enabling you to meet internal production goals and deliver high quality food for your customers. Each belt in the KleanTop line of plastic modular belts was designed to give food processors confidence that the conveyor they install is safe and delivers high performance in food processing applications. Each product series within the KleanTop line offers a unique set of benefits for a variety of food processing applications, including: • Food-safe materials and colors approved for direct food contact, and ideal for longevity — even in harsh applications and frequent sanitation • Reinforced designs to minimize risk of product contamination
• Designed to convey optimal loads in application to maintain throughput levels with minimal product damage • Optimized rod retention designs that make assembly and disassembly faster, and keep the rod in place during conveyance
Contact Rexnord today to learn more about KleanTop plastic modular belts. sales.australia@rexnord.com or Tel 02 4677 6000
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www.rexnord.com www.foodmag.com.au | October 2019 | Food&Beverage Industry News 33
DIGITISATION
APS eyes long-term partnerships as key to helping industry move forward Food & Industry Beverage News explains why at just 18 months old, APS is already making waves in the automation sector.
APS has a huge portfolio of gear for automating plant.
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PS was born on March 1st, 2018, a time seen by the company as when it provided industry with a new choice by consolidating what can at times be a fragmented market. It brought a range of high-visibility brands in the industrial low- and medium-voltage electrical and automation space under one roof. Headed by industry leader Lloyd Thomas (chairman – APS Group) and David Hegarty (managing director – APS Industrial), APS came into being when two companies were acquired – Ramelec and HiTech Control Systems. Thomas and his board then quickly set about putting national distribution deals in place with highly rated global manufacturers such as Siemens, Rittal and Weidmüller. Siemens has a leading global market share, but less so in Australia. It was the apple in Thomas’s eye
"The advantage we bring to local customers is that not only do we sell quality products but the breadth of our portfolio is so impressive. Our global manufacturing partners produce an incredible number of products and that’s what we give the local market access to. We are giving consumers a large choice in one place." when he thought about putting APS together. Building on that, APS then signed national distribution deals with a range of other German companies including the aforementioned Rittal and Weidmüller. Other brands under its umbrella include KATKO and Epcos (TDK). In Hegarty’s words, APS has become a “one-stop shop for industrial automation and power distribution needs”. As if to reiterate
34 Food&Beverage Industry News | October 2019 | www.foodmag.com.au
the point, Hegarty is also clear on what APS has to offer the market. “The advantage we bring to local customers is that not only do we sell quality products but the breadth of our portfolio is so impressive,” he said. “Our global manufacturing partners produce an incredible number of products and that’s what we give the local market access to. We are giving consumers a large choice in one place.”
APS is here for the long game, and doesn’t consider itself an overnight success, despite its rapid rise in the industrial electrical space, said Hegarty. He also knows the direction the company is heading is the right one. He feels that the sooner the industry can appreciate the benefits of Industry 4.0 and commence their digital journey, the better for all companies participating in the Australian industrial ecosystem. “I was at the Siemens Digitalise 2019 in Brisbane, and it is clear a key challenge that the industry is going to face is getting started on their digitisation journey,” he said. “There are already early adopters paving the way, and there are going to be more examples of this over the next six months where companies are willing to take a step from what they are currently doing manufacturing, product and process wise. They’ll say, ‘we’re on the cusp of something big here and we are going to take these first steps to go down the path of digitisation and are ready to commence our journey. It takes courage, but we are going to do it because this is how we will survive and thrive. We have to’.” Siemens invest billions of euros globally on research and development and the whole idea of Industry 4.0 and smart manufacturing, said Hegarty. They are leading the way and that APS can exclusively help bring this to Australia is a unique point of difference for him. “Take a brand like Siemens – when all of your products are from the same manufacturer you get unrivalled communication and integration capability – power distribution, automation, motor control – everything comes from
DIGITISATION
APS’s David Hegarty believes that embracing digitisation is a win-win situation for the Australian industrial ecosystem.
the same manufacturer and are all connected,” he said. “Nobody else can offer this. In terms of what industries that suits, manufacturing is obviously a big one, as well as mining and utilities who are the ultimate beneficiaries of this performance and data visibility. Switchboard builders can see the benefits, as well as wholesalers and contractors. For the end user, it ultimately means they can manufacture more efficiently, have less downtime, and experience gains across their operation that are currently unattainable. Our manufacturing partners are also at the pointy end of Industry 4.0. This should provide the local market with a lot of faith in terms of what we can offer and help them achieve.” Hegarty also said that APS will now give local manufacturers more of a choice when it comes to industrial, electrical and automation gear. He knows it will take time for consumers to get to know the company, but is confident that what they have to offer is something unique. “We want to be in the conversation and we want the industry to understand the full benefits of Industry 4.0,” Hegarty said. “The suite of products, the communication abilities of
digitisation technology are what are important and we want to be a trusted partner in that space. Within the next few years we will have proven our offerings to industry, and they will consider us a trusted advisor and partner.” APS is seen as a relatively new player in the market, but its already having an impact on the industry.
This is proven by not only the increase of staff since inception (it has almost tripled), but also by the amount of investment it has put into bricks and motor. “In September 2018, we moved to a brand-new national distribution centre in Melbourne,” said Hegarty. “And that allowed us to dramatically increase our stock holdings and
invest in expanding our team. In August this year, our Queensland office also moved into a new facility, to do the same.” Although still only young in terms of being in existence, it is the experience it has behind it at management level that will make APS a long-term player in what is an increasingly competitive market. F
APS allows consumers more choice when it comes to local automation and industrial gear. www.foodmag.com.au | October 2019 | Food&Beverage Industry News 35
FOOD PROCESSING SOLUTIONS
Steel belts for chocolate manufacturing solutions IPCO offers a range of processing solutions for confectionery manufacturers. Food & Beverage Industry News looks at its latest range.
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ooling and forming are critical stages in the production of both chocolate and confectionery, and few companies have more experience in these areas than Melbourne-based IPCO. As an independent company owned by FAM AB, and part of the Swedish-based Wallenberg group, IPCO is a globally active engineering company with sales and service offices in more than 35 countries. As a business its connection with the food industry stretches back almost
a century, when its steel belts were first used in bake ovens. Milestones since then include their use for cooling chocolate drops at an American confectionery company in the 1930s, for ice-cream freezing (1959) and for chocolate conveying (1960). Today, IPCO steel belts are used in applications ranging from simple conveying to continuous processes such as cooling/solidification, conditioning, casting, freezing and finishing. In parallel with this, IPCO has developed its own forming systems including the Rotoform FD – a foodgrade pastillation system used to turn molten product, such as chocolate,
The Rotoform FD can be used with a whole range of different confectioneries. 36 Food&Beverage Industry News | October 2019 | www.foodmag.com.au
fruit-flavoured jelly, gum base, fats and other additives, into solid, consistently sized pastilles.
Processing solution for industrial and decorative chocolate This expertise in pastillation in general, and chocolate in particular, has seen the company create a specialist division focussed on chocolate processing. With its own production facilities in Breda, The Netherlands, this division produces versatile forming systems for both industrial (chunks, chips and blocks) and decorative (rolls, shavings, blossoms etc.) chocolate products. These systems are designed to maximise productivity while also ensuring a premium quality end product. The company has developed a
portfolio that includes depositors, extruders, cutters and decorative forming systems, as well as highperformance, steel-belt conveyors and economical plastic belt systems. By combining these different elements, IPCO can offer process lines suitable for everything from low-cost, rapid-deployment start-ups to high-performance, multi-layer systems.
