Food Magazine February 2015

FD0215_MAT2

-

1

2015-01-28T13:30:37+11:00

Foodmagazine INGREDIENTS | PROCESSING | SAFETY | PACKAGING | EXPORT

INFORMING FOOD AND BEVERAGE MANUFACTURERS

FEB/MAR 2015

WWW.FOODMAG.COM.AU

Print Post Approved 100007267

Improve your production line reliability

FD0215_000_MAT1

-

2

2015-01-14T10:13:38+11:00

1300 CODING (1300 263 464) www.matthews.com.au Call us today to discuss your application

pturecodecheckcapturecodecheckcapturecodecheckcapturecodecheckcapturecodecheckcapturecodechec

FD0215_001

- 1

2015-02-06T10:17:53+11:00

Foodmagazine INGREDIENTS | PROCESSING | SAFETY | PACKAGING | EXPORT

INFORMING FOOD AND BEVERAGE MANUFACTURERS

FEB/MAR 2015

WWW.FOODMAG.COM.AU

Packaging & Labelling

Print Post Approved 100007267

Digital printing and faster turnaround are among the latest innovations shaping the industry

PLUS: AUSPACK 2015 preview | How to tap into the China market | Raw milk cheese

FD0614_000_MTI

-

1

2014-05-13T14:07:30+10:00

Industrial Door Solutions

r a e Cl

t s e b e h t ly

Contact our team today to find a solution for you

MTI_FullPage.indd 1

M.T.I. Qualos Pty. Ltd. are leaders in the manufacturing and service of Industrial Transparent Flexible Doors, Insulated Traffic Doors, and Roll-Fast Doors.

We produce to the highest quality standard within a full range of industrial doors to suit any door application.

NEW 36pp brochure now available.

Contact us to get your FREE copy.

M.T.I. Qualos Pty. Ltd. 55 Northern Road, West Heidelberg, Vic. 3081 Tel: 1300 135 539 Email: sales@mtiqualos.com.au Website: www.mtiqualos.com.au

12/05/14 12:30 PM

FD0215_005

- 5

2015-02-06T09:45:38+11:00

WELCOME

PUBLISHER Martin Sinclair P: 02 8484 0607 F: 02 8484 0915 E: martin.sinclair@cirrusmedia.com.au

FTAs can transform the industry

T

EDITOR Kevin Gomez P: 02 8484 0976 F: 02 8484 0915 E: kevin.gomez@cirrusmedia.com.au JOURNALIST Jasmine O’Donoghue P: 02 8484 0854 F: 02 8484 0915 E: jasmine.o’donoghue@cirrusmedia.com.au GRAPHIC DESIGNER Louis Santos P: 02 8484 0724 F: 02 8484 0915 E: louis.santos@cirrusmedia.com.au

NEXT ISSUE

NATIONAL SALES MANAGER Sharon Amos P: 07 3261 8857 F: 07 3261 8347 M: 0417 072 625 E: sharon.amos@cirrusmedia.com.au PRODUCTION COORDINATOR Tracy Engle P: 02 8484 0707 F: 02 8484 0915 E: tracy.engle@cirrusmedia.com.au

SUBSCRIPTIONS 1 year subscription 2 year subscription

AUS NZ 99 109 189 199

Editor: Kevin Gomez

• Scanning • Packaging & Labelling • Bulk Handling • Baked Goods • NMW Preview

he ink had barely dried on the Free Trade Agreement Australia recently signed with Japan, when that country started running low on french fries. Well McDonald’s did - limiting customers to a small pack of fries with each order.

Japan was already reeling from a butter shortage, with shoppers restricted to one stick - if butter could even be found on the supermarket shelves. Labour disputes in the US container ports caused the potato shortage. And the butter? Well blame it in a hot Japanese summer and ‘tired cows’ unable to produce adequate milk.

It is unlikely that Australia could have quickly loaded up cargo ships and rushed potatoes and butter to our new FTA partners but it does illustrate the tremendous opportunities food manufacturers now have to tap into a growing Asian food market.

The US currently supplies 80 percent of Japan’s

requirement for french fries. Is there scope for Australia to muscle in? There are several food sectors where we now have an edge because of the recently-signed FTAs. Rumour has it that an FTA with India is in the works. Plus, the low exchange rate can only help our food exports.

Just on its own, the FTA is not a magic bullet but it gives us a distinct advantage. This issue includes an interesting article that advises SMEs to look beyond the FTA and use operational landscape, consumer understanding, and valueadded production to penetrate overseas markets.

As always, the team at Foodmagazine would love to hear from you, so drop us an email, follow us on Twitter and join the discussions on Facebook. kevin.gomez@cirrusmedia.com.au

INSIDE 12

O/S 119 209

14

26

For subscription enquiries call customer service: 1300 360 126 ISSN 2202-0268

CIRRUS MEDIA Tower 2, Level 3, 475 Victoria Ave, Chatswood, NSW 2067, Australia Locked Bag 4700 Chatswood Delivery Centre, NSW 2067, Australia P: 02 9422 2999 F: 02 9422 8657 ABN 80 132 719 861 www.cirrusmedia.com.au

6 NEWS

14 SAFETY

26 DAIRY

Australia benefits from China’s growing appetite for cheese

Segregated zones at Temptation Bakery enable stringent quality control standards for manufacture and hygiene

Saul Sullivan unearthed a rare bacteria in the Adelaide Hills and used it to create a unique raw milk cheese

15 AUSPACK 2015 PREVIEW

30 MOTORS & DRIVES

Check out some of the innovative products and equipment that will be on show at the event this March

In chocolate manufacture ingredients must remain in near-continuous motion for days

© Copyright Cirrus Media, 2014

7 EXPORTS Why the China FTA isn’t immediately right for your SME Average Net Distribution Period ending SEP ‘14 - 5,384

8 AIP COLUMN The importance of Africa in the world of packaging

Australia saw a rise of 1.9 per cent in the value of wine exports in 2014

11 FOOD AWARDS 2015 PRINTED BY: Bluestar Print 83 Derby Street, Silverwater NSW 2128 P: 02 9748 3411

32 WINE

33 ON THE SHELF

These are set to be our biggest yet with the addition of three categories

Six new products on retailers’ shelves

12 PACKAGING TRENDS

24 BEVERAGES

34 LAST WORD

How light weighting and digital direct-topack printing are delivering benefits to the industry

Training can be the difference between a disastrous product recall and a thriving manufacturing plant

Schneider Electric’s Craig Roseman outlines the key challenges facing food manufacturers

www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 5

FD0215_006

- 6

2015-02-05T11:39:33+11:00

NEWS

Australia benefits from China's growing appetite for cheese China’s cheese imports were up 47 percent year-on-year during the first ten months of 2014.

