Food Magazine February 2014 by Prime Creative Media

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Weighing up the accuracy of your whole grain content claims.

PLUS: The anti-energy drink trend | Logistics lessons | Industry update from the AFGC

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WELCOME

Mixed messages on our future Let’s hope 2014 is a turning point for our homegrown manufacturing brands.

EDITOR: Danielle Bowling danielle.bowling@cirrusmedia.com.au

Happy New Year to all our dear Food mag readers! I hope you’re well rested and ready to make 2014 your best year yet. After signing off on the last issue of Food for 2013, one of the biggest news stories of the year landed on our desks: Treasurer Joe Hockey ruled against the sale of GrainCorp, Australia’s largest publicly-listed agribusiness, to US giant Archer Daniels Midland. To be honest, it was a shock. I was almost positive the new government would give ADM the go-ahead; I basically had the story written in my head. But Hockey proved me wrong, arguing that a more competitive network is still emerging in Australia and that now is not the right time for a 100 percent acquisition of a key Australian business. What was even more surprising is that Hockey admitted that the public’s concern over the sale had influenced his decision. “...Allowing it to proceed could risk undermining public support for the foreign investment regime...” he said. I wonder if the same will be said for our much loved fruit processor SPC Ardmona? While acquisition isn’t on the cards, there’s a very real chance that manufacturing will go offshore, just like it has for other iconic Australian manufacturers

in recent times. Earlier this year, in response to SPC’s plea for a $25 million co-investment from the federal government, trade minister Andrew Robb and others within the federal government, said granting such assistance could send the wrong message to other struggling companies, and that “continuous structural change is a fact of life.” Granted, throwing money at local manufacturers doesn’t ensure their success or their longevity, but something needs to be done to keep Australian brands in Australia. Whether that’s government assistance, initiatives to promote the importance of buying locally to consumers or addressing the often exorbi-

"Throwing money at manufacturers doesn't ensure their success or their longevity." tant cost of doing business here, I’m not sure. What I am sure of is that Australia produces some of the best, highest quality food and beverage products in the world, and that’s a unique selling point we need to hold on to.

INSIDE 04 NEWS Manufacturing trends for 2014; free range dispute; another Fonterra recall.

08 HEALTH & LABELLING

update on the progress surrounding front of pack labelling.

10 BEVERAGES

12 CEREALS The GLNC has launched a voluntary code to provide clarity on whole grain content claims.

16 LOGISTICS

costs and minimise errors in your food manufacturing business.

20 ON THE SHELF We profile four of the latest products on retailers’ shelves.

21 PACKAGING Blow moulding basics from the Australian Institute of Packaging.

22 PRODUCTS & EVENTS The Australian Food and Grocery Council’s Geoffrey Annison provides an

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A new ‘anti-energy’ drink movement is making waves in the beverages market. We speak to two new entrants.

We look at how improving your logistics model can boost efficiencies, reduce

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WHAT'S

HOT ONLINE W W W. F O O D M AG .C O M . AU

Five food manufacturing trends for 2014

FoodMagAU posted:

Not too sure about this ready meal.....haha Linda Samson commented: Very funny, perhaps it’s true? Yvonne Myob commented: Ahahahaha ummm pass lol

@foodmagaus tweeted

Industry Minister recruits Combet to advise on SPCA rescue package @angrysocialst commented: Has Minister McFarlane gone insane? Combet was a spectacular failure in Gillard’s government and now gets rewarded?

James commented on article

Lacklustre growth of GM canola in Australia The reason growth hasn’t been as fast in Australia as in Canada was because bans by Australian states held back variety breeding for 10 years ... GM canola grew 22% last year which is not lacklustre ... This technology is a tool for farmers to fight pests in an economical and sustainable way. Concerned Granny replied: James, Agent Orange was also considered a ‘safe’ herbicide (defoliant). Its impact on human health was only realised after its use. Concentration of glyphosate residue levels in the Gwydir & Namoi Rivers in the NSW cotton districts have also increased & will eventually affect the germination of the many plant and vegetables grown in the region. Australia should err on the side of caution when it comes to GM crops.

4 Foodmagazine | Feb/Mar 2014 | www.foodmag.com.au

more holistic approach in providing nutritious food and beverage solutions to consumers. Clinical nutrition is being eyed as a highly profitable platform along with health alternatives, such as traditional Chinese medicine.

Barnaby Joyce ruffles feathers over free range claims

Addressing food waste and health are going to be two of the big issues in food manufacturing this year, according to Innova Market Insights, which, through performing ongoing analysis of market trends, developments and product launches around the world, has identified some of the most significant trends food manufacturers can expect throughout 2014. 1. Waste Not Want Not: For some time now manufacturers' sustainability efforts have been zeroed in on, with a more recent shift in focus being to reduce food loss or waste wherever possible. Food loss during production and at the retailer and consumer end of the food supply chain will be heavily scrutinised. Ingredients derived from the waste stream will also hold enormous potential. 2. You Can Trust Us: Recent food safety scares and scandals have crippled consumer confidence. Ingredient origin will be used as a marketing tool. The consumer should ultimately benefit from higher quality foods that are clearly traceable. 3. Simpler Pleasures: Consumers are reassessing their needs and going back to basics, by finding more pleasure in simpler food. There has been a shift towards home cooking. Where consumers shop has also been affected, with the so-called 'hourglass model,' still in effect. This relates to growth on the budget and premium sides, but the centre of the industry is being squeezed. Value packaging and 'good value' claims on the products themselves and in-store value promotions are prospering. 4. Look Out For The Small Guy: Small innovators are rising to the challenge, with the development of high quality and distinct products that have small-scale appeal, but big trend potential. Social media platforms have provided more opportunities for small companies to develop a market by directly targeting niches across their home market and abroad. 5. Health is More Holistic: Some big food manufacturers are looking to all areas of health for a