Rotoform rotary depositing chip production At the heart of every IPCO highspeed, high-capacity chocolate forming system is the Rotoform rotary depositor, a unit first developed for the chemical industry but subsequently adapted for food processing. More than 2,000 Rotoform depositors are now used around the world. The Rotoform itself consists of a heated cylindrical stator and perforated rotating shell that turns
FOOD PROCESSING SOLUTIONS
concentrically around the stator. Chocolate drops are deposited across the whole operating width of a continuously running cooling belt. The outer depositor shell can be replaced to enable the production of chips of a different size, with a changeover in less than 30 minutes. The circumferential speed of the Rotoform is synchronised with the speed of the belt so drops are deposited without deformation. The heat of the drops is transferred to cooling air blown onto the product and also to the belt itself. The most recent addition to this range is the Rotoform HP, a highperformance system offering a range of advantages including increased productivity, reduced maintenance and the ability to handle higher viscosity products. Reliable, versatile and easy to use, the Rotoform HP is available on all IPCO chocolate production lines, or as a retrofit replacement for piston depositors. Suitable for the production of chips from 250-35,000 pcs/kg, this versatile module delivers a consistently sized product at depositing speeds of up to 40 m/min. Available in 800mm, 1,200mm and 1,500mm widths, the Rotoform HP can process viscosities up to 25,000 mPas.
Single- and triple-pass cooling lines IPCO produces a range of cooling systems to meet different throughput requirements. Single-pass, end-toend cooling lines are designed for low-to-medium capacity requirements from 200-2,000 kg/hr. These affordable systems can incorporate a gear or rotary depositor for chip production and/ or extruder and servo cutter for chunks. IPCO triple-pass cooling systems enable high throughput rates while minimising floor space requirements. The product is deposited on the first belt and adheres to the underside for the second pass. It is then removed on to a second conveyor for a third pass.
IPCO steel belts for confectionery processing As well as producing complete process systems, IPCO is also a manufacturer of steel belts, supplying third-party machine builders (OEMs) throughout the food industry in general, and the confectionery industry in particular.
Caramel being cooled by an IPCO steel belt.
Steel belts are widely used for cooling and solidifying with many products including chocolate, sugar mass, caramel, gelatine, melt candy, nougat, nut brittle plus a whole lot more. Steel belts are a versatile conveying medium. They are available in solid or perforated form and can be manufactured to virtually any length and, at IPCO’s manufacturing plant in Sweden, to widths from 25-9,000mm. Steel belts offer a unique range of thermal properties, being capable of operating in temperatures from minus 80°C to +750°C. Cooling is an area in which IPCO has end-toend process expertise, working with machine manufacturers to ensure optimum productivity and return on investment. These systems are used for cooling and solidifying, with applications including chocolate, sugar mass, caramel, gelatine, hard-melt candy, nougat, nut brittle and more. Steel belts are also used in zoned conditioning systems; slab and bar casting applications (e.g. caramel and sugar mass); freezer lines; drying units; chocolate melt reclamation; and in finishing operations (e.g. cutting, folding, layering). In terms of cleanliness and hygienic food handling, the flat
surface of a steel confectionery conveyor means there are no joints or crevices in which germs can hide. Its smoothness means a cleaner, easier discharge of lollies, chocolate and similar products at the end of a conveying or processing line. And stainless steel can be subjected to any method of cleaning – steam, pressure, detergents, brushes, chemicals, even aggressive scrapers – to ensure the lowest levels of bacteria and the highest standards of hygiene. IPCO supplies belts for use in OEM systems and it can also supply every aspect of a steel-belt conveying unit, including drums, compact belt tracking devices, belt and drum cleaners, safety scrapers and beltedge detectors, cast-iron skid bars, graphite skid bars and both active and passive belt-tracking controls. Engineers can advise on upgrade paths or optimum process layouts, and the company’s worldwide technical support network means that installations and commissioning can be carried out quickly and efficiently.
The company can also supply complete, standalone conveyor units that represent best practice in terms of hygienic food conveying. These feature a stainless-steel framework designed to allow access for cleaning, with no narrow gaps or other hard-to-reach places in which dirt, debris and bacteria could otherwise collect. The framework is designed to minimise the risk of water pooling after cleaning, reducing the possibility of bacterial growth. The stainless-steel conveyor belt is “endless welded” to eliminate any trace of a joint and its smooth surface means there are no hidden gaps or recesses in which bacteria could collect. All bearings are food approved and lubricated for life with food-approved lubricating grease. The motor is food-approved and has IP65 protection.
Enhanced technical and service support throughout Oceania In line with the strategic vision for business growth in the region, IPCO recently announced its relocation to a new office, warehouse and workshop facility at Burwood, Victoria. This new facility will enable IPCO to increase efficiency and enhance support capabilities – resulting in stronger partnerships with clients throughout Oceania. F
www.foodmag.com.au | October 2019 | Food&Beverage Industry News 37
SUSTAINABILITY Cookers blue trucks pick up used oil so it can be repurposed.
Tracing every last drop of cooking oil Traceability and sustainability are key to Cookers Bulk Oil’s success. Food & Beverage Industry News explains why.
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il – in all its forms, including vegetable – doesn’t have the best of reputations when it comes to sustainability and the environment. It takes a long time to break down, can have a disruptive impact on habitats, and can take on toxic forms once used. With tens of thousands of eating establishments throughout Australia – all of which use one form or another of cooking oil – it is an issue that bulk oil specialist Cookers Bulk Oil knows all too well. When it comes to sustainability, traceability and how vegetable oil can affect its surrounds, the company has processes in place aimed at keeping the environment free from any negative outcomes caused by vegetable oils. National quality and safety manager for the company Hari Srinivas makes no apologies
for the standards the company sets when it comes to where it sources its vegetable oil supplies. “To deal with Cookers, you need to be an approved supplier, which means we look and see what sort of practices and standards you are following,” he said. “Suppliers need to meet minimum standards. And it means we don’t go to any supplier who hasn’t got a certification/traceability system in place that is not internationally recognised.” He cites the Global Food Safety Initiative (GFSI), which is a private organisation, established and managed by the Consumer Goods Forum in Belgium. It maintains a scheme to benchmark food safety standards for manufacturers. Certification can be achieved through a successful third-party audit
38 Food&Beverage Industry News | October 2019 | www.foodmag.com.au
Cookers Bulk Oil sticks to stringent high standards with all its oils.