CHINA imported 56,028 tonnes of cheese between January and October 2014, far more than the 47,316 tonnes imported during the whole of 2013, according to Chinese market research firm CCM. The main beneficiaries of China’s newly-acquired taste for cheese so far have been New Zealand, Australia and the US, with Europe’s cheese makers trailing behind.

New Zealand remains China’s preferred source of cheese – imports from New Zealand during JanuaryOctober 2014 totalled 24,013 tonnes, a 44 percent increase over the same period in 2013. However, Australia is catching up fast – its total cheese exports to China rose 78 percent year-on-year to 15,189 tonnes – and its exports are likely to be boosted further in 2015 thanks to the China-Australia Free Trade Agreement.

Imports from the US also increased, rising 27 percent year-on-year to 10,084 tonnes. New Zealand now exports more than twice as much cheese to China as the US, and the gap between Australia and the US has widened from 593 tonnes in 2013 to 5,105 tonnes in 2014.

China is steadily developing a taste for European cheese – imports from France, Italy, Denmark, Germany, and the Netherlands all rose by 25 percent or more year-on-year – but in absolute terms this is a drop in the ocean. The total volume of imports from the top five European nations added up to just 4,696 tonnes, less than one fifth of the amount imported from New Zealand.

China is currently importing cheese from the US, New Zealand and Australia at an average of US$4.71/ kg, US$5.10/kg and US$4.69/kg respectively, as opposed to US$8.14/kg from France, US$8.27/kg from Italy, and US$8.51/kg from Denmark, which suggests that European suppliers are currently focusing on retail products.

In addition, US and Australasian suppliers hold strategic advantages over their European competitors, including New Zealand’s (and from 2015, Australia’s) market access due to its Free Trade Agreement with China, and lower freight costs for New Zealand, Australian, and West Coast US suppliers. www.cnchemicals.com

Total volume of cheese exports to China, January-October 2014 (kg) 0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

Australia US France Italy Denmark

Australia's oldest chocolate manufacturer, Ernest Hillier, appointed administrators less than a year after it was acquired by RE Capital. One week later, confectionery business Betta Foods, also announced it would go into voluntary administration.

Japan-Australia free trade deal comes into effect Minister for Trade and Investment Andrew Robb has encouraged businesses to explore potential export opportunities with Japan.

The Japan-Australia Economic Partnership Agreement (JAEPA) provides improved access to Japan's growing markets, and more than 97 percent of Australia's exports will receive preferential or duty free access when JAEPA is fully implemented.

Industry disputes caffeine and soft drink study The Beverages Council said a Deakin University study linking caffeine content with increased soft drink consumption had 'inherent design flaws', and needs to be kept in context. The research prompted calls for tighter regulation of caffeine in soft drink.

Simplot saved by 'compromise'

Argentina Netherlands Uruguay UK

Volume vs. value of cheese exports to China, January-October 2014 (kg) 0

3,000,000

6,000,000

9,000,000

12,000,000

15,000,000

$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$

Denmark $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ Germany $ $ $ $ $ $ $ $ $ $ $ $ $ Netherlands $ $ $ $ $ $ $ $ $ UK $

6 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

Total volume of cheese exports to China, January-October 2014 (kg) $ Total value of cheese exports to China,

January-October 2014 (kg)

The NSW government is set to introduce a rebate of around 10 cents for returned drink containers in an effort to reduce litter in the state. The scheme is likely to involve the introduction of reverse vending machines which accept cans and bottles in exchange for a small refund. They would be capable of handling about 3000 items each and would be placed in public areas for the benefit of the public.

Victoria legislates against raw milk The Victorian government has introduced laws to prevent the consumption of unpasteurised milk, following the death of a child who drank the product. Unpasteurised 'raw' milk can now only be sold in the state if it contains a gag-inducing ingredient that makes it undrinkable.

For more industry news, check out: foodmag.com.au

Images: Photodisc (top) ; TimArbaev (bottom) - Thinkstock

Drink container deposit scheme

Germany

Italy

Ernest Hillier collapses

The Australian operations of food processor Simplot were saved by a 'compromise' in wage negotiations. The AMWU and Simplot agreed to a six percent pay rise for workers over three years.

New Zealand

France

In brief

FD0215_007

- 7

2015-02-04T08:30:21+11:00

TRADE

FTA: Not Right, Not Yet Why the China FTA isn’t immediately right for your SME, and two things that are. By Andrew Kuiler.

O

n the surface, the China/Australia Free Trade Agreement (FTA) might seem like a holy grail for Australian producers trying to find an avenue into China.

Overall, however, the FTA has the most immediate impact on Australian commodities such as dairy, beef, wine, seafood and processed foods. It is a bureaucratic enabler that will take several years to a decade for impact to be felt. For example, it’s going to take up to 11 years to eliminate dairy tariffs alone. That’s a long time to wait for a rapidly changing market like China.

For small- and medium-size enterprises, especially those specialising in food and beverage, this means the trickle down of FTA agreements may take an even longer time to realise. In fact, the agreement is sparse on details about how it can specifically help SMEs win or where the opportunity is for food and beverage manufacturers. Instead of focusing so much on the FTA, SMEs could be better poised to take advantage of China’s growing middle class through two distinct avenues already in place.

Avenue #1: China's Easing Operational Landscape One of the most important things to consider is that the operational landscape in China is getting easier to work within and navigate, even compared to a couple of years ago. Just take a look at the impact companies like Alibaba are having on warehousing and logistics.

It’s now possible to send something from Shanghai to Tibet in a day, drop ship globally in a week or less and conduct business online in seconds. In short, you no longer need to have major in-house resources like the major multinationals to “make it” in China.

Engaging partners and talent – Once the bane of anybody looking to do business in China, local partner and talent quality is improving daily. While there are still thousands of potential suppliers, legal systems for the protection of foreign business are much stronger than only 5 years ago. Today, the World Bank ranks China 15th globally in terms of contract enforcement. Compare that to Mexico at 81 and India at 182. Talent is also easier to come by. Foreign-educated

Murray Goulburn's relaunched Devondale long life milk. www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 7

FD0215_008

- 8

2015-02-04T08:31:54+11:00

TRADE

Chinese are returning to the mainland in large waves.

These returnees (‘hui gui’) have strong overseas experience, with foreign language skills to match.

Tapping into these partners and the available talent pool is now easier as well, especially with the widespread use of social media and the Internet. I recently toured an Australian client around Shanghai and introduced them to WeChat. This mobile phone app has largely replaced traditional phone calls and other social mediums, including Facebook and Weibo, as a means of real-time communication and networking. They were amazed with how easy, and extensive, the app was to use and have now adopted as a means of connecting better with what’s going on in China. Now back in Australia they can communicate with us and their other China-based suppliers for free.

Engaging Chinese consumers – The Internet has revolutionised the way Chinese consume and how brands

8 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

interact with these consumers. In many respects it has democratised opportunities between larger organisations and SMEs. Still, brands have to stay fresh and new, not simply relying on their historical ties to the market.