Animal protection organisation, Humane Society International, has responded to claims that a bird flu outbreak on a free range egg farm in Young is threatening the supply of cage-free eggs, arguing the farm isn't free range at all. Verna Simpson, director of HSI, contacted Food magazine after it published news that the supply of cage-free eggs is under threat following an outbreak of the H7 Avian Influenza strain on a Langfield Pastoral Company farm in Young in October 2013. The outbreak saw all 400,000 hens from the property, as well as 50,000 from a neighbouring property destroyed. In the story, Bede Burke, chairman of the NSW Farmers egg committee, said some egg producers will have to walk away from the industry, arguing free range operations are risky business. "People who have grown and expanded into free range in the last seven years, to be now 35 to 40 percent of egg production base, they are now carrying this risk factor that you cannot insure against and we don't include in our pricing structure for our eggs," he said. The farm in question, however, was not free range at all, claims Simpson. "This was anything but a free range facility with massive amount of hens on a small parcel of land. There has NEVER been an outbreak of bird flu traced back to a REAL free range facility," she said. "The Young property was running 420,000 birds on a couple of hectares (with council approval for only 80,000) so I'll let you do the math." In a letter to Barnaby Joyce, federal minister for Agriculture, Simpson claims, "The hens on the 'free range' farm were stocked at an enormous 80,000 hens/ha which is hardly free range when compared to those who abide by the guidelines of the Model Code."

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NEWS

Currently, the code states that 'free range' can mean stocking densities of up to 1,500 birds per hectare, but last year the Queensland government increased its densities to 10,000 birds per hectare. Simpson also criticised Joyce for claiming that free range egg production encourages bird flu outbreaks. "Research shows that there is ample evidence to counteract your statements, instead showing that it is confinement on factory farms that contributes widely to the spread of avian flu," she said. In her email to Food magazine, Simpson suggests Bede Burke, who says retailers would be foolish to stop stocking caged eggs, is looking after his own business interests. "It is in the interests of Bede Burke to discredit free range as he is trying desperately to protect his cage production." Tosca commented: "It's all just about profit, ripping off the consumer and to hell with the consequences. We will end up like the US with factory farming incubating all sorts of disease. These farms in Oz were not free range and don't deserve the title.

leader at TNO, says a number of experimental 3D food printers have already been installed in a few restaurants in Eindhoven. According to 3D Printer Plans, Barilla and TNO hope 2014 will be a big year for food printing, and have plans to move into the international market. TNO has been working on improving the speed of the printers, which are now 10 times faster than they were two years ago. Barilla is hoping 3D food printing will get to a point where users fill printers will dough cartridges, similar to the current inkjet printers, and providing consumers with great flexibility in terms of their pasta designs. "For example, you could surprise your wife with pasta in the shape of a rose for your marriage anniversary. You can simply save your design in a USB and bring it to the restaurant. The 3D food printer there will print it on site," van Bommel said.

¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥

Snack Foods Packaging Design Sustainable Manufacturing Food Safety and Innovation in Non-Food Health and Wellness Organics Prepared Foods Ingredients Innovation Meat and Smallgoods

The nomination deadline is 1 April, 2014 and information and nomination kits can be found at www.foodmag.com.au/awards

Fonterra confirms E. Coli contamination

Nominations now open for 10th annual Food Magazine Awards

Sophie commented: "Barnaby Joyce needs to get his facts straight before making incorrect, irrational statements in the media, what a joke! I hope he apologises and sets the record straight. He should be supporting all farmers, not just factory farms making the biggest profits..."

Barilla pushes for 3D printers in restaurants

Pasta manufacturer, Barilla, is looking to introduce 3D food printers in commercial kitchens, allowing diners to design and print their own pasta. Over the past couple of years, the company has been working with research organisation TNO in the Netherlands, and Kjeld van Bommel, project 6 Foodmagazine | Feb/Mar 2014 | www.foodmag.com.au

2014 will mark the 10th anniversary of the Australian and New Zealand food industry's night of nights, the annual Food Magazine Awards. First launched in 2004, the Food Magazine Awards recognise and reward best practice and innovation within the food and beverage manufacturing sector. Nominations are now open for manufacturers both large and small, and those eligible to enter the awards will have developed a food or beverage product that was/will be launched in Australia or New Zealand (or Oceania) between March 2012 and March 2014. The Food Magazine Awards are judged on innovative ingredients, processing techniques, packaging and/or sustainability features. Categories for the awards include: ¥ Beverages ¥ Dairy ¥ Confectionery ¥ Ready Meals ¥ Baked Goods

Fonterra is conducting a voluntary recall of its 300ml and 500ml Anchor and Pams fresh cream products, with tests showing E.Coli may be present. The recall affects 8,700 bottles of fresh cream with a best-before date of 21 January, 2014, distributed in New Zealand's North Island from Northland to Turangi, including Gisborne. The cream has been distributed to retail and foodservice outlets, Fonterra said in a statement, urging consumers not to consume the product and to return it to its place of purchase for a full refund. Fonterra Brands NZ managing director, Peter McClure, said "We are sorry for the inconvenience and concern this recall might cause but food safety and quality are our top priorities." The recall comes just months after another contamination scare at Fonterra, which saw widespread recalls of Danone's Karicare infant formula product. In August 2013, Fonterra issued a warning that the whey protein in the formula could contain a bacterium known to cause botulism. Thirty-eight tonnes of the protein were believed to have been contaminated by an unsanitary pipe, however it was later uncovered that the bacteria wasn't clostridium botulinum as originally thought, but was identified as clostridium sporogenes, which doesn't lead to any known food safety issue.

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HEALTH & LABELLING

Shooting

stars for the

Geoffrey Annison, deputy chief executive of the Australian Food and Grocery Council, provides an update on the progress surrounding front of pack nutrition labelling, arguing there’s still more work to be done.