SUSTAINABILITY
by schemes recognised by the GFSI, including the BRC (British Retail Consortium) Global Standard for Food Safety Issue 8, IFS Food Version 6 and SQF Safe Quality Food Code 8th Edition to name a few. “Without those types of certifications we don’t even entertain any supplier,” said Srinivas. “We are stringent with our suppliers. If you look into the way the industry is going now, the majority of the supply chains are going through some sort of certification system including HACCP. These sorts of certifications are one of the core fundamentals for traceability. The product could be coming from anywhere in the world nowadays. It may be via an underdeveloped country, a developing country or a developed county. Also, most of my customers whom I supply to have at least some food safety certification. Cookers ensures product integrity with no dilution as we provide Certificates of Analysis to meet specifications. ” He said that although 99 per cent of the oil is refined locally, even the small amount of product they source from overseas has to have a certain standard of certification. This includes where the seed has been sourced, where it is crushed and even the batch number it came from. “If they give us a batch number you can trace it back to the farm,” said Srinivas. “This is why farm to fork is the new mode that everybody follows, including us. We make sure we go back to the beginning and we use GSFI-certified refineries where they can trace backward from their end, too.” Srinivas doesn’t want to tempt fate, but he is proud that the company has yet to have any of its products recalled. He puts it down to not only the standards it sets, but also compliant suppliers, and their own end users as well. This doesn’t mean the company is complacent. In fact, far from it. Frequently, they do an exercise where they have a mock recall, which involves checking its suppliers’ traceability to make sure they have the correct systems in place, and that they are working. This is because he knows that if there ever is a recall, they need to know where every drop of oil they have distributed has ended up. The good news for end users is that if that does happen, Cookers Bulk Oil will be able to trace the batch number and know where
The company uses batch numbers to trace all of its oils.
the offending product is very quickly through their centralised system. Traceability is also key when it comes to dealing with customers in case things go wrong once the oil has been distributed. As mentioned, Cookers makes sure its customers also comply with standards and regulations, too. This is important to ensure customers are getting the product they paid according to specifications. “We get audited every year, and our auditor checks things like how long it takes to check something, and the accuracy of our traceability,” said Srinivas. “If we have an issue we can compare it with the same batch delivered nationally to different customers,” said Srinivas. “We can get a sample and test it with same batches from other customers who have used the same batch.” And the environmental side of the equation? Well, it is simple really: the customers who they supply their fresh oil to are also their used oil suppliers. The Cookers Bulk Oil truck fleet is divided into two types of vehicle. The stainless-steel trucks deliver fresh cooking oil, while the blue ones pick up the used product. Cookers not only supplies fresh oil and pick up used oil, it provides separate purpose built storage equipment used on-site by the customer, one for fresh and another for used oil. Not only does that help
the customer, but it allows Cookers to make sure that they know what is happening with the oil. “Once a customer uses the oil, we provide the equipment to transfer the used product into our on-site mobile storage units, which are emptied at regular intervals,” said Srinivas. “We get the oil back and we have got mechanisms to handle the oil in such a way it can go into biodiesel production. It means that with every drop of oil we sell, we make sure not a single drop goes into the drain.” But what about the client? How does Cookers know that the amount of oil they delivered and collected is roughly the same? Sure some, might get absorbed into food, but there could be huge discrepancies between the amount delivered and what they pick up after use, right? Not so, said Srinivas. “We measure UCO, which is collected,” he said. “We do all the calculations, so if there are any big variations, we will go and speak to the customer to see if there is anything going wrong and find whether we can help with oil management.” He said another reason to use a company like Cookers Bulk Oil is that, due to its tanker delivery method, there are no empty oil tins heading to the local landfill. If a customer needed 100 litres of oil per week, that would usually consist of
five 20-litre drums, which may end up in land fill. With Cookers’ tankers, the drums are redundant. And where exactly does the company source it oils from? Srinivas is quick to point out that they don’t use palm oil, and their main oils are canola, sunflower and cottonseed. “We get most of our oil in Australia, and over 90 per cent is refined in Australia,” he said. “For example, the canola oil we sell is 100 per cent Australian. Other oils, depending on the cropping situation, are imported in crude form from reputable suppliers who have proper certifications in place – usually from Argentina and European countries.” At the end of the day, traceability is one of the key planks upon which Cookers Bulk Oil has built its reputation – thus the plethora of certifications and processes it has in place to make sure its meets its customers’ needs. “The traceability is so important,” said Srinivas. “When you think about it, it is important in anything you do. If you are buying a piece of land you have to have documentation to see who the previous owner was, and the owner before them, and before them and so on. It is the same with anything that you are putting into your mouth, which is going to impact your health – we need to know the traceability and this is why we have these processes in place.” F
www.foodmag.com.au | October 2019 | Food&Beverage Industry News 39
AUTOMATION
One cable solution for automation in processing factories Beckhoff’s One Cable Automation provides additional power supply capabilities in a range of applications. Food & Beverage Industry News explains.
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he One Cable Automation (OCA) philosophy from Beckhoff is based on the connection of individual field devices, decentralised terminal boxes, and machine modules using only one cable. This cable technology combines ultra-fast communication via EtherCAT, with the power supply required by the connected components. For the 24V field level, this was implemented using the EtherCAT P technology expansion connected via special M8 connectors. To provide additional power supply capabilities via a one cable solution, Beckhoff developed the new ENP and ECP connector families. These combine EtherCAT or EtherCAT P communication with additional power conductors in one cable, and are easy to use, mechanically coded to prevent installation errors and offer a high waterproof rating of IP67. One Cable Automation has a flexible design that is suitable
for use in a range of applications. Different sections in a network can be connected selecting a suitable one cable solution for devices and components according to their individual power requirements. The unrestricted openness for mixed network topologies is a key benefit, which allows flexible transitions between: • E therCAT P communication with integrated power supply (one cable solution with M8 connector). • A one cable solution using hybrid cables that combine an EtherCAT or EtherCAT P communication element with additional power conductors (one cable solution with the new ENP or ECP connectors). • A conventional two-cable solution with separate power supply (EtherCAT via M8/RJ45 connector or EtherCAT/EtherCAT P via ENP/ ECP connector). The new ECP and ENP connector series implements the combination of communication and power elements
in different performance classes that range from 3A to 64A, all in a compact design. The system is a new product development and meets the full scope of OCA requirements regarding connected devices and modules, including drives, sensors/ actuators, control cabinets and machine modules. Reducing the system to the essentials – namely the EtherCAT or EtherCAT P communication element and DC or AC power supply lines – creates a cost-effective connection concept. In addition, the system is easy to use due to the bayonet connections with mechanical and colour coding. The ECP variant for EtherCAT P also provides another benefit – the power transmission integrated into EtherCAT P enables the elimination of the four wires normally required for 2V x 24V. This allows the use of thinner, lower-cost cables and alternatively, the supply of other voltages.
EtherCAT P as an OCA solution for 24V I/O systems With EtherCAT P, the company has expanded the globally established EtherCAT technology to combine ultra-fast EtherCAT communication with a 24V system and peripheral power supply (US or UP), all in a standard Ethernet cable. Beckhoff developed special M8 connectors for EtherCAT P with mechanical encoding that eliminates possible confusion with connectors used for standard EtherCAT slaves. The design of a specific machine or plant installation is simplified using a TwinCAT software tool that helps specify all individual EtherCAT P consumers and cable lengths to configure the highest performance and most cost-effective EtherCAT P network. For that purpose, the new and highly compact EPP90220060 EtherCAT P Box module, with dimensions of only 30mm x 86mm x 26.5mm, can be used to gather important data. This module measures One Cable Automation has a flexible design suitable for a range of applications.
40 Food&Beverage Industry News | October 2019 | www.foodmag.com.au
AUTOMATION
One Cable Automation is a cost-effective solution for various automation processes.
the US and UP voltages along with the IS and IP currents in the system and passes on the information to the controller. Provided the system has the data from all consumers, it can also take the individual devices’ power consumption over time into account. For example, if two actuators never switch at the same time for logical reasons, this can be taken into account when configuring the maximum current. This introduces additional savings potential with regard to the required number of power supply feeds and power supply units.