According to Victoria Wicker, Category Planning Manager for Ole Supermarkets in China, “…the winning recipe is a combination of strong concept, added to a real story to tell to the consumer, and very visual and attractive packaging.” Larger companies, including Coca Cola, are struggling in the market because they cannot innovate fast enough to match changing consumer demands. Smaller firms have a “…very strong advantage because it means they adapt, or localise, and this acts as a real quality trigger in the consumer’s mind.”

With the rise of social networking apps like WeChat and Weibo, brand owners and consumers can directly communicate. Wicker notes that consumers “…love posting pictures of [products] on social media, using

Simply setting up an e-commerce site without further thought is not enough to spell success them as…lifestyle accessories.” WeChat has also even recently launched a payment system where users can buy products directly on the app. Adaptability and nimbleness is becoming critical to succeed in China.

The greatest impact of the internet is being felt in China through the country’s massive E-commerce market.

Single’s Day, China’s version of Cyber Monday, sales figures for 2014 topped US$9 billion. U.S.-based Costco Foods raked in US$3.5 million, shocking management and “…totally transform[ing] [their] annual business plan.”

Websites are also experimenting with innovative ways to ease entry into China. Kuaijingtong, a government-sponsored e-commerce site, allows for online sales and shipment without undergoing Chinese customs.

E-commerce giant Alibaba has recently penned a deal with Australia Post to ease customs processes, shipment and delivery between both countries. A mini-FTA of its own, this deal makes trade between Chinese and Australian SMEs an easy reality.

Even with this massive potential, PriceWaterhouse Coopers estimates that only 9 percent of Australian businesses are currently operating in Asia, with 65 percent of business having no intention of changing their stance towards Asia over the next 3 years. The Australian Trade Commission qualifies these numbers further in estimating there are only 50 Australian brands effectively running online stores in China. Clearly, there is a lot of room left for the 1,000 plus businesses with a connection to the Chinese market.

Avenue #2: Informed Value-Added Food Products Simply setting up an e-commerce site without further thought is not enough to spell success. Product adaptation and focused promotional efforts trump simple product placement. Food and beverage companies have finally embraced this need to localise when entering China. Ten years ago, the market for western products in China was such that any new addition would create a massive buzz among consumers. Today the market is so saturated with western, and comparable Chinese, products that making waves takes local consumer insight, strategy and adjustment.

FD0215_009

- 9

2015-02-04T08:35:11+11:00

TRADE

I like to call it making informed value-added products.

Time and time again, companies entering China make the fatal mistake of assuming Chinese consumers will simply buy their product because it is western. They plug and play instead of adapt. Often, this doesn’t work out as planned. Tesco and Carrefour are both in talks to sell their businesses to Chinese partners after many years in the market. Companies like Barbie, Home Depot and Best Buy have failed in the market completely.

Sure, statistically speaking you might have a percentage of the population purchase your goods. Even if your product only reaches 5 percent of China’s 300 million middle-class consumers, that’s 15 million people or about three-quarters of the Australian population. This may work initially, but making informed value-added changes to a product and its messaging increase its likelihood of long-term success.

These changes aren’t always revolutionary, but they do always take into account the intersection between macrotrends and local insights.

In 2011 the Quaker (oatmeal) brand ranked third in China’s breakfast cereal market, with revenue rising 50 percent from the previous year. Though the brand had been in China for 20 years, its true success happened only after a relaunch “…incorporating ingredients that are known to have therapeutic function.”

Through its research center in Shanghai, Quaker set out to bring traditional Chinese medicine to the breakfast table. The result was a diversified offering of cereals, including oatmeal with functional ingredients like red dates for a healthy Qi, wolfberry and white fungus for the lungs and lotus root starch to match mouth feel preferences of Chinese consumers. Torsten Stocker, head of Asian Consumer Goods at consulting firm Monitor Group, said, “Quaker has done a good job in extending the appeal of its existing range…it has a brand image associated with health.” He adds “…consumers like the fact that it has adapted to local palates and habits.”

Ferrero Rocher is another great example of adapting to the Chinese market and succeeding. A major China importer remarked, “…the key thing I expect from a brand is flexibility…Ferrero, without modifying their identity as

a foreign delicacy, showed an excellent understanding of Chinese consumers.” Instead of replicating large packages of chocolates, a strategy the company uses in western markets, Ferrero in China made small packets perfect for festivals and weddings. “Such success would not have been possible without a real investment locally.”

Australia’s largest dairy foods company, Murray Goulburn, has also found success in China after adapting to local tastes. Recently Devondale long-life milk was re-launched as the company sought to gain market share by addressing the Chinese need for safe, reliable foods. The brand’s packaging now includes bilingual translations, clear messaging about country of origin and the farm’s cooperative story, as well as family and gift packs. Managing director Gary Helou talked about the new packaging, saying it is “…tailored to the local Chinese market based on extensive local customer insights.”

The move seems sensible given Devondale exports accounted for 51 percent of revenue last year, with more than AUS$200 million coming from China and Hong Kong.

On the FTA itself, Helou feels it will “…improve the competitive positioning of Australian dairy foods into China, but dairy farmers must have ownership of the supply chain…otherwise value will be lost to others.”

Overall, the FTA certainly marks a time of increased cooperation between Chinese and Australian businesses.

While it’s exciting to know that two of Asia’s largest markets are collaborating, it’s also important to remember the ink on the agreement has yet to dry. The FTA is not the only motivator on the block. The current operational landscape, including access to partners and consumers, and use of informed valueadded production can all help facilitate access, today, to what will soon be the world’s largest economy.

Andrew Kuiler (andrew@thesilkinitiative.com) is a native Australian and founder of Shanghai-based consultancy The Silk Initiative.

The Silk Initiative’s Olivier Stauff and Geng Huang also contributed to this story.

CHINA-BOUND SME ACTION POINTS: • Get to really know the FTA. As it stands, the FTA will only minimally impact SMEs for the foreseeable future.

Get to know commodity strategy and where the opportunities are for your brand and product.

• Understand and engage with Chinese suppliers and talent. Chinese partners and talent are now more experienced and accessible through social media, and the legal environment is growing more favorable towards foreign firms.

Come to China to determine which partners are not only capable but offer the right chemistry.

• Realise how to utilise and manoeuvre within China’s e-commerce space.

China’s e-commerce market is bringing in billions of dollars a day and dramatically changing how people do business.

Australian brands have yet to scratch the surface. Remember though, a retail strategy in China still needs to be both offline and online to achieve scale.