8 Foodmagazine | Feb/Mar 2014 | www.foodmag.com.au

he Blewett Review of food labelling reported in 2011 recommending a national, uniform front of pack nutrition labelling (FoPL) scheme to assist consumers in selecting foods and constructing healthy diets. The Council of Australian Government responded by requesting that the [then] Department of Health and Ageing bring together representatives of industry, public health, consumers and the food regulatory agencies to develop a new FoPL system. The new labelling was to include an interpretive element (i.e. a ‘health mark’ or ‘health rating’) and build on existing systems used by industry. A FoPL Project Committee of stakeholders has been developing the methodology for assessing foods based on their levels of nutrients and aggregating the data into a ranking or score as well as practical considerations such as the design of the label itself. It has also considered the implementation of the labelling scheme and its promotion to consumers. Progress to date has been substantial. Proposals include: 1. An interpretive food rating system based on a modified form of the Nutrient Profile Scoring Criterion system currently used for Standard 1.2.7 Nutrition health and related claims of the ANZ Food Standards Code. Foods receive a score appearing on the food label as a Health Star Rating (a half to a five star scale with half-star increments); 2. The levels of nutrients including energy are to be shown to assist consumers seeking specific information which may be important to them – the Australian Food and Grocery Council (AFGC) proposes that its Daily Intake Guide (DIG), which currently appears on over 7,200 products, can be carried forward to fulfil this function for the new FoPL scheme; 3. Implementation of the FoPL scheme to comprise an AFGC managed voluntary industry code with specialist committees of stakeholders providing advice on different aspects of the management of the scheme; and 4. A government funded social marketing campaign explaining and promoting the use of the new scheme to the public. Notwithstanding this progress, further work is required before the system can be finalised and implemented. The AFGC, a key participant in developing the new FoPL scheme, considers that any new system must: 1. Be scientifically and technically sound providing guidance to consumer choice aligned with current

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HEALTH & LABELLING

nutritional wisdom; 2. Be understandable to consumers so they are assisted in making appropriated choices and healthy diet selections; 3. Be practical for industry to implement with minimal cost impost; and 4. Be supported by well resourced social marketing promoting the use of the scheme. The AFGC has argued for a Regulatory Impact Statement to be conducted to demonstrate that the considerable costs which industry will bear in making label changes, if they adopt the new FoPL, is justified by substantial benefits passing through to consumers. In a welcome move, the Coalition government has decided to conduct a cost benefit analysis with full industry consultation – thereby for the first time 1. giving a proper examination of the costs of the system and if it will achieve its public health objectives. Further research is also to be conducted to confirm the effectiveness of the Health Star Rating labels in helping consumers make healthy diet selections. Despite the considerable progress, 2. in addition to these key aspects of the proposed FoPL system (confirmation of which remains outstanding) there are a number of other issues which need to be worked F D 0through. 2 1 4 _ 0 0 0 _ T AI 1

Progress to date: an industry update The Legislative and Governance Forum on Food Regulation met in December, where ministers responsible for food regulation considered a range of issues regarding front of pack labelling (FoPL). Developments from the Forum include: ¥ The Health Star Rating Calculator was endorsed as part of the Health Star system, but it was agreed that a process is required to deal with anomalies. ¥ The Forum agreed on membership and chairing arrangements for the tripartite FoPL Oversight

and Advistory Committee, to be established early this year, with representations from industry, public health, government and consumers. ¥ The Forum re-emphasised that the system will give consumers at-a-glance information about the food they're buying through a star rating scale of half to five stars for packaged food products. ¥ New Zealand is considering joining the Health Star Rating System and will advise of its decision in the coming months.

These include: 3. Providing appropriate transition Finalising the guidance provided to arrangements so that companies can industry on how to implement the have time to implement the labelling proposed labelling – the integrity of within reasonable time frames; and the system will rely on a consistent 4. Establishing effective monitoring yet flexible approach which reflects and surveillance of the program to the great variability of food packaging confirm, whether or not it is effective sizes and formats; in communicating to consumers and Agreeing on the core messages to assisting in their food choices. consumers regarding use of the labelThe AFGC remains committed to the ling to assist choice – the key paradigm process, but is not naïve to the fact that of variety, moderation and balance as these are major hurdles which must be the bedrock of healthy eating must be negotiated before implementation can be supported and not undermined; 2 0 1 3 - 1 2 - 1 2 T 1 5 : 1 0 : 4 agreed 5 + 1 on 1 :and 0 initiated. 0

The food industry is expected to carry the $200 million cost of implementing this scheme, which is a substantial regulatory burden. If industry is going to make this investment in a new front of pack system, it must be scientifically credible, meaningful to consumers and practical and attractive for industry to implement from the outset. Otherwise we risk consumers losing confidence in a “work in progress” labelling system, thereby undermining the whole purpose of the exercise: encouraging consumers to construct healthy diets. F

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BEVERAGES

Chill out Growth in the non-alcoholic beverages market has been dominated by energy drinks in recent years, and while there’s no sign of this changing, the ‘anti-energy’ drink segment is gaining traction. By Danielle Bowling.

Image: Chepko Danil - Thinkstock 10 Foodmagazine | Feb/Mar 2014 | www.foodmag.com.au

he beverages market in Australia is dominated by a few big players, which year after year pump out new and innovative products that are almost always snapped up by the big retailers. Energy drinks including Red Bull, Mother and V have dominated growth in the non-alcoholic beverages market in recent years, but Geoff Parker, CEO of the Beverages Council of Australia, says this growth needs to be put into perspective. “Certainly there has been an increase in their popularity, but it needs to be put into context,” he told Food magazine. “They’re coming off a very low base and energy drinks as a sub-category of the total non-alcoholic beverages category only represent 2.5 percent of the total category. Have they increased in popularity? Absolutely. Do they have aggressive marketing? Absolutely. But again, they’re only 2.5 percent of the total category.” In regards to the most significant trends in the industry, Parker says the two stand-out performers have been energy drinks and iced teas, which have experienced strong year on year growth for the past couple of years, recording 10 percent and 12 percent, respectively. Vitamin waters have had a small percentage of growth, and bottled water has experienced approximately eight percent growth year on year. “We’re seeing a significant trend towards what we broadly call low or no kilojoule soft drink options and that’s also being reflected in a trend of consumers [moving] away from full kilojoule options. You just have to look in any convenience store or petrol station fridge or supermarket aisle to see the influx of low and no kilojoule varieties. Today, three out of the four top selling soft drinks (Coke, Diet Coke, Coke Zero and Pepsi Max) are low or no kilojoule options, so consumers are clearly getting the message, and industry and manufacturers are responding by providing a greater range,” he says. It can’t be denied, however, that the energy drink segment has been the victim of a fair amount of bad press over the years, with most criticisms surrounding the drinks’ sugar and/or caffeine content, and the consequences of overconsumption. While Parker believes these criticisms are misguided, he says an opportunity in the beverages market has opened up for manufacturers wanting to offer an alternative to energy drinks. Relaxation or ‘anti-energy’ drinks are gaining traction in the industry, with brands including bChill, Koala Karma and Everyday Sunday. And while their growth doesn’t exactly rival that of their energy drink counterparts, there are a growing