Connector series for EtherCAT and EtherCAT P If higher power or additional supplies are required in addition to the 24V system and peripheral power supply via EtherCAT P, power can be supplied via corresponding hybrid cables together with the ECP and ENP connector series developed by Beckhoff for this purpose: • ECP (EtherCAT P + Power): This connector series combines a compact, trapezoidal EtherCAT P element (using the same pin allocation as the EtherCAT P encoded M8 connector) with additional power pins. In this way, the 24V supply integrated into
EtherCAT P is complemented with an additional power supply line. • E NP (EtherCAT/Ethernet + Power): These connectors combine a trapezoidal, central communication element with additional power pins in the same way as ECP. The trapezoidal element has an inverse design to prevent incorrect connections and provides data transmission via EtherCAT, standard Ethernet or other Ethernetbased communication protocols. Different connector sizes from B12 to B36 are available with a varying number of power pins (two to six pins) so that they can be easily adapted to the requirements of different network types and the power consumption of connected consumers. The complete and full-length 360˚ shielding of the central trapezoidal element continues the typical high performance of EtherCAT. Furthermore, the compact design also provides adequate space for the power pins, ensuring high current-carrying capacity and dielectric strength. The quick and easy-to-use bayonet connection, along with the broad flange spectrum in the diverse housing variants for rear panel, front panel and square installation, provide additional user benefits. Additionally, there are versions for field assembly that
enable extreme time-savings during installation.
Broad range of applications The ECP and ENP connector families, together with the EtherCAT P-encoded M8 connector type, cover all applications from 24V DC on the I/O level to drive systems with 480V AC and a maximum of 64A. The
flexibility of the connection system is available in every application area. Depending on specific needs, EtherCAT, EtherCAT P or a mixture of both can be used. Typical engineering requirements for smalland mid-sized systems are covered by EtherCAT P with up to 3A for US and UP in combination with M8 or ECP connectors. In contrast, the ENP connector series is the ideal solution for larger installations involving longer transmission distances. The same also applies for applications without EtherCAT P, such as an endpoint with a 24V power supply unit or for the supply of 24V consumers with high power demands. Expanding the One Cable Automation concept through the growing diversity of the EtherCAT P, ECP and ENP devices and components constantly expands the range of application options for users. Current examples are the two new infrastructure box modules EP9221-0057 (1 channel) and EP9224-0037 (4 channel) from Beckhoff. Via B17-ENP connectors, these power distributors provide two 24V supplies and a protective conductor along with EtherCAT communication in the trapezoidal element. The power cable has a cross-section that is approximately five times larger than the EtherCAT P element and can bridge longer distances or conduct significantly higher currents (up to 20A at ambient temperature). F
Connectivity is key to the Beckhoff One Cable Automation solution.
www.foodmag.com.au | October 2019 | Food&Beverage Industry News 41
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SOFTWARE SOLUTIONS
Unleashed a game changer for award-winning bakery Drowning in paperwork, Pinjarra Bakery general manager, Daniel Pantaleo, needed a one-stop-shop solution to make running his business easier. He found one. Mike Wheeler explains how.
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ocated an hour’s drive south of Perth, Pinjarra is a little town with a huge drawcard – its renowned bakery run by the Pantaleo family. Founded just over 22 years ago by patriarch and former panel beater Larry, the bakery has not only put the town on the map, but has won a
bookshelf-full of national awards for its pies. Its award-winning ways were capped off this year by taking out the Best Meat Pie award in the Great Aussie Meat Pie Competition at the Fine Food Australia Exhibition held in Sydney. Like any company, growth is key, and since starting the business
Pinjarra Bakery’s award-winning pies, along with Unleashed’s inventory software, are what makes it such a successful business.
44 Food&Beverage Industry News | October 2019 | www.foodmag.com.au
in 1997, Larry and the rest of his family, has grown the business to include stores in Maddington and Waroona, also in Western Australia. However, while expansion is exciting, it does come with a set of challenges, one being more paperwork. When in its infancy, dealing with spreadsheets wasn’t
a problem for the Pantaleo family. However, as the business expanded, so did the bureaucracy of keeping it running. The bakery’s general manager, Larry’s son Daniel, knew something had to be done to streamline processes with paperwork. Enter Unleashed Software’s solution. “The old system that we had of dealing with the paperwork and spreadsheets was no longer going to work,” said Daniel Pantaleo. “It was very inefficient and time-consuming for us. It all came to a head when we opened our Maddington store.” Unleashed’s inventory management software was a perfect solution for the family, and Pantaleo noticed the impact straight away. “What we like about Unleashed is that it is a hosted solution, which means I can jump on it from anywhere in the world and I can check what is going on,” he said. “I can update my prices. I can contact my customers through the CRM. So it allows me – as someone who is here, there and everywhere at any given time of the day – to jump on any time anywhere and see what is going on. This is very important for me, because the last thing I want was a dedicated software solution on one computer at one location. A key to me was having that flexibility.” According to Pantaleo, the system also streamlined a lot of processes that the bakery had, which were old and clunky. Many mistakes were getting made and Unleashed allowed Pantaleo to enter all the parameters he needed to cover in one place. From there, he could control the ordering of stock, see what stock he had, as well as the taking feedback from the other two stores. “Everything became a lot clearer as to how we were operating that business,” said Pantaleo. “You need to keep control of your numbers otherwise it is pretty daunting feeling
SOFTWARE SOLUTIONS
The Pantaleo family (left to right) Paul, Daniel, Jodie, Narda and Larry.
when you think you are losing control of the stock, the numbers and what is going on with that side of the business. “Unleashed is quite precise in what it does. It is flexible, too. Not only in terms that we can operate it from anywhere, but also how you can tweak it to your style of business. It tells you everything you need to know. If you manage your stock and distribution correctly, Unleashed will do all the hard work for you. It allows you to customise and design your own purchase orders, invoices and stuff like that, which is very handy.” Pantaleo is confident that Unleashed is capable of being used in many other industries. He said that it takes a while to set everything up, but once it is up and running it is a powerful tool “The biggest issue we worried about was that we had all these items that we needed to enter into it, which we thought was going to take forever,” he said. “But we were pretty much given a template of a spreadsheet and then told how we needed to enter the data. And from there, once we had the 1,000 plus items in there – the product, the supplier, the prices, the sell price tiers etc – we uploaded it to Unleashed and then we were ready to use it.” With more than 70 staff onboard,
Pantaleo knows that he is not the only one who needs to know how to use the software, which means he has had to teach others how implement it, too. He said that he has found teaching others how to use it easy for a couple of reasons. “Unleashed is really easy to teach, because they have a lot of online
training tools,” he said. “They have what they call a university that shows people how to use the software. If I do need to onboard somebody to use it, I usually send them to do that training first. From there, I manage them for a couple of days to give them pointers of the little intricacies of how we operate our business. It’s
fairly straight forward.” There are several highlights that Pantaleo points out. This includes being able to run a reorder report, which reads all the stock levels the bakery has at any given time. “From that report you can generate a purchase order to all of your suppliers with the levels you require,” said Pantaleo. “That saves us a lot of time and this is why it is one of the main highlights of the product.” The other feature that Pantaleo loves is its business-to-business portal that was released a year ago, which is an online ordering platform. It was a real game changer for Pinjarra Bakery. “Initially we got Unleashed because it was reducing the paperwork, but as we increased our stores that paperwork was starting to increase again, just through the volume of the stores we had,” said Pantaleo. “Having that online portal allowed us to place our orders online and that would then pull the orders straight in as a sale order, which saves us possibly two or three hours a day of not having to enter stock manually. The orders that come in are now a lot more accurate and saved us a tonne of time and allowed our distribution manager to focus on more things to improve the distribution as opposed to being stuck behind a computer all day.” F
Unleashed helps the Pinjarra Bakery keep up to date with its stocks of ingredients such as flour.
www.foodmag.com.au | October 2019 | Food&Beverage Industry News 45
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SAFETY
The dairy flooring challenge Strict standards apply to flooring in dairy factories. Food & Beverage Industry News looks at one option that meets those requirements.