• Create informed value-added products - they are not only innovative, but also critical for the success of a brand. Localised consumer and market insights are key – including flavors, textures, packaging and distinct brand messaging and consumer expectations around product experience – are all hallmarks of a brand doing it right in China.

www.thesilkinitiative.com www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 9

FD0215_010

- 10

2015-02-04T08:50:04+11:00

PACKAGING

The importance of Africa in the world of packaging Africa is rapidly becoming a packaging growth centre and the industry needs to be ready to reap the benefits. By Pierre Pienaar.

G

rowth centres for packaging are shifting, with Africa destined to surpass India and China as its population grows, says World Packaging Organisation (WPO) President Tom Schneider. Africa has the most arable land suited to farming of any continent, meaning that with the right packaging and supply chain knowledge, and achieving population forecasts for 2050, African countries should be able to export across the globe.

By the end of the century, if current demographic patterns continue for another 85 years, Africa would have 4.2 billion people, against 1.1 billion today.

Nigeria, whose land mass is similar to Pakistan’s or Venezuela’s, would rise from 180 million today to 910 million, registering one in 12 of the world’s births. This will require more food and more packaging, which is why the World Packaging Organisation runs Residential Training in Packaging (RTP) courses in developing countries including Nigeria, Ghana and Kenya. I have been privileged to be involved in these training schemes and the results have been encouraging.

Open markets The challenge in Africa, I found was the packaging of some agricultural products, some local foodstuffs as well as packaging for the informal sector, locally known as ‘open markets’ which is a huge percentage of sales in Nigeria. I visited a Unilever plant in Lagos and saw massive volumes of toothpaste in 15 ml sachets being packed, and was told that this was by far their biggest sales and had far exceeded sales of the larger toothpaste tubes that we are familiar with in Australia. The ‘open markets’ sells practically every possible household good in small size flow wrapped packs or sachets consisting literally of only one day’s supply of the product. This is purely driven by cost and affordability.

There is a significant amount of informal packaging happening in Central and West Africa as well as throughout the African continent. This is where vendors buy in bulk and repack into small pack sizes for ‘open market’ sales. It is therefore in this area of packaging that requires support, advice and help.

A growth centre Africa is on the rise, according to Sarah Smith, a Research Advisor at Reportbuyer. Economy, for the most part, is booming, given the relatively stable political scenario in the region. Africa’s GDP growth from 4.7 percent in 2013 to 5.2 percent in 2014 and the FDI growth of 16 percent, reaching US$43 billion in 2014, show a positive economic 10 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

trend. Countries across Africa, from mineral-rich Sierra Leone and Congo to the economies like Ethiopia and Rwanda, have shown growth across multiple macroeconomic parameters, with inflation in Africa going down from 10.7 percent in 2013 to 6.2 percent in 2014. Packaging in Africa is fast catching up to meet the growing needs of a continent that is booming with investment from a vast number of foreign players. Given the relative lack of proper infrastructure, the vast distances that goods need to be transported over land from a few international ports make packaging a necessity.

Food and industrial goods imports into Africa make up a significant share of the packaging market in the region. Rising demand for packaged foods, a need to keep costs down and investments in food processing are propelling the growth of packaging in the region.

Automation of packaging is helping speed up the process of packaged goods, allowing it to meet growing demand. As the demand for packaging increases, so does the demand for automated packaging.

Africa’s middle class (defined as those earning at least US$450 per month) has triples, according to a recent study

by Standard Bank. This group in the continent’s 11 biggest economies has tripled, from fewer than five million in 2000, to 15 million today. In the next 15 years its numbers may swell by another 25 million. The GDP of the biggest economies has also grown faster than its population.

Africa’s demographic boom is exceptional and all indications are that the continent might be able to cope with it.

This massive growth in Africa’s middle class will have a direct impact on the purchasing power shift into the future. It’s this shift that we in packaging have to be aware of, plan and prepare for, and ensure that necessary steps, like education and training happen now so that all involved can reap the multitude of benefits in the years to come.

Education, I believe, is what stands between wherever we may be now and a successful, productive, competitive and rewarding future. Packaging is a science and if we want to prevent a void of knowledge in the near future, then we need to ensure that we continually update our knowledge.

Management consultants for retailers, wholesalers and manufacturers suggest that the packaging industry will suffer if it does not take itself seriously enough and ensure that its participants are continually being educated to improve packaging knowledge and skills.

Africa in this regard is no different to the rest of the world and so I’d like to suggest that back-tostrong-basics, consolidation of business, a cooperative, consultative approach within the industry, underpinned by ongoing education will ensure that Africa meets the needs of the future in a vibrant packaging industry; and I wish them and those that assist them, every success.

Pierre Pienaar is education director at the Australian Institute of Packaging (AIP). www.aipack.com.au

FD0215_011

- 11

2015-02-04T08:55:21+11:00

Get your nominations in for the 2015 Food Magazine Awards!

The 2015 Food Magazine Awards are set to be our biggest yet, h awards. d with the addition of three new categories and the launch of a website dedicated to the

T

he Food Magazine Awards boasts 16 categories, including addition of: Label Design, Community Engagement and Employer of the Year.

We have launched a website for the awards, filled with all the information you need to nominate. You can also find out about our awards night, purchase tickets and check out the previous winners.

Now in its 11th year, the Food Magazine Awards have become a pivotal event in the food and beverage industry’s calendar; bringing manufacturers, large and small, together to celebrate some of the latest and greatest new product launches.

In order to enter a product, it needs to have been launched between April 2013 and April 2015 and all nominations must be in by 1 April, 2015, 5pm EST.

Categories: • Beverages: For ready to drink alcoholic and nonalcoholic beverages.

• Baked Goods: All products that use a dry heat cooking process, whether sweet or savoury can enter this category.

• Dairy: For all products that include cow, milk, buffalo or goat milk as a main element.

• Organics: For all products that include cow, milk, buffalo or goat milk as a main element.

• Ready Meals: Meals that are ready to go, and do not require any additional ingredients. Ready meals include all the elements of a meal and require one or less steps for preparation.

• Snack Foods: Foods which do not constitute an entire meal, and are eaten between main meals. They can be sweet or savoury but do not require significant preparation before consumption.

• Prepared Foods: Commercially packaged foods that require some additions and can take two or more steps to create a meal. Prepared Foods differ from Ready Meals as they are only components of a meal, rather than an entire meal.

• Food Safety and Innovation in Non-Food: This product or service needs to be directly applicable to the Australian or New Zealand food and beverage industries and offer a food safety benefit to the food industry. This benefit may be realised through design, improved sanitation or allergen testing.

• Health and Wellness: These are foods that benefit the health and wellness of consumers, and should have scientific research and reports to back up the claims.

• Ingredient Innovation: This category is for new developments in ingredients at any level of the process.

• Packaging Design: This category is to recognise and reward creativity and innovation in food and beverage packaging. Note this category is not appropriate for new/redesigned product labels. These entries are more appropriate for our Label Design category.