number of brands launching products in this new market, Parker says. “There have been a number of small niche brands enter this space, predominantly over the last 12 to 24 months. Whilst it’s still early days for the segment and volumes are still relatively small, any increase has the potential to be significant and growth of 200 to 500 percent could be achievable for the right product in the right space at the right time. “The increase in products into the market in recent times signals a possible gap that niche brands are looking to fill. Certainly in today’s fast paced world there are a myriad of products that suit that lifestyle, but for others who are looking for the opposite of an energy boost, the relaxation beverage provides a unique fit to a way of life or time of day when people are looking to slow down and take things a little easier,” he says.

On the market Rockwell Beverages Company manufactures Everyday Sunday, a relaxation beverage launched in 2013. The product targets university students and comes in three flavours: Citrus Crush, Tropical Punch and Berry Bliss. “The ingredients are all natural, so the main relaxing ingredients are chamomile, valerian, passionflower and rose hip puree – and then there’s a little bit of Stevia as a sweetner and a little bit of sugar as well. So there are no artificial preservatives. It’s marketed as an all natural relaxation drink,” says Amanda Chase, managing director of Rockwell Beverages.

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Chase believes relaxation beverages like Everyday Sunday are becoming more popular because consumers are increasingly aware of the health concerns surrounding not only high levels of stress in our population, but also of sugary beverages and energy drinks. “[The Everyday Sunday concept] came about from the levels of anxiety and stress out there. People are becoming more and more aware of the impacts of this stress on society as a whole, so instead of all the caffeinated drinks with loads of sugar in them, Everyday Sunday is really an alternative, to make you feel the opposite of what an energy drink makes you feel. So this makes you calm and relaxed and keeps you steady rather than having you crash and burn, which is what energy drinks do,” she says. “I certainly think there’s a bit of an anti-energy drink movement [happening], but I also think that if you look at the beverages segment in Australia, the growth areas are really water and teas, so it’s really about healthy living. People are becoming much more aware of what

they take it at night and they can sleep,” says Jaime Turner, who manufactures Koala Karma with Cheryl Stewart from functional food manufacturer, Morlife. “What we’ve done with our product is make sure the herbs are as strong as they legally can be to actually have an effect. I know of some other products that pasteurise the herbs, but basically when you do that you burn off all the goodness and the effect that the herbs have.” Both Chase and Turner say one of the biggest challenges they’ve faced since launching their products is having to compete with the likes of Coca-Cola Amatil and Lion. “It’s very hard to be a start-up firm when you’re against the likes of Coke and Schweppes and so forth. So what we really need to be strong with is our brand. So if we can’t spend the money to educate people about what the relaxation segment is and the functional benefits of it, we really need to appeal to people’s love of brands. So we’ve created this great looking can with a great brand association of being very relaxed and having a really relaxed attitude, so that’s how we’re going to sell it. That’s our persona online, that’s what the cans look like. It’s retro, relaxed and has a cool, healthy lifestyle feel,” says Chase. When Food magazine spoke with Chase, Everyday Sunday was sold only in Melbourne but was in the process of launching nationally, targeting the convenience market and service stations, then hoping to crack into the supermarket duopoly. But this is no easy feat. At the moment Koala Karma is found in a number of small supermarkets like IGA, as well as in various cafes, restaurants, convenience stores and even tattoo parlours, but both Turner and Chase agree that getting onto supermarket shelves would make all the difference. “We want Koala Karma to be accessible,

"The importance of being in those bigger brands is it actually gives you more sales in the smaller stores." they’re putting into their bodies and I think they’re just aware that carbonated soft drinks and energy drinks aren’t necessarily the best thing to be consuming loads of. There is certainly a shift away from those drinks and towards slightly healthier versions.” Koala Karma is a similar product also launched in 2013, comprising valerian root, passionflower powder, hops extract, chamomile, triptosane and magnesium. “Everyone that tastes it loves it, and while we don’t make any claims on the can, most people say that it has an effect, and a lot of people who’ve said they can’t sleep,

so we’re talking to certain distributors to get it out into the convenience and impulse market. We would obviously like to get it into the supermarket line too because we’ve found that … if it’s in supermarkets then people have the perception that it’s a bigger brand and they’ll be more likely to buy it from a café, which is quite strange. The importance of being in those bigger brands is it actually gives you more sales in the smaller stores. “I’d just love for it to be a mainstream drink. Years ago, energy drinks were never mainstream, now they are. Ultimately, that’s what our goal is.” F

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GRAINS

Cereal

s r e d n e off

ealth claims and certifications were a hot topic for food manufacturing throughout 2013. The Health Star Rating system was designed as a replacement for the Daily Intake Guide, the FODMAP Friendly certification (foods that are low in Fermentable Oligosaccharides, Disaccharides, Monosaccharides and Polyols) was launched and a number of food manufacturers were ousted by consumer watchdog Choice for ‘misleading claims’ regarding fibre content and other nutritional claims. The wording of nutritional claims has long been a grey area for legislation within the food industry. Various claims such as ‘a good source of protein’ or ‘a » great source of calcium’ were not previ-

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Cover, Artwork & Photography: Rizwan Nawaz - Anarchy concepts

The push to ensure transparency in health and content claims continues, with a new industry code introduced for products containing whole grains. Aoife Boothroyd reports.