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ccording to the Australian Department of Agriculture, the country’s dairy industry accounted for $4.4 billion of Australia’s gross value of agricultural production and around seven per cent of the country’s export income. It has a reputation for producing good quality products that are in huge demand around the world. In order to keep this reputation intact, the factories where food and beverages are produced have to adopt clean and safe working environments. Not only for the sake of the products themselves, but for the workers, too. A key area of any factory is its floor space. The ever-demanding world of cheese and dairy manufacturing offer tough conditions for flooring in most facilities that produce and process the products. Typically, with the producers of milk and milk ingredients such as
cheese, ice cream, butter, cream and yogurt, face a common challenge with concrete corrosion, as well as dangerous, damp and wet conditions, which are compounded by heavy impact traffic. Dairy processing floors are exposed to aggressive acids and alkaline chemical cleaners, including Clean in Place (CIP) chemicals. Heavy-duty, epoxy-trowelled flooring from a company such as Roxset Health and Safety Floor Coatings handles a range of corrosive acids. This includes nitric and phosphoric acid typically found in processing and chemical storage areas. Milk and other ingredients break down on the floor, forming acidic by-products that can also damage the concrete. It is critical that companies protect their concrete from oils and chemical deterioration, while handling impact, abrasion and thermal cycling.
There are strict regulations in the dairy industry, which are required in order to meet Food Standards Australia New Zealand Food Standards Code (FSC) Standard 4.2.4. This is a primary standard that dairy farms must adhere to and follow assiduously. Food Standards Australia New Zealand, Standard 3.2.2 – Food Safety Practices and General Requirements states: “Floors must be designed and constructed in a way that is appropriate for the activities conducted on the food premises”. When the facility gets wet, which is common in dairy production, it can lead to serious slip issues. This can escalate into expensive lawsuits if care and caution are not taken. It is critical that an anti-slip HACCP complaint aggregate is built into the full thickness of the floor. The profile of this would typically be
between 6-10mm for maximum protection. Drains are important in tackling slip hazards where is it important to contour the falls with the correct anti-slip aggregates. It is these types of considerations that Roxset looks into when laying down epoxy flooring at factories that specialise in dairy products. A dairy facility floor is also challenged by extremes, like cold conditions in the coolers and warm conditions in the processing raw milk and intake side. This is where a potential for thermal shock and thermal cycling in the floor can occur leading to damage. A heavy-duty non-toxic HACCP epoxy coating from a company like Roxset will be sensitive to any shock. However, it can also handle very hot wash downs, which are also needed in order to keep a factory in excellent condition. F
www.foodmag.com.au | October 2019 | Food&Beverage Industry News 47
TRANSMITTERS
Ceramic sensors ideal for food processing plants Vega’s range of process pressure transmitters tick many boxes when used in food and beverage manufacturing plants. Food & Beverage Industry News explains why.
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The biggest leaps in technology, however, are being experienced by the ceramic measuring cell CERTEC. Only a few suppliers have ceramic-capacitive cells in their portfolio, and fewer still have the know-how to produce them themselves. Eighty per cent of all units sold operate with ceramic sensors.
ith the introduction of the plics family almost 18 years ago, Vega turned the vision of simple, standardised measurement of level and pressure into reality. The Vegabar 80 series represents a systematic further development of the concept and the products. The clear structure of the new instrument series ensures easy selection when looking for the right instrument for a particular application. The new handling with “quick start” procedure allows fast, simple and reliable setup and commissioning. The integrated diagnostics system makes fast maintenance and servicing possible.
to produce them themselves. Eighty per cent of all units sold operate with ceramic sensors. In principle, both technologies can be used in the majority of applications. But the company is convinced that in many cases ceramic is the better technology, because it is more robust and durable.
Making three from five
Nothing can shock them
With the new Vegabar 80 series, all conceivable applications can be covered with only three process pressure transmitters. There is the all-rounder Vegabar 82 with ceramic measuring cell, which can cover 80 per cent of all applications. Then there is the Vegabar 83 with metallic measuring cell that is designed for high-pressure applications. Finally, there is the classic Vegabar 81 with chemical seal, which is deployed when high temperature and/or chemical resistance is required.
Ceramic measuring cells have many advantages, but also some weaknesses. For example, they are susceptible to thermal shock and moisture. Through intensive further development of CERTEC, both of these problems could be reduced or even eliminated altogether. Equipping Vegabar 82 with temperature-shock compensation resulted in a technological masterpiece. A patent for this worldwide innovation is awaiting approval. When sudden temperature changes occur, it can take several minutes before sensors with ceramic measuring cells begin delivering reliable readings again. Often, users do not know that a sensor is experiencing a temperature shock, which means it is transmitting incorrect values. With the ceramic measuring cell in Vegabar 80, customers can be sure that they are getting correct measurement data. Because now, even fast temperature changes cannot affect
Ceramic versus metallic A lot has happened in the development of both metallic and ceramic measuring cells in recent years. The biggest leaps in technology, however, are being experienced by the ceramic measuring cell CERTEC. Only a few suppliers have ceramiccapacitive cells in their portfolio, and fewer still have the know-how
48 Food&Beverage Industry News | October 2019 | www.foodmag.com.au
the pressure measurement. In addition to the usual temperature sensor on the backside of CERTEC, there is a second sensor in the glass joint directly behind the ceramic diaphragm – this sensor is mounted in a technically challenging process. Due to its exposed position, it doesn’t miss even the slightest temperature change. Any thermal shock is fully compensated by means of a sophisticated algorithm. A side benefit of the second sensor directly next to the process is a temperature measurement of high quality, with an accuracy of ± 2 K. Earlier versions of the measuring cell could also output a temperature signal. However, due to its slowness, the sensor was only suitable for storage tanks, which normally have a stable temperature. In many applications, installation of a separate temperature sensor can be eliminated.
Moisture? No problem The typical moisture sensitivity could also be lowered. The problem with the naked electrodes of capacitive system – ingressing dielectric fluid, such as water – changes the dielectric constant and the capacitance, and therefore the pressure reading. However, the instrument cannot distinguish the reason for the change in capacitance.
The solution? In the new instrument generation, Vega has applied a measurement and a reference capacitor and covered the entire surface of the measuring cell with a thin layer of glass. Due to the glass passivation, there is no longer any contact with the medium, which means the dielectric constant in the entire system changes – for both the measurement and the reference capacitances. A coefficient is then formed from the two values and then computationally balanced for the measuring result. Another special feature of the Vega ceramic is its high overload resistance of up to factor 200 – more than double what other ceramics are able to provide. Progress has also been made with regard to the temperature range. Until recently, 120°C was the limit with the standard version, but CERTEC can now withstand temperatures up to 130°C. These additional 10°C are especially interesting for the food and pharmaceutical industry because, in many cases, customers no longer have to buy the high-temperature version for their sterilisation processes. Application temperatures have increased in relatively small steps, but when it comes to extending the measuring ranges, Vega has put on a pair of proverbial “sevenleague boots”. Vegabar 82 has a tiny measuring range of only 25 mbar (previously 100 mbar). And that is without electronic turndown. The measuring range has also increased in the upward direction, from 60 to 100 bar. This has extended the application limits. Customers will be able to solve more applications with the standard Vegabar 82 sensor in the future.