• Sustainable Manufacturer: This category will recognise companies that have made a concerted effort to reduce their environmental impact. This could be through implementing a new manufacturing process which reduces carbon emissions, introducing staff initiatives to foster sustainability in their work environment, or efforts to reduce the ‘food miles’ of their products. Please note that this category is for manufacturers, not for individual products.

• Meat and Smallgoods: This incorporates all fresh meats and deli meat products. The innovation here could be in regards to how the meat is cooked/

prepared by the manufacturer or the end user, or an innovative combination of ingredients or processing techniques.

• Label Design: This award recognises companies that have invested time and energy into designing a unique and effective label for their food or beverage product/range. The label should be unlike any other on the market and clearly communicate the manufacturer’s philosophy and who its target market is. This category is suitable for brands that have undergone a redesign, or for recently released products.

• Community Engagement: This award aims to recognise a company within the food and beverage manufacturing industry that makes a concerted effort to engage with its local community. This could be through hosting and/or participating in charity events and/or fundraisers, lobbying for a cause which affects the manufacturers’ local area or conducting research in the area to help the manufacturer deliver products that resonate with the end user.

• Employer of the Year: This award is for a company that employs and fosters staff that are engaged in strategic goals and company values. The companies entering this category will have prioritised investing in people and initiatives that foster a collaborative culture, harnessing the skills of its team to grow and prosper the company. The company will have evidence of staff retention, staff satisfaction and/or implemented initiatives aimed at improving/maintaining morale and performance of team members.

So what are you waiting for? Get nominating!

To nominate, or for more information, check out our awards website: foodmagazineawards.com.au www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 11

FD0215_012

- 12

2015-02-04T09:14:45+11:00

PACKAGING

Staying ahead of the pack Light weighting, minimising use of resources, and digital direct-to-pack printing are some of the innovations delivering benefits to the food and beverage manufacturing industry, writes Hartley Henderson.

L

eading packaging manufacturer and innovator, Pact Group, has a dedicated innovation division comprised of a cross-functional team of industrial designers and engineers, inventors, marketers, and specialists focussing on sustainability and environmental aspects.

The innovation process at Pact Group always starts with a focus on practical performance, says Siobhan McCrory, General Manager of Sales, Marketing and Innovation at the company’s Inpact Innovation Centre in the Melbourne suburb of Richmond.

“Integral to this process is developing an understanding of what the pack has to do throughout the entire supply chain.

We send our designers to our customers’ factories to walk their filling lines, and follow the products through distribution centres, stores, customers’ homes and recycling streams,” she explained.

“Good packaging needs to be easy to use, freight well, stand out the on shelf and be easy to replenish in stores, but it also needs to be sustainable, so Pact has a dedicated sustainability division that enables a closed loop operation, meaning material is able to be recycled and reused.”

Siobhan points to the development of the recyclable plastic light-proof milk bottle, which the company developed in conjunction with Fonterra in New Zealand, as a good example of groundbreaking innovation.

12 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

“Light drains some of the goodness out of milk, including vitamins A and B2, and even though opaque cartons and bottles already exist, up to 25 percent of light still finds its way through the packaging and into the product.

“This light-proof bottle that was developed for the Fonterra Anchor range starts with an induction foil sealed cap that keeps light out of the bottle neck and finishes with three light-protective layers that make up the body, thus providing a 100 percent shield from light.”

Light weighting Light weighting and minimising the resources required to produce a product are

some of the latest developments in packaging for the food and beverage industry.

Siobhan says a good example of light weighting is the imminent launch of the Infini milk bottle. Under exclusive license from Nampak Plastics, Infini will be the lightest bottle in the Australian and New Zealand marketplace and has been designed to fit both domestic supply chain requirements and consumers’ fridges.

“Another important development is the evolution of direct-to-pack printing in the form of digital technology.

Pact Group has invested in the ability to print directly on to containers and caps, removing the need for labels.

“We believe this will be a paradigm shift in the industry as it allows marketers to form a dialogue with customers and print in real time. Digital technology also means that there is no lead time needed to set up artwork and no inventory.

“It also means that every pack can be different – allowing you to build a billboard in store with personalised messages. We believe that this will transform the way that marketers will engage with their customers.”

In relation to key issues and challenges facing the industry, Siobhan advises that growth in private label

FD0215_013

- 13

2015-02-04T09:15:36+11:00

PACKAGING

counterfeiting. This is not only important from a brand management perspective but also in ensuring consumer safety.”

Innovative labelling

products has put branded goods under more pressure and that there is a need to differentiate to make it easy for customers to see that the value in the branded premium is stronger than ever.

“In heavily commoditised categories like milk and flour, packaging can enable branded players to differentiate their products and justify a price premium.

Differentiation through product formulation can be difficult and packaging can play a key role in offering consumers convenience, extended shelf life, and reseal or storage ability.

“As exporting continues to increase, there are other challenges around security and maintaining the integrity of the pack in light of an increased risk of

The Labelmakers Group produces a wide variety of packaging formats for the Australian and New Zealand markets, using both conventional and digital printing processes with the aim of providing innovative labelling solutions for major companies and brands.

Developments over the past 25 years have expanded from wet glue paper and self-adhesive labels to areas such as rollfed polywrap, barcode labels, promotional, shrink sleeves, and the recent addition of digital printing and folding cartons.

National sales manager at Labelmakers, Domonic Calderan, says every brand owner is looking for their version of a ‘Share a Coke’ style campaign, where the brand can engage with as many consumers as possible.

“These days a lot of on-pack promotions relate back to social media or online platforms, and in most cases additional promo packaging is not required. All new packaging needs to focus on customer experience and then work back toward how your technology or new investments can achieve that format,” he said.

“Single serve packaging is steadily

Viking 1020 Conveyor Belted Vacuum Packer Viking Food Solutions has recently introduced the Viking 1020 Conveyor Belted Vacuum Packer for sale in the Australian market.

This specialised unit incorporates four seal bars of 840mm, with automatic conveyor belting for an incredibly efficient packaging operation.

The unit operates with an automatic lid, and is equipped with Viking’s intelligent interface. This allows operators to adjust all parameters on the equipment for fine-tuned control over the final packaged product. This communicates with your computer to allow adjustments to up to 20 programs and 90 different packaging labels, which can then be downloaded via USB and imported into the machine.

The new 1020 model continues the smart, hygiene-oriented design seen in the rest of the Viking range, and a hefty 302m 3/h Busch vacuum pump. It also has quick-release mechanisms for the conveyor belts allowing easy HACCP compliance. Lastly, it includes a simple service program for easy maintenance.

Viking Food Solutions 1300 88 99 51 www.vikingfoodsolutions.com.au

increasing, so it’s important that packaging suppliers are able to react quickly to customer demands and support this change in consumer spending.

“Environmental sustainability is another key focus for the packaging industry and it’s our intent to design all our products with the aim to be processed and captured through the waste and recycling streams.