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GRAINS

TABLE 1: WHOLE GRAIN INGREDIENT CONTENT CLAIM LEVELS Whole grain ingredient content per manufacturer serve

Permitted whole grain ingredient content claim

< 8g whole grain

No whole grain ingredient content claim permitted

≥ 8g whole grain

Contains whole grain

≥ 16g whole grain

High in whole grain

≥ 24g whole grain

Very high in whole grain

Table source: Grains & Legumes Nutrition Council

TABLE 2: CRITERIA FOR USE OF THE GRAINS & LEGUMES NUTRITIONTM LOGO High in whole grain *

High in Cereal Fibre**

A serve of legumeso

Meets Heart Foundation Tick Category specific nutrient criteria

Ã Ã Ã

Ã Ã

Permitted Statment

Certified by Grain & Legumes Nutrition CouncilTM Sunbake bread is high in whole grain. Enjoy grain foods 3-4 times a day, and make at least half your grains whole grain or high fibre. Certified by Grain & Legumes Nutrition CouncilTM Sunbake Cereal is a high fibre grain food. Enjoy grain foods 3-4 times a day, and make at least half your grains whole grain or fibre. Certified by Grain & Legumes Nutrition CouncilTM Gerry's lentil burger is a high fibre legume food. Enjoy 2-3 serves of legumes a week.

* Meets criteria for high whole grain claim according to Grains & Legumes Nutrition CouncilTM Code of Practice5 ** Meets criteria for high fibre claim according Food Standards Code Standard 1.2.7 5 o Equivalent to one vegetable serve of legumes according to the Australian Dietary Guideline3 F D 0source: 2 1 4 Grains _ 0 0 0& _Legumes S O U 1Nutrition 1 Council 2 0 1 3 - 1 2 - 1 2 T0 9 : 2 8 : 5 5 + 1 1 : 0 0 Table

14 Foodmagazine | Feb/Mar 2014 | www.foodmag.com.au

ously legislated – this resulted in confusion amongst consumers and questionable tactics by some marketers that did not adhere to the voluntary Code of Practice. In an effort to address this, Food Standards Australia and New Zealand (FSANZ) announced a new standard designed to regulate nutrition content claims and health claims on food labels and in advertisements, which food manufacturers must comply with from 18 January 2016. Under the new standard (Standard 1.2.7), nutrition content claims which relate to the content of certain nutrients such as ‘high in calcium’ and ‘high in fibre’ will need to meet certain criteria in order to make the claim. In an effort to provide some consistency in relation to whole grain ingredient content claims (which are not included in Standard 1.2.7), peak body on the nutritional benefits of grains and legumes, the Grains & Legumes Nutrition Council (GLNC), launched a voluntary industry Code which aims to provide consumers with clear messages regarding the whole grain content of foods. The new standards will come into play in early 2014, a move that managing director of GLNC, Georgie Aley, says is being welcomed by consumers and industry alike. Food magazine recently spoke to Aley about the specifics of the Code and why it was necessary for Australia to develop a voluntary standard that accurately communicated content levels to consumers. “The Code was developed to provide clear and consistent messaging to consumers on the whole grain content of food,” says Aley. “Food manufacturers can opt-in by formally becoming a Registered User of the Code with GLNC, enabling them to register products which will carry the approved whole grain ingredient content claim.”

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GRAINS

The ingredient content claims are as follows: • A product containing less than 8g whole grain will not be permitted to make a whole grain content claim. • A product containing greater than 8g whole grain may use the ‘contains whole grain’ claim. • A product containing greater than 16g whole grain may use the ‘high in whole grain’ claim. • A product containing greater than 24g whole grain may use the ‘very high in whole grain’ claim. “In addition, the Code covers the use of the GLNC 48g whole grain Daily Target Intake which was launched in 2006, and is widely used across the industry along with the option for companies to apply for the GLNC logo and/ or certification for foods that identify as ‘core foods’ (foods represented within the Australian guide to healthy eating) as per the 2013 Australian Dietary Guidelines.” Since the launch of the Code in July 2013, a number of large manufacturers have signed up as registered users including Goodman Fielder, Sanitarium and Bakers Delight. Both Bakers Delight and Goodman Fielder have chosen to use the Daily Target Intake (DTI) statement and content claims on a range of their products, and

of whole grain foods, including the recently approved characterisation of the AACCI (American Association of Cereal Chemists International) standard of 8 grams of whole grain per 30 grams of product. The AACCI standard was introduced in May 2013 – a move that Aley says was highly anticipated by the American, European and Australian cereal grains industries. “Many countries have explored and implanted whole grain certifications or symbols over the years, however some programs did not have strict criteria or a minimum whole grain content amount specified to quantify the overall whole grain level of the food,” says Aley. “The AACCI released a whole grain characterisation in May 2013 which characterised a whole grain food as having 8g whole grain per 30g serve size. “We believe that GLNC’s new voluntary industry standard is leading the way in terms of establishing a consistent message to consumers through clear, scalable levels to communicate the whole grain content of a food.” The current Australian Dietary Guidelines specify that Australians need to consume six serves of grain foods each day, and Aley says that the new GLNC characterisation will provide consumers with the information that they need in order to reach these recommended levels

"For the food industry it signals their adherence to best practice within the industry" Sanitarium will use the DTI statement across its Weet-Bix range from this year. Nestle/Cereal Partners Worldwide – makers of Uncle Tobys breakfast cereals has also jumped onboard, outlining that their breakfast cereals contain at least a minimum of 8g whole grain per serve, with the majority of products representing a high whole grain content per serve. Aley also explains that GLNC’s Code is in line with international labelling standards

effectively, as well as providing industry with a measurable benchmark for claims that they can use in their marketing. “The Code is a win for consumers as whole grain content varies across food and this provides them with a clear comparison of foods that assist them in meeting their daily target. For the food industry it signals their adherence to best practice within the industry and a commitment to communicating clearly to consumers.” F

Grains go gangbusters

Food manufacturers have noticed the increasing popularity of ancient grains and are incorporating them into their ingredients lists. According to Innova Market Insights, launch numbers for food and drink products containing grains such as quinoa, chia, buckwheat and amaranth have been rising strongly in recent years. Launches of products containing quinoa rose nearly 50 percent over the 12 months to the end of September 2013, with a five-fold increase over a five year period. Products using the grain, which has a distinctive nutty, earthy flavour, include breakfast cereals, snack bars, biscuits, confectionery, beverages, ready meals and baby foods. There is also a focus on gluten-free formulations, with 38 percent of launches featuring quinoa in the 12 months

to September 2013 also being gluten-free. Large manufacturers are taking note of the growing popularity of ancient grains, with Kellogg's recently launching Special K Nourish multigrain cereals and cereal bars which comprise quinoa in combination with oats, barley and wheat. Lu Ann Williams, director of Innovation at Innova Market Insights said, "Interest in these alternative grain products, perceived as traditional, natural and nutritious, has become increasingly apparent ... and their use is extending out of the specialist health foods sector and into the mainstream, as well as out of cereal products and into the wider processed foods market."