TRANSMITTERS
No such thing as impossible CERTEC is the only ceramic measuring cell on the market that allows absolute front-flush mounting, as its radial seal is recessed and protected from the medium. It can bring this advantage to bear especially in abrasive applications. Build-up is also said to be a thing of the past. This is because the sensor is capable of cleaning itself in the flowing medium.
The Vegabar 82 process pressure transmitter comes with a ceramic measuring cell.
Safe, reliable operation Another key topic is the second line of defence. This feature is indispensable, for example, in phosgene applications, in order to prevent the toxic medium from penetrating into the terminal compartment and endangering people and the environment. At present, customers have to resort to encapsulated absolute pressure transmitters with special chemical seal assembly. Vegabar 82/83 is a fully welded sensor module with a second line of defence, which, in combination with climate compensated electronics, can reliably and accurately measure relative pressure even in such applications. This unique innovation allows high measurement accuracy to be achieved also with small process fittings. Reliable and stable measurement data is one of the most important features of a pressure measurement setup. Vegabar 80 with Safe Integrity Level (SIL) differs from a standard instrument both in hardware and in software. Vegabar 80 with SIL is a separate instrument developed according to the guidelines of IEC 61508. In single-channel systems, Vegabar 80 can be implemented up to SIL2, and in homogeneously redundant systems even up to SIL3 via the software.
Electronic differential pressure An innovative software and hardware concept makes it possible to combine any two instruments from the Vegabar 80 family, whether all-rounder, high-pressure or high-temperature sensor, into
an electronic differential pressure system. What does this mean in practice? An example is that a customer only has to take a Vegabar 82, a standard instrument that he or she has in stock anyway, order an additional sensor, select the “slave” electronics version and connect them together. That is all that is needed to be done. Users benefit from simple selection, identical adjustment and operation as well as simplified stocking. There are many other features of the electronic differential pressure system. This includes there are no
An innovative software and hardware concept makes it possible to combine any two instruments from the Vegabar 80 family, whether all-rounder, high-pressure or high-temperature sensor, into an electronic differential pressure system. oil-filled capillary tubes that need to be insulated – usually at great cost – to avoid environmental influences, such as temperature changes or strong vibration and the resulting measurement errors. And oil-filled chemical seal assemblies are usually expensive.
If a customer adds everything up, an electronic differential pressure system is not only a simple solution but also a more cost-effective one for their business. Vega is the only supplier on the market that has a solution with ceramic sensors in its portfolio. F
www.foodmag.com.au | October 2019 | Food&Beverage Industry News 49
CONVEYOR BELTS
Belts meet rigorous food safety standards Rexnord manufactures a range of belts designed with sustainability in mind. Food & Beverage Industry News explains.
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oday’s food consumers’ preferences are constantly evolving. Ingredients, packaging and portion sizes mean an operation is constantly adjusting to meet demand. What remains constant throughout this change is the need to reduce costs, achieve sustainable operational objectives and ensure rigorous food safety requirements are met. With Rexnord, its KleanTop line of plastic modular belts is designed specifically for food processing. Its team of industry experts is here to help users find the right product for their operation, enabling them to meet internal production goals and deliver high-quality food for their customers. Each belt in the KleanTop line has been designed to give food processors confidence that the conveyor they install is safe and delivers high performance in food processing applications. Each product series within the line offers a unique set of benefits for a variety of food processing applications, including: • Food-safe materials and colours approved for direct food contact, and ideal for longevity — even in harsh applications and frequent sanitation. • Being designed to convey optimal loads in applications to maintain throughput levels with minimal product damage. • Optimised rod retention designs that make assembly and disassembly faster, and keep the rod in place during conveyance. • Reinforced designs to minimise risk of product contamination. Corporate stewardship is a shared endeavour for everyone, according to Rexnord. Eliminating waste is an important element in any company’s quest for a more sustainable operation and to do its part in taking care of the planet. Rexnord’s focus on engineered sustainability means companies can partner with them for products and support that guarantee optimal
product handling while helping users meet productivity goals and minimise water and chemical usage.
Optimise productivity The reliability and durability of the conveyor belting and components determine total uptime and cost to keep the line performance at required levels. Rexnord’s team of experts can help users upgrade their conveyors to increase productivity by using stateof-the-art designs and materials for the belts and components.
Minimise water and chemical usage Sanitation is a critical part of food processing, but it also means more water and chemicals used to clean systems. Rexnord focusses on ways to
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help users reduce the need for excess water in sanitation through easily cleaned belt designs, or consultation on designing conveyor systems that reduce water usage overall.
Plastic modular belting
590 Series KleanTop This belt has an optimal combination of ease in cleaning and transfer capability for the bakery, snack, fruit, vegetable, seafood, and poultry industries. It has a belt pitch of 12.7mm
Each belting series in the KleanTop line offers a set of unique benefits to the food processing industry including reinforced edges, open hinge for ease in sanitation, and rod retention designs.
1010 Series KleanTop
390 Series KleanTop
1090 Series KleanTop
This unit has superior transfer capability suitable for applications with delicate baked goods, or any operation requiring careful handling of fragile products. It has a belt pitch of 8mm.
The 1090 is designed for ease in cleaning and efficient maintenance to reduce downtime in bakery, snack, fruit, vegetable, seafood and poultry processing. It has a belt pitch of 25.4mm. F
This series has 60 per cent rod exposure for maximum sanitation. It is for applications in bakery, snack, fruit, vegetable and protein processing. It has a belt pitch of 25.4mm.
The KleanTop range of plastic modular belts is fast to assemble and disassemble.
INTERNET OF THINGS
Industry 4.0’s firm hold on iconic Australian brand What happens when an iconic food brand and a company at the cutting edge of Industry 4.0 collaborate? Food & Beverage Industry News finds out.
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eroplane Jelly is a national treasure. Created in a bathtub in 1927 in Sydney, it was once one of Australia’s largest familyoperated food manufacturers. Even today, hearing the old jingle, “I like Aeroplane Jelly, Aeroplane Jelly for me, I like it for dinner, I like it for tea, A little each day is a good recipe” creates a strong feeling of nostalgia. Acquired by what was McCormick Foods in 1994, today, more than 20 million packets of Aeroplane Jelly are consumed each year. Now incorporated as McCormick & Company, the nostalgic jelly brand’s owner is no stranger to large-scale food production, as it is a global flavour company that manufactures, markets and distributes an extensive range of spices, seasoning mixes, condiments and other flavourful products to the food industry.