“Looking ahead, some of the key industry challenges revolve around how the market is shaping with the consolidation of large companies and the investment in global brands. After cost, innovation and security (anti-counterfeiting) will become the key drivers in global branding.

“The increase in digital platforms will continue to grow to facilitate global branding through online/social media

campaigns. The two major retailers will have more control over branding, cost and placement, continuing to put pressure on supply chain costs.

“Added to that, the growth around private label will continue to rise aggressively, and food companies and retailers will both be seeking innovation and speed to market.

“Then there is the next generation of packaging which will continue to emerge, such as liner-less construction and directly printed primary packaging.”

Pact Group 03 8825 4100 www.pactgroup.com.au Labelmakers 03 9303 3300 www.labelmakers.com.au

Produce your own nitrogen right from the word go with the modular system from BOGE. Choose from a wide range of output and purity.

The BOGE ISO class ‘O’ oil free converter for use with any brand of oil injected screw or integrated in the BOGE Bluekat compressor.

For your nearest distributor please call (03) 5940 3266 www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 13

FD0215_014

- 14

2015-02-04T09:12:50+11:00

SAFETY

Catering for a niche market

At Temptation Bakeries, continuous improvement isn’t just an industry catch phrase – it’s absolutely vital, Food magazine reports.

T

emptation Bakeries started as a small regional bakery on Victoria’s Mornington Peninsula, but 21 years on the bakery has recently completed construction of its $2.5 million manufacturing plant in Melbourne.

Niche markets “As demand has grown, so has the need to increase productivity, along with having to regularly come up with new products,” says Michael Ratcliff, CEO, Temptation Bakeries.

“Things really started to ramp up and we had to keep pace. We knew we had to innovate if we were to be taken seriously for large contracts, but we had the willingness and creativity to think outside the square and come up with our own niche markets.”

Ratcliff says the up-front challenge was to be able to deliver a marked point of difference and maintain that, while the ongoing challenge has been to stay competitive in a country with high costs and low margins.

“We have actually capitalised on the advantages of being small and having the flexibility to bring together timely innova-

tion, technology and business operations aimed at keeping costs down, while at the same time being able to deliver on rapidly shifting market demands,” he says.

Finding and keeping business for Temptation means constant quality improvement, introducing new products to keep up with the changing demands of supply chain consumers. But that, says Ratcilff, is the advantage in being able to make short production runs profitable.

“Our company’s competitive advantage leverages off the combination of innovative and sustained new product development and a flexible manufacturing culture that expects and welcomes change.

“Running in tandem with all this, is the need to up the ante on our research and development to enable us to convert great ideas into manufacturing reality.

This can require considerable investment of time and money.”

“It is a challenge,” says Ratcliff, “with

14 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

the constant need to introduce new lines, but it helps ensure we stay at the top of our game.

“So continuous improvement isn’t just an industry catch phrase – it’s absolutely vital for us and for that matter, any business deadly serious about what they’re doing”.

Quality assurance has also been integral to their planning and development which has helped grow opportunities for their branded and house branded products and has been at the forefront of the company’s latest expansion.

Plant upgrade Last financial year, Temptation Bakeries produced around 32 million individual products. With the completion of its new $2.5 million plant and expansion of its technological capabilities, the company is aiming to double its output within 3-5 years.

“We now have the capabilities of a

complete, high efficiency, test kitchen-toconsumer-ready production line,” Ratcliff explains.

The blueprint included segregated zones aimed at meeting the most stringent quality control standards for manufacture and hygiene.

Separate areas for preparation and post baking are designed for the premium care of products prior to wrapping and packing to ensure sustained quality and freshness. The facilities also accommodate increased storage of finished goods.

Overall, it means significant efficiencies in the production, packaging, storage and dispatch all on the one site.

The company employs around 100 people and Ratcliff hopes to be able to recruit more as they progress.

Temptation Bakeries www.temptation.com.au 03 9773 4800

FD0215_000_HEA

-

1

2015-01-14T10:15:50+11:00

# 364

Design & Engineering | Manufacturing | Installation & Commissioning Service & Spare Parts | Operator Training

complete processing + packaging systems our brands

seasoning + coating

conveying + seasoning

our partners

weighing + inspection + packaging

food grade steel belt

metal detection

sorting + inspection

size reduction

chocolate enrobing

progress through innovation since 1950 info@heatandcontrol.com | heatandcontrol.com

Food Processing & Packaging Systems

FD0215_000_EXH1

14847 AUSPACK ADVERT 235x297.indd 1

-

1

2015-01-27T11:47:53+11:00

22/01/2015 11:07 am

FD0215_017

PACKAGING

- 17

2015-02-04T08:58:47+11:00

PROUDLY SPONSORED BY

+ PROCESSING

30TH ANNIVERSARY

OWNED AND PRESENTED BY THE APPMA

AUSPACK 2015 24th - 27th of March 2015, 9:00 am to 5:00pm

Melbourne Convention & Exhibition Centre AUSPACK 2015 is Australia’s premier international exhibition of packaging and processing machinery, material and associated technology.

This year’s show is set to be largest to date in both size and number of exhibitors, with an expansive line-up of multinational companies exhibiting.

It’s a must-attend event for anyone in the food and beverage manufacturing industry.

AUSPACK exhibitors represent the entire spectrum of the industry – from packaging, processing and filling machinery through to packaging materials, product identification solutions, materials handling and ancillary components.

Last year, the exhibition showcased over 308 exhibitors, including 112 international exhibitors from 18 countries in 2013. This is a true indication of the importance of AUSPACK on the industry calendar.

This year, AUSPACK has an expansive line up of multinational companies set to exhibit.

“Companies like Premier Tech Chronos, BEUMER Group, Biotec Solutions Australia and Mettler Toledo will be showcasing their latest solutions with many of the multinationals running moving packaging machinery and equipment on their stands,” says Luke Kasprzak, portfolio director – Industrial Division, Exhibition and Trade Fairs.

Three decades ago several local machinery manufacturers established an association known as the Australian Packaging Machinery Association (APMA) to run their own exhibition as they believed the packaging industry needed a specialised trade exhibition for packaging and processing machinery.

Malcolm Miller of National Packaging was the original visionary and invited Bob Brook of Bud Pak,

Bill Juknitis of Advance Machinery,

David Tierney of Heat and Control

Packaging and Processing week will form the umbrella over a series of events including: • • • • • •

AUSPACK 2015 30th Anniversary Networking Event APPMA Industry Awards National Technical Forums APPMA Scholarship Master classes

and Barton Porter of Inteco Australia, to work together to develop an exhibition worthy for the Australian and New Zealand market. Thus AUSPACK was born.

AUSPACK 2015 will see a range of concurrent events held throughout the duration of the show creating an enhanced exhibition extending past the show floor. These events will make up Packaging and Processing Week 2015 Ingo Jonas, Managing Director, Premier Tech Chronos (PTC), said exhibiting at AUSPACK assists their brand awareness and growth potential in the Oceania market.