www.foodmag.com.au | Feb/Mar 2014 | Foodmagazine 15

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LOGISTICS

Lifting the

standards D'VineRipe operates to the Delivered In Full, On Time logistics model

Whether you’re running a small food manufacturing business or a large scale distribution operation, logistics matters. By Aoife Boothroyd.

here are a myriad of logistics models that businesses can subscribe to, with the size, scope and nature of the business being the key determining factors influencing which model is most appropriate. Food magazine recently spoke to two food manufacturers that employ automation as a key part of their overall logistical operations: South Australian tomato producer D’VineRipe and cereal giant Kellogg’s. D’VineRipe was established in 2006 as a joint venture between food marketing company, Perfection Fresh Australia and investment company, The Victor Smorgon Group. The company produces a wide range of tomatoes from cocktail-sized, right up to the larger truss varieties. D’VineRipe has the capacity to produce up to 15,000 tonnes of vine-ripened fruit year round in its state-of-the-art, 27 hectare glasshouse facility, complete with climate control and irrigation. D’VineRipe supplies some of the nation’s largest retailers including Coles, Woolworths, Aldi and Costco, and delivers

16 Foodmagazine | Feb/Mar 2014 | www.foodmag.com.au

to all the eastern states, with a smaller concentration in Western Australia and South Australia. Most impressively, they do this within a 24 to 72 hour turn-around from when the fruit is picked from the vine. D’VineRipe operates to the Delivered In Full, On Time (DIFOT) logistics model which is designed to measure delivery performance throughout the supply chain, and is geared to tailor deliveries to the customer by measuring how often the customer gets exactly what they want, at the time that they want it. As D’VineRipe is in the business of perishable goods, it is imperative that its

“All the picking operations are manually done, however the automatic guided vehicles improve efficiencies by eliminating that extra operation of someone transporting the fruit back to the pack house, picking up the box, weighing it, recording the weight on a piece of paper and then entering it into a computer,” says Jon Jones, general manager of D’VineRipe. “The vehicles enable all those steps to happen automatically.” The automatic guided vehicle system was built for D’VineRipe by Belgian company, Bogaerts Greenhouse Logistics. The vehicles deliver accurate recording

"Sometimes you can experience a glitch here or there, but the majority of the time it's bulletproof." operations run as timely and as smoothly as possible. To achieve this, the facility is fitted out with a network of automatic guided vehicles which run down the rows of each glasshouse to collect fruit, and then deliver the full boxes straight back to the pack house where they are automatically weighed, entered into a buffer system, graded, and packed based on variety.

data capabilities in terms of weighing the product, and also feature a built-in sensor, or a photo eye, that picks up if a person or object is within its range, enabling it to slow down or stop to avoid a collision. When asked about the reliability of such a sophisticated system, Jones says that it’s almost “bulletproof.” “It’s like any computer system, it is »

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LOGISTICS

Boundary Bend straightens up The producer of Cobram Estate and Red Island olive oils recently enlisted the help of logistics experts, CHEP, to tighten up their processes following a year of strong growth.

D'VineRipe has the capacity to produce up to 15,000t of fruit year round. extremely reliable. Sometimes you can experience a glitch here or there, but the majority of the time it’s bulletproof,” he says. Jones says that since the system was put in place over four years ago, operational efficiencies have improved even further thanks to various updates in technology. “We are always looking for new efficiencies. We as a company have changed and gotten bigger; the technology in the automatic guided vehicles has also been upgraded and improved.”

be subject to strict use-by dates, while RDS controls the physical and operational aspects of a company’s distribution centre from the receipt of goods to processing, storage, order fulfilment and despatch in real time. Kellogg’s new ASRS includes pallet conveyors, robotics, storage and retrieval systems and IT hardware that enabled the new distribution centre to hold 32,000 pallets – 4,000 more than what was previously possible – within the automated storage component and the conventional

"Production damage has been reduced by a staggering 85 percent and labour costs have also dropped." Logistics automation is key to the operations of many businesses, however the processes required by long shelf life FMCG’s are obviously different compared to that of perishable produce like tomatoes. Global food manufacturer Kellogg’s decided to make the switch from an almost entirely manually operated 27,000 square metre distribution centre in Botany, New South Wales, to a system that could automatically process high demand volumes whilst also achieving high storage densities. The system back in 2003 was capable of accommodating 28,000 pallet positions across the warehouse’s 27,000 square metres, but the introduction of a new system saw the company achieve impressive storage and operational efficiencies that it did not expect. Kellogg’s worked with Dexion, a distribution management specialist, and supply chain solution company, Linfox, to create a more efficient and sustainable distribution model. The model incorporated an automated storage and retrieval system (ASRS) which was implemented as part of a broader Real-Time Distribution System (RDS). ASRS is designed to tackle some of the most difficult challenges that FMCG distribution centres face including completing orders that cover high volume, fast moving and fluctuating quantities of goods that can

section of the warehouse. The new system enabled pallets to be stored in five aisles, six pallets deep on either side, with each aisle serviced by its own automatic crane. The ASRS enabled Kellogg’s to have the capacity to put away up to 90 pallets per hour, and retrieve 120 pallets per hour. Another impressive aspect of the new system was the command and control centre that provides a pictorial overview of the ASRS system, enabling the operator to see what the system’s doing in real time and quickly resolve any issues that arise. Since the introduction of the system, Kellogg’s has reported a 10 percent reduction in pick error; production damage has been reduced by a staggering 85 percent and labour costs have also dropped as only half the amount of forklifts are now required, even with the increased capacities. The most important part of any logistical operation is to have appropriate processes in place, enabling the operation to run as smoothly as possible by eliminating inefficiencies. While investing in sophisticated automation systems might mean a reduction in staff levels and a considerable investment initially, the productivity and long-term financial gains can most definitely outweigh the disadvantages. F