McCormick & Company’s enthusiasm and appetite for innovation is now taking its operations into the Fourth Industrial Revolution – Industry 4.0. The teams at McCormick & Company and Bosch Australia Manufacturing Solutions have commenced an Industry 4.0 pilot project in conjunction with Australian Manufacturing Technology Institute Limited (AMTIL) and Australian Manufacturing Growth Centre (AMGC), which will start at the McCormick facility in Clayton South. As the lead technical partner, Bosch Australia Manufacturing Solutions is responsible for implementing the project across the three existing Aeroplane Jelly automatic packaging lines. “Instead of interfacing with McCormick’s existing machines,
The pilot project will help eliminate McCormick & Company’s manual data collecting process.
we are strategically placing sensors onto the line that can detect the parts going past. With this simple and cost-effective solution, these sensors are counting parts going into and out of machines,” said Bradley Trewin, national sales and business development manager at Bosch Australia Manufacturing Solutions. “This simple solution will eliminate McCormick’s existing manual data collection process, and by doing so, will remove possible errors in data collection and give them real-time insights into what is happening on their lines. Now, instead of collecting manual data, they can focus on analysing this precise cloudbased data to make improvements to their production,” continued Bradley. Currently, McCormick’s factory is similar to many other manufacturing facilities across Australia – there are multiple operational shifts, with different operators manning each shift. Under the existing system, if there is a machine breakdown on one shift, incoming operators have no knowledge about the reason behind the break and whether there have been solutions implemented. With the Industry 4.0 project, the factory will now centrally control all machine data, providing a fault tree of reasons, which will also include a finite set of solutions for technicians to reference as they troubleshoot. With this pilot programme in place, McCormick & Company has begun to add transformation to its local operations. With successful implementation underway, the company continues to seek future implementation for Industry 4.0 practices to solve other pain points. “Through this first level Industry 4.0 pilot project, McCormick & Company will see the benefits of real-time visibility of accurate, reliable data. This allows them to identify where there might be problems and solve them, quickly
Bosch Australian Manufacturing Solutions is helping implement an Industry 4.0 pilot project. and easily,” said Bradley. For Bosch Australia Manufacturing Solutions, the recipe for success is combining the best data and machines, with people being the secret ingredient. The solution created for McCormick is the perfect example – by recording and providing meaningful data and insights, the solution enables the company’s people to make critical decisions and actions required to improve production. “Through our ‘Journey to Excellence’, reliable production performance data plays a critical role in supporting loss analysis and continuous improvement,” said Stewart Dwelly, operations manager McCormick Foods. “The production team needs real-time information to enable this at the shop floor level. This project is a fantastic opportunity to showcase how a simple solution can improve operating efficiencies.” Aeroplane Jelly has a special place in the hearts of all Australians. By embracing digital transformation and paying attention to the trends leading the Fourth Industrial Revolution, it will remain competitive long into the future. F
www.foodmag.com.au | October 2019 | Food&Beverage Industry News 51
NEW PRODUCTS
Neousys’ Nuvo-7000E/P series of next-generation fanless, embedded PCs Backplane Systems Technology has released Neousys Technology's Nuvo-7000 series of next-generation fanless, embedded PCs, powered by Intel's latest generation of processors. The Nuvo-7000E/P is powered by Intel 9th/ 8th-Gen Core ‘i’ processors with up to 8/ 6-core architecture that offer performance improvement over previous 6th and 7th-Gen platforms. This series includes Neousys' track-proven technologies for superior ruggedness and versatility, such as effective fanless design, patented expansion cassette and proprietary MezIO Interface. It also incorporates cutting-edge computer I/O like USB 3.1 Gen2 with up to 10 Gbps throughput and M.2 2280 M key socket for NVMe SSD or Intel Optane memory for ultimate system performance. The plethora of on-board I/O Ports (GbE, USB and COM) feature sophisticated protection circuits to endure stress from ESD and power surge. This makes Nuvo-7000 series the most rugged embedded computer created by Neousys. Flexible and versatile for a variety of applications, Nuvo-7000 variants are available with different cassette expansion options. With Neousys Nuvo-7000 series, users get a true rugged platform that can accommodate a single PCIe card (Nuvo-7000E), dual PCIe cards (Nuvo-7000DE) or a single PCI card (Nuvo-7000P) according your application needs. Key Features: • Intel 9th/ 8th-Gen core i 35W/ 65W LGA1151 CPU; • patented cassette for PCI/PCIe add-on card accommodation; • MezIO interface for easy function expansion; • rugged, wide temperature range from -25°C to 70°C fanless
operation; • up to 6x GigE ports, supporting 9.5 KB jumbo frame • M.2 2280 M key socket (Gen3 x4) supporting NVMe SSD or Intel Optane memory; • 4x USB 3.1 Gen2 ports and 4x USB 3.1 gen1 ports; and • VGA/ DVI/ DP triple independent display, supporting 4K2K resolution. Backplane Systems Technology (02) 9457 6400 www.backplane.com.au
FER2 electric chain hoist for food, beverage and pharmaceutical industries Kito PWB’s food-grade ER2 electric chain hoist is well-suited for lifting applications in food, beverage, and pharmaceutical processing industries where pristine cleanliness is critical. Food-grade lubricants used on the load chain and in the gearbox are NSF H1-compliant for safe use in any facility where incidental contact with product is a concern. Customer-specified options include white epoxy paint, stainless steel and nickel-plated hardware, and nickel-plated load chain making this hoist well-suited for contaminant controlled or corrosive processing environments. Features include: • 0.5-2-tonne capacities available; • three-phase single and dual speed; • Motorised trolley available; • NSF H1 compliant food-grade grease and oil; • CE certification; • Grade 80, case-hardened chain; • 0-2-tonne capacities available; • IP55 environmental protection; • nickel-plated load chain; and • a Certificate of Conformance is included. PWB Anchor 1300 792 262 www.kitopwb.com.au
52 Food&Beverage Industry News | October 2019 | www.foodmag.com.au
NEW PRODUCTS
Bosch flow-wrapper designed for hygienic requirements in food industry Bosch Packaging Technology has developed a new version of its fully automated horizontal flow wrapper Pack 403, which is specifically designed for harsh environment use. The Pack 403HE comes with all the features of the Pack 403 and is suited for medium to high-speed wrapping. The machine is able to wrap a variety of products ranging from biscuits, chocolate, cookies and crackers to frozen foods or meats. “We have designed the new Pack 403HE to meet the growing need of customers with strict hygienic requirements. To avoid contamination with allergens, germs or unwanted ingredients, food manufacturers need machines that are easy to clean,” said Kelly Meer, product manager at Bosch Packaging Technology.
Optimised for deep cleaning Today, food manufacturers often produce different products on the same machine. “Keeping the products free from unwanted substances such as traces of peanuts or wheat can be a challenge in terms of cleaning. The Pack 403HE provides improved features to facilitate particularly intensive cleaning,” Meer said. It differs from the standard version in terms of product design and material. Customers can apply aggressive cleaning agents including alcohols or acids, and easily wipe them off with water after they have taken effect. Water and cleaning agents will simply run down the drain. “We call this the foam-and-rinse concept. In contrast to high-pressure cleaning with air or water, customers avoid the risk of spraying substances or germs. The foam-and-rinse method guarantees an easy and reliable washdown. The concept will soon also apply to the Paloma pick-and-place robot,” said Meer.
welded stainless-steel main frame plate. Stainless-steel guarding, robust plastics, removable parts, sloped surfaces, and easy-to-clean gaps between machine components further simplify the cleaning process. The machine’s cable connection to its electrical cabinet has been sealed to prevent the penetration of moisture or unwanted substances. Clear tubes help to detect any contamination. The wrapper is also equipped with a washdown infeed and stainless-steel etched and stand-off labels to also support convenient cleaning.