“Premier Tech Chronos believes that AUSPACK is the only interesting and innovative packaging trade show in Oceania. We are looking forward to showcasing our entire portfolio at AUSPACK, including our new vertical form fill and seal systems (VFFS) and new hygienic open mouth bagging machine in an interactive way.” Jonas said.

With such an expansive line-up of exhibitors and working equipment being showcased on the stands attending AUSPACK on the 24th to the 27th of March 2015 at the Melbourne Convention & Exhibition Centre is a must.

For more information visit www.

AUSPACK.com.au

www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 17

FD0215_018

PACKAGING

- 18

2015-02-04T09:00:29+11:00

PROUDLY SPONSORED BY

+ PROCESSING

30TH ANNIVERSARY

OWNED AND PRESENTED BY THE APPMA

APPMA AUSPACK is owned and presented by the Australian Packaging and Processing Machinery Association (APPMA), Australia’s only national packaging and processing machinery organisation.

Operated for the industry, AUSPACK truly is the premier biennial packaging and processing machinery and materials exhibition in Australasia.

AUSPACK will see those in the industry recognised at the biennial 2015 APPMA Industry Excellence Awards on 25 March at the Crown Complex, Melbourne. Companies will be acknowledged for their contribution and outstanding achievements against their peers within the wider packaging industry.

Award categories include:

Export Achievement Award The recipient of the Export Achievement Award will have made a

worthwhile contribution to an existing or new export market. Contributions can include establishing a new market, achieving a significant increase in sales by both the supplier and the customer, identifiable by monetary gain from an export activity. It can also be any developed packaging or processing machinery sold into overseas markets which contributes to improved business outcome, efficiency, sales and profit increases.

Design Achievement Award The Design Achievement Award will recognise the development of a packaging or processing line or module that results in the significant advancement of packaging and processing machinery technology by either introducing a new idea or modifying an existing principle.

The design concept and implementation are weighted highly in the award decision, where better business performance must be achieved.

Customer Partnership Award The Customer Partnership Award has a major emphasis on the customisation of packaging and processing machinery to suit a customer’s individual needs. The winner, individual or team will be able to demonstrate that the end user has experienced increased sales, increased

OW M NLE A R OG AB PR AVAIL

plant efficiency and profitability. Customer improved ge outcomes will form a very large n. element of the Award decision.

Imported Equipment Award The Imported Equipment Award is designed to recognise the efforts of a company who promotes their overseas principal’s equipment in the Australian market, where the equipment in itself represents a high standard of excellence in every respect relevant to the industry consistent with the standard applied.

Best New Product Award The Best New Product Award is designed to recognise the most innovative product or equipment in the packaging and processing industry that is launched in Australia for the first time during AUSPACK 2015.Criteria for Best New Product includes: the equipment or product must have proven efficiency and productivity gains, be innovative and have proven and improved cost of ownership.

APPMA Scholarship For the seventh year, the APPMA and AIP will award one packaging engineer the opportunity to complete a Diploma in Packaging Technology to the value

of $$9000. The Diploma in Packaging Technology is an internationally recognised qualification for those wishing to pursue a career in the packaging industry, or for those who are already in the industry and who wish to extend their knowledge and expertise. The Diploma in Packaging Technology is a Level 5 qualification that prepares students to take responsibility for packaging operations at any level through the supply chain and can also lead to higher level study.

The 2015 National Technical Forums The 2015 National Technical Forums will deliver a four day educational program. Eight internationals and 38 speakers will cover an extensive range of topics relating to the theme Open Innovation & Collaboration.

The National Technical Forums will be held in breakout sessions, to ensure that a diverse range of issues and topics are covered. All of the industry is invited to attend the forums.

APPMA stand: 255 AIP stand: 116

PACKAGING & PROCESSING WEEK PROUDLY OWNED AND PRESENTED BY

2015 NATIONAL TECHNICAL FORUMS OPEN INNOVATION & COLLABORATION 24th to 27th March

in conjunction with AUSPACK 2015, Melbourne Convention & Exhibition Centre Following a number of highly successful National Technical Forums over the last six AUSPACK exhibitions, the 2015 National Technical Forum will be designed to deliver a four-day educational program that will cover a broad range of topics relating to the theme Open Innovation & Collaboration. Register to attend today!

PROUDLY SPONSORED BY

info@aipack.com.au 18 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

aipack.com.au

EEK SSING W PROCE ESENTED BY PR GING & PACKA DLY OWNED AND PROU

FD0215_019

PACKAGING

- 19

2015-02-04T09:01:44+11:00

PROUDLY SPONSORED BY

+ PROCESSING

30TH ANNIVERSARY

OWNED AND PRESENTED BY THE APPMA

Inspection systems Choosing an inspection system that assists in complying with government regulation and minimises risk through the detection and removal of contaminants can be a difficult decision.

Inspection systems cover a wide range of industries that rely on the detection of harmful contaminant materials in food processing and packaging lines, from x-ray inspection, checkweighers, optical sorting equipment and metal detection systems. Heat and Control is your one-stop source for CEIA metal detectors, Ishida checkweighers, and Ishida X-ray systems, plus demonstrations, service, parts and training.

As a leading manufacturer and supplier of food processing and packaging equipment, we have the experience and resources to provide a single machine or combination system with conveyors and rejecters designed for your operations.

Inspection and intervention require the most sensitive, reliable equipment available. You can rely on the latest inspection technology from Ishida and CEIA, backed by ongoing technical support from Heat and Control.

For food and pharmaceutical products, CEIA THS 21 metal detectors continuously self-calibrate

OWNED AND PRESENTED BY

ORGANISED BY

to maintain peak detection stability and sensitivity to all metal contaminants. Auto-learn set-up is surprisingly simple and eliminates errors.

Bluetooth connectivity facilitates programming and trouble-shooting using a laptop computer.

Ishida X-ray systems combine the capabilities of a checkweigher and metal detector with the ability to detect ultra-small non-metallic contaminants, such as bone, glass, shell and plastic. They can also verify weight and missing or defective product. Ishida offers X-ray superior inspection for every application and budget, from entry-level, to IP69K wash-down, to systems for large cartons.

Ishida Checkweighers promote quality control and customer satisfaction with accurate verification of package weight or product count, or detection of missing components.

Available for dry, wash-down and multi-lane applications, Ishida checkweighers are compact and easy to clean. Combine them with a CEIA metal detector for multi-purpose inspection that saves floor space.

Heat and Control info@heatandcontrol.com www.heatandcontrol.com Stand: 364

AUSPACK. The natural home for food processing and packaging machinery.