Boundary Bend has grown from an initial planting of 200 hectares in 1998 to more than 6,000 hectares, spanning seven sites across Victoria, with its popular olive oil brands now found on the shelves of major retailers and independent supermarkets in Australia, as well as in export markets such as the USA, Canada, China, Hong Kong and Singapore. Adding to this, Cobram Estate won four Gold Medals at the inaugural 2013 New York International Olive Oil Competition, and garnered eight awards at the 2013 Australian Olive Association National Extra Virgin Olive Oil Competition in October. But it was during this period of growth that Boundary Bend realised it needed to tighten some of its pallet management processes in order to gain maximum efficiency. Boundary Bend logistics and purchasing manager, Alistair Gray said, "We did a count on our pallets and found a large discrepancy. As a company we've really grown in the past 12 months, and with the large growth we were so busy sending out the orders that we didn't have the resources to look back." As a result, CHEP Australia asset management specialist, Sarina McKeon, was invited to conduct a process review and needs analysis of their Boundary Bend's CHEP account, learning about the existing processes, for example how transfers and exchanges were handled, how invoices were reconciled, and how corrections and rejections were managed. "Where we weren't correcting rejections, we are right on that now," Gray said. "We weren't doing stocktakes of our CHEP account so we never used to have feedback on our account. Now we're doing it fortnightly and we get immediate feedback ... we can see any leakages. It makes a difference - we've seen an improvement of 25 to 30 percent. "We needed to make people responsible [for equipment control] in their roles. I think we realised we needed some direction and some help training our staff at the same time," he said. "I'm happy where we are now. I feel we're smarter, we're better. The training has made a big difference. I'm confident we've got the right people and processes in place now."

www.foodmag.com.au | Feb/Mar 2014 | Foodmagazine 19

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ON THE

SHELF

SodaStream gets spirit Product name: SodaStream Night Spirits range Product manufacturer: SodaStream Ingredients: Cosmopolitan: Carbonated water (water, carbon dioxide), sugar,

Have an OMG moment Product name: OMG! Mudâ&#x20AC;&#x2122;n Mousse desserts Product manufacturer: OMG! Fantastic Food Shelf life: 30 days from date of manufacture Ingredients: Water, sugar, wheat flour, vegetable oil, cocoa powder, egg

food acid (citric acid), reconstituted juice (apple) - (5%), flavouring, non nutritive sweeteners (sodium cyclamate, acesulfame potassium), food colour (black carrot juice, caramel E150d), acidity regulator (sodium citrate - 331), preservative (potassium sorbate -202). Shelf life: 12 months Packaging: 500ml plastic bottles with black colouring and bright multi-coloured lids and fonts Brand website: www.sodastream.com.au

powder, colours, emulsifiers, antioxidant, maltodextrin, potato flour, milk solids, salt, raising agents, natural flavour, vegetable gum. Chocolate ganache: Belgian chocolate, cream, mineral salts, sugar, vegetable oil, cocoa, whey powder, glucose, emulsifiers, flavours, salt White mousse: Sugar, milk solids, glucose syrup, hydrogenated vegetable fat, dextrose, emulsifiers, thickener, stabiliser, flavours, gelatin, maltodextrin, tapioca starch, white chocolate White chocolate flakes: sugar, milk solids, cocoa butter, soya lecithin, flavours. Packaging: 2x90g twin packs Brand website: www.omgfantasticfood.com.au

Pure pasta sauce Product name: Ozganics Spring Vegetable Pasta Sauce Product manufacturer: The Right Food Group Ingredients: Spring Vegetable Pasta Sauce: Certified organic tomatoes 84% (reconstituted tomato puree, diced tomatoes), certified organic spring vegetables (11% carrot, celery, zucchini), certified organic onion (3.2%), sea salt, certified organic garlic, certified organic herbs & spices, certified organic basil, food acid (citric). Shelf life: Two years Packaging: 375g glass jar Brand website: www.ozganics.com.au

20 Foodmagazine | Feb/Mar 2014 | www.foodmag.com.au

Mr Beaks goes bite-sized Product name: Mr Beaks Mini Meatballs 400gm Product manufacturer: Beak and Johnson NZ Ltd Ingredients: Beef (80%), water, potato starch, dehydrated vegetables, vegetable fibre (pea), salt, sugar, herb & spices, acidity regulator (450), flax seed oil (contains Omega 3), preservative (223), antioxidant (300, 306 contains Soy) , anticaking agent (551), spice extract Shelf life: 12 days from date of manufacture Packaging: Clear plastic base and clear film Brand website: www.facebook.com/pages/MrBeaks/696184367080863

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PACKAGING

Blow moulding basics T

he strength and success of a bottle design is a direct descendant of the bottle shape. The shape - which includes the corners, handles, the neck and panels - governs both the physical performance in filling and the degree of difficulty in moulding; the two are delicately connected and cannot be separated. Below are some useful pointers and guidelines regarding blow moulding:

Shrinkage One of the important facts about mould-

Stephen Barter from ing plastic is it shrinks as it cools; the longer it takes to cool the more it shrinks. the Australian Institute The mould acts as a heat transfer mechaof Packaging sheds nism removing the heat from the plastic light on the best ways to at 190 degree celsius down to less than 70 approach blow moulding degree celsius, at which point the plastic is a solid and no longer liquid. and the influence it can Variabilities have on a packageâ&#x20AC;&#x2122;s As the plastic takes the shape of the mould, effectiveness. the plastic becomes variable throughout the bottle, thicker cross sections shrink more than thinner sections inducing stress within bottle features and creating issues like buckled label panels. The best method to reduce this effect is to design contours to reduce thicker sections.

Function Features can be added to the shape to F D0 2 1 4 _ 0 0 0 _ DAT

1 improve 2 0 1mouldability 4 - 0 1 - and 2 0function T 1 2 and : 5 do 4 :

not detract from the appearance. Features like corners act as hinge points for slumping and topload weakness. Using variable radii in corners will increase structural strength; fixed radii will reduce structural strength.