Fast and easy handling The Pack 403HE produces up to 400 packages per minute, reaching a maximum film speed of 76 metres and includes all of the same features offered in the Pack 403. The automatic film splicer allows for fast film changes without interrupting production. The machine is equipped with servo-driven power feed rollers to optimise film tension and tracking. It also has cantilevered and removable discharge belts that reject faulty packages with compressed air. Bosch Packaging Technology www.bosch.com
Improved washdown features The Pack 403HE also features washdown motors and gearboxes meeting the BISSC standard, sanitary feet, and a continuously-
High-resolution, high-speed cameras from iX Cameras The i-SPEED 220 and i-SPEED 221 from iX Cameras represent the first cameras in a class of small footprint, easy-to-use, low-cost and high-resolution high speed cameras. A highresolution 1600x1600 CMOS fast-transfer sensor allows the imagery of minute details even when zoomed in. The maximum full frame rate of 600 fps with both a global exposure shutter and optional G-shock housing makes this high-speed camera suitable for robotics, auto-crash testing, graphics inspection, 3-D biomechanics, web inspection, and more. The i-SPEED 220/221 high-speed cameras fit in a briefcase, consume little power and create nice images that can be zoomed and analysed. Image transfer is simple via Ethernet. The one-hour battery that comes standard on the model 221 coupled with a standard laptop make this camera suitable for untethered portable field work. Add a layer of rugged durability with the optional Hi-G shock package. The iX Cameras i-SPEED 2 high-speed cameras provide a variety of storage levels from 2GB, 4GB, 8GB and 16GB, allowing for everything from discrete transient event capture to extended full resolution record times of over 11 seconds. The cameras come in either a mono or colour version. Control 2 Series software provides a user-friendly interface for recording, playback, and editing of i-SPEED 2 high-speed videos. This powerful camera control software has been developed specifically to handle large amounts of data, fast transmission, and ultra-slow motion in videos recorded at up to 200,000 frames per
second. Control 2 Series is suitable for a range of video applications, including manufacturing and process automation, quality assurance testing, research and development and biomechanics. Other features include certification to 100 G shock, 10 G vibration, long recording times with up to 16 GB memory (Model 221 only), small package fits on microscopes and in tight spaces as well as global exposure shutter and interchangeable C-mount lenses. Scitech (03) 9480 4999 www.scitech.com.au
www.foodmag.com.au | October 2019 | Food&Beverage Industry News 53
NEW PRODUCTS
Highly adaptable vacuum solution Vacuum technology remains a key requirement for plants around the globe. Whether a business operates in the packaging, pharmaceutical, food or printing industries, the need for efficient, highly adaptable vacuum solutions are still on the priority list. SMC’s latest vacuum pads are designed for optimum absorbing performance and efficient handling. The ZP3P series features a blue-coloured, silicone rubber pad to prevent wrinkles and is compliant with FDA requirements. According to Rodney Ryan, SMC state manager Victoria, South Australia and Tasmania, the ZP3P series is good for product handing. “It is equipped with a thin, soft pad skirt for a strong grip and reduced leakage,” he said. “This makes it ideal for thin workpieces that generally deform during adsorption.” The product is designed for delicate operations such as the handling of vinyl and film. “Thanks to the flat shape of the vacuum pad (with a central stopper), it prevents wrinkles and damage to the product and
provides the customer with better quality packaging,” said Ryan. The vacuum pad is made from FDA-complaint silicone rubber and is suited to stringent applications in the food and pharmaceutical industries. “The blue colour can also be spotted easily during contamination inspections and this is a big selling point for customers operating in these environments,” said Ryan. As a welcome addition to the family, SMC recently released a new fluoro blue bellow option, the ZP3P-JT series. “The flat-style vacuum pad is suitable for the handling of soft film, paper or foil packages and sheets, while the new bellow style allows for absorption of a bigger range of bags shapes and pouches filled with food stuff. In both cases, the unique ribs design provides a fast and secure grip,” said Ryan. SMC (02) 9354 8222 www.smcanz.com
Lightweight and compact toothed belt axis ensures low-cost automation in the tightest of spaces Fast automation in confined installation spaces: igus has now developed an extra-compact toothed belt axis based on its flat drylin N linear system. The new axis consists of a standard fitment of components and is therefore cost-effective and easily assembled within a few minutes. Equipped with motor and control, the new system can carry loads of up to 20 Newton and a translation of 60mm per revolution. From the lubrication-free plain bearing and the maintenance-free linear guide up to the ready-to-install linear robot, igus develops solutions for the industry with its plastics either as a single part or as a system. With the help of its linear construction kit, the company has combined its drylin N low-profile linear guide with a toothed belt and has now developed the new cost-effective drylin ZLN toothed belt axis as standard. Whether in vending machines, service robotics or even in automation systems, the new compact toothed belt system can be installed quickly and easily in the smallest of spaces. The flat drylin N linear guide ensures compact construction, which is just 27mm high and 40mm wide. The toothed belt mounted on ball bearings enables high speed dynamics. With the combination of low-profile linear guide and toothed belt, loads up to 20 Newton can be moved vertically at a ratio of 60mm per revolution. By using high-performance polymers in the sliding carriage, users can completely dispense with lubricants and thus, the maintenance of the unit. Moisture, dirt and dust are no problem for the drylin ZLN because it has great advantages, especially for machines that are in use 24/7.
54 Food&Beverage Industry News | October 2019 | www.foodmag.com.au
Plug in, install, low cost The new toothed belt axis for low-cost automation consists of standard components from the drylin modular system that can be fitted together and assembled quickly. Therefore, the new axis is not only lightweight due to the use of plastic components, but also cost-effective and delivered quickly. A ready-to-install drylin ZLN can be ordered with NEMA stepper motors or with EC/BLDC DC motors, as well as a suitable drive control system. The new, cost-effective toothed-belt axis can be delivered from Treotham in the desired size with a maximum length of up to 750mm from 24 hours.
From individual components to complete systems With its plastic components, igus has now developed the compact and costeffective toothed belt axis drylin ZLN for fast automation in tight spaces.
Treotham Automation 1300 65 75 64 www.treotham.com.au
FER2 Electric Chain Hoist for Food / Beverages / Pharma Absolute purity and highest reliability. For contaminant controlled or corrosive environments. Kito PWB’s Food Grade ER2 Electric Chain Hoist is well-suited for lifting applications in food, beverage, and pharmaceutical processing industries where pristine cleanliness is critical. Food grade lubricants used on the load chain and in the gearbox are NSF H1 compliant for safe use in any facility where incidental contact with product is a concern. Customer specified options include white epoxy paint, stainless steel and nickel-plated hardware, and nickel-plated load chain making this hoist well-suited for contaminant controlled or corrosive processing environments.
STANDARD AND OPTIONAL FOOD GRADE FEATURES
FER2 Shown with options: white epoxy paint, motorized trolley, stainless steel hook, nickel-plated stopper and stainless steel chain container
0.5 - 2T CAPACITIES
White Epoxy Paint
Nickel-Plated Load Chain
Food Grade Oil and Grease
Stainless Steel and Nickel-Plated Hardware
Fail Safe Brake
White Epoxy Bottom Hook
Stainless Steel Hook Latch
Extreme Duty TEFC Motor
½ - 2 ton capacities available
Duty Rating
Single Speed
Adjustable 2-speed & Dual Speed
FEM Class
3M / 2
3M / 2M
Max. Starts / hr
36
240 / 120
Grade 80, Case Hardened Chain
%ED
60
40 / 20
IP55 Environmental Protection
60 min
30 / 10 min
Short Time Rating
3-phase Single & Dual speed Motorized trolley available NSF H1 Compliant Food Grade Grease & Oil CE Certification
Nickel plated load chain A Certificate of Conformance is included