Bottle components Neck - orientating the thread start over the part line (opposite the handle) will improve the capping process, the bottle is able to handle downward pressure from the capper when the thread start of the cap lands on top of the thread start of the bottle. In these conditions the bottle is able to bounce back after being hammered by the capper. Shoulder - making the bottle strong through the shoulder by keeping surfaces in the form of an upside down funnel and compound radii allows the top load to be dispersed down through the bottle into the base. Compound curves reduce plastic and ovality in the neck finish, especially on oval shaped bottles. Handles - the closer to square or round for the handle crossection the easier the handle will be to mould. As the depth of the handle increases in relation to the handle width the risk of webbing increases, a major quality complaint. This rule applies to blending the handle out into the bottle; avoid blending the handle by increasing the depth of the handle, only without increasing the width 1 in8 similar + 1 1 ratios. : 0 0

Panel features 2D or conical curves in label panels make labelling easy. 3D curves in panels will lead to the labels lifting and bubbling. The reason for a conical shape in particular is the increase in the bottle topload strength. Bulging in the panel is difficult to control, especially with thin walled bottles. Start the design with bulge in the shape and work back by changing only the label panel back to a 2D curve. Imagine the bottle shape you have in mind and then partially blow up a balloon inside this bottle shape. Take particular note of the corner radii and then factor these into the shape of the bottle. These will not only improve slump resistance, it will also make the bottle easier to mould.

Base corners Base controls the topload strength and stability of the bottle. Using a simple radius in the base corner will result in poor topload, slump resistance, base rock as well as difficult moulding. Compound curves are essential here. It is paramount the bottle designer is aware that most design flaws cannot be â&#x20AC;&#x2DC;processed outâ&#x20AC;&#x2122; by the moulder. An over-confident moulder can underestimate these details, adding substantial costs to new projects and the finished bottle weight - costs that may be carried for the life of the bottle. F

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PLC Programming and Documentation www.foodmag.com.au | Feb/Mar 2014 | Foodmagazine 21

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PRODUCTS

EVENTS

Full on flavour from tna

Image: Vladimir Kolobov - Thinkstock

tna has launched a new main line spray system which delivers optimum coverage and flavour adhesion. The tna intelli-flav CLO 3 is a closed loop oiler suitable for a range of industries, delivering accurate and concise oil application in tumble drums for product flavourings. The tna intelli-flav CLO 3 builds on the design of previous CLO systems but now includes additional features to ensure customers obtain the most consistent seasoning application in the industry with an extended product life. These combine to produce a more hygienic and operator-friendly main line system which provides accuracy in application on salty, baked and extruded snacks as well as on nuts, biscuits and pet food. Suitable for main line seasoning in particular, the intelli-flav CLO 3 uses coriolis mass flow measurement and a closed feedback loop. Its technology allows for a variety of application rates by increasing the number of spray guns. Combined, this ensures that the sprayed liquid meets the target requirement even when levels fluctuate, providing the most consistent oil coverage in the market and enabling accurate seasoning adherence. The tna intelli-flav CLO 3 is also the only oiling system to offer an air filtration system ensuring 99.9 percent of the facility air is completely dry, as moisture can significantly reduce shelf life.

foodpro 2014 22 - 25 June, 2014 tna Australia 02 9714 2300 www.tnasolutions.com

Image: Kevin Brown

Lighten the load Tork Carry Packs' Tork Xpress Multifold H2 and Tork Ultraslim Multifold H4 hand towels make handling bulk hand towels easier and safer for employees and cleaners. Made from recyclable PE-LD plastic, the carry packs are flexible but tough and feature handles that make it easy to carry two packs, the equivalent of two cartons, at a time. Matthew Bond, managing director of City Central Property Services, said "It would be much easier from a manual handling perspective to be able to bend knees and grab a handle and lift rather than wrapping your arms around a box." There's also the added advantage of easy opening, which doesn't require the use of a knife. The Tork Carry Packs have perforated sections that can be opened by hand, again making them safer to use. Tork Carry Packs also create 84 percent less waste than cardboard cartons with the bag scrunching down to a fist-sized ball.

Image: Peter Hoelstad

Tork by SCA Hygiene Australasia P: 1800 643 634 www.tork.com.au or www.sca.com

22 Foodmagazine | Feb/Mar 2014 | www.foodmag.com.au

Melbourne Convention and Exhibition Centre, Southbank, VIC foodpro, Australasia's largest and longest running food manufacturing trade show will be held in Melbourne for the first time this year. Held once every three years, foodpro 2014 will span over 20,000 square metres at the Melbourne Convention and Exhibition Centre showcasing every aspect of the Australasian food processing industry. About 10,000 people are expected to see more than 300 suppliers of the food and beverage sectors at the high profile trade event for the industry within the Asia Pacific region. One section of the show will cover processing equipment for meat, poultry, seafood and vegetables, while a technical area will cover food science and technology, including ingredients, additives and flavourings, laboratory equipment and food safety. The event will also have a dedicated plant equipment section featuring water treatment, doors and flooring, pumps, and a complete range of food plant services. In addition, a vast packaging and handling area specialised for the food industry will also be on show. foodpro 2014 will provide today's manufacturing industry with an opportunity to meet the market face-to-face, provide practical

demonstrations, launch new products, explain in detail the benefits of products and services, and generate sales and media coverage. www.foodproexh.com

AIP National Conference 17 - 18 June, 2014 Sofitel Wentworth, Sydney, NSW The Australian Institute of Packaging (AIP) is currently planning the 2014 National Conference, to be held at the Sofitel Wentworth on 17 and 18 June. The 2014 conference will deliver a two day educational program that will cover a broad range of topics relating to the theme Packaging and Innovation Excellence. The biennial AIP National Conference is the largest packaging conference of its kind in Australia and New Zealand, and is expected to attract delegates from all facets of the packaging industry, in both technologist and management positions, including development, marketing, production, supply chain and logistics personnel, as well as equipment suppliers, raw material providers, users of packaging, retailers and consumers. The AIP intends to break the conference into separate sessions after the opening and keynote presentations, to ensure a diverse range of issues and topics are covered over the two days. www.aipack.com.au

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