REGISTER NOW AT AUSPACK.COM.AU

www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 19

FD0215_020

PACKAGING

- 20

2015-02-04T09:05:42+11:00

PROUDLY SPONSORED BY

+ PROCESSING

30TH ANNIVERSARY

OWNED AND PRESENTED BY THE APPMA

Foster Packaging Foster Packaging has a specialised division dedicated to the production of mock up pouches. Mock up pouches allow clients to have a physical version of what their packaging would look and feel like, making it easier to pitch their product to prospective customers and distributors. Mock up packaging can also have the product itself packaged inside, which can demonstrate how the final product will look on the shelves.

Mock up packaging also allows clients to test out new designs or a different style of pack-

aging without having to do a full run of flexible packaging with all of the set-up costs. It is a quick and easy way to test the market with a new design, or see if a new size of packaging fits your product. It also allows new businesses to get their product on the market and judge its reception before investing in large, full production runs.

Foster Packaging joe@fosterpackaging.com.au www.fosterpackaging.com.au Stand: 417

Beef jerky mock up pouch

Vegetable shredder

The FAM vegetable shredder 'CENTRIS'

Summit Machinery will be exhibiting a range of processing machinery at the upcoming Auspack expo.

Machinery on hand will cover the vegetable, cheese and meat industries including: cheese dicer/shredder, vegetable shredder, carrot peeler, baton cutter, meat dicer and dewatering centrifuge.

The experienced sales staff will have information and videos on hand to cover an extensive range of processing options

including peeling, washing, drying, cutting, dicing, slicing, grating, grading, inspection and materials handling.

Summit machinery also represents the following companies in Australia and New Zealand: FAM cutting machinery, Belgium; STUMABO industrial knives, Belgium; TENRIT processing machinery, Germany; DOFRA processing machinery, Holland.

Whatever your processing room machinery needs may be, with more than 30 years’

experience in food processing machinery, it is likely we have a solution to fit.

Trials are possible during or after the expo, please call our office to pre-arrange or to discuss any other needs.

More formal or lengthy discussions and meetings are also possible during the expo by arrangement.

Summit Machinery sales@summitms.com.au www.summitms.com.au Stand: 530

Come and meet us at AUSPACK 2015 Booth 518

20 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

FD0215_021

PACKAGING

- 21

2015-02-04T09:07:25+11:00

PROUDLY SPONSORED BY

+ PROCESSING

30TH ANNIVERSARY

OWNED AND PRESENTED BY THE APPMA

Hygienic buttons

Sanitary transfer pumps Graco has announced a new addition to its SaniForce line of FDAcompliant sanitary transfer pumps for product evacuation out of drums and bins.

Featuring a lightweight, durable construction, the new SaniForce 2:1 piston pump is portable in design, and weighs 10.8kg for the standard drum length, and 11.7kg for the extended length. The piston pump fits through a standard bung hole and can be easily mounted utilising the included FDA-compliant bung adaptor.

The new SaniForce 2:1 sanitary transfer piston pumps are capable of transferring low to medium viscosity materials (up to 50,000 cps) from

drums and bins, including personal care products such as lotions and creams, and food products including syrups, oils and sauces. The SaniForce 2:1 can reach a fluid pressure of 17 bar with continuous duty flow rates from 5.7 lpm at 60 cpm, up to 9.5 lpm at 100 cpm.

Graco’s complete SaniForce line includes diaphragm pumps, piston transfer pumps, drum unloaders and bin evacuation systems capable of moving a broad range of items with differing viscosities such as juice (or materials less than 5,000 cps) to peanut butter (or materials up to one million cps). All SaniForce models are FDA-compliant.

SaniForce 2:1 piston pump Graco 1300 027 933 www.graco.com/us/en.html

Metal detection system Mettler Toledo is the world’s leading supplier of in-line checkweighing, metal detection and x-ray inspection solutions.

Experience gained over many years in a range of industries, including food and pharmaceutical, enables Mettler Toledo to fulfil your specific requirements and ensure your competitive advantage.

Auspack 2015 provides Mettler Toledo the opportunity to demonstrate how our integrated product inspection solutions can address the challenges faced in todays food, pharmaceutical and manufacturing environment. Through an interactive production line, Mettler Toledo will demonstrate how our equipment safeguards the quality, safety and integrity of products out inside and out.

Mettler To Toledo will be showcasing packaging and equipm filling equipment, dynamic quantity and quality control systems and pproduct safety and compliance solutions.

Schmersal’s N-Series range of products has been designed and tested specifically for the food industry and other hygiene sensitive environments. The product range consists of a large portfolio of command and signalling devices including emergency stop mushroom buttons, push buttons, illuminated push buttons and pilot lights, selector switches, main switches and more.

Constructed using the “hygienic design” principle, there are no corners or edges, which prevents contamination and allows the device to be cleaned and maintained easily.

UV and ozone resistant, The N-series is also resistant to cleaning agents typically used in the food processing industry. Special seals extensively prevent the penetration of product residue in the gaps between the fixed and moving parts, effectively preventing the formation of bacteria that are hard to reach for cleaning.

This range includes the NDTP30 and the NDLP30 and features the extremely hygienic mushroom shape push button technology. These buttons boast an ergonomically improved shape as well as the cost effective 3-colour LED module. With a single standard command unit (ELDE.N), three different signals or commands can now be displayed at the button head.

These products are distributed by Control Logic.

Control Logic sales@control-logic.com.au www.control-logic.com.au Stand: 471

Mettler Toledo 1300 659 761 www.mt.com/a www.mt.com/au-auspack Stand: 436

A Metler Toledo Safeline Profile Advantage metal detection system.

N-Series Hygienic (IP69K) Operator Devices by Schmersal

ELIMINATE METALLIC FOREIGN MATTER FORCE 10: SPECIALIST MAGNETS FOR THE FOOD AND DAIRY INDUSTRY TARGETING: > > > > > >

Work hardened 300 Series Stainless Steel fines 400 Series Stainless Steel Contamination that evades metal detection and xray Contamination from rotary valves, augers, screws, sifter screens, blowers, fans, ingredients etc Reduced metal detector trips Eliminate recalls

AUSPACK 2015 l see us on stand #710 | www.aurora-nz.com

www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 21

FD0215_022

PACKAGING

- 22

2015-02-04T09:09:04+11:00

PROUDLY SPONSORED BY

+ PROCESSING

30TH ANNIVERSARY

OWNED AND PRESENTED BY THE APPMA

Packaging solutions

High speed bagger Integrated packaging and processing solutions provider, tna, will highlight its flagship high performance packaging and distribution systems at AUSPACK. Visitors to the stand can learn about the tna robag FX 3ci high speed bagger. tna’s global team will demonstrate how its automation and controls capabilities can help manufacturers maximise performance.

Delivering throughput of up to 250 bpm, the tna robag FX 3ci high speed vertical form fill and seal (VFFS) packaging machine offers production flexibility in a compact and easy-to-clean system. This system provides up to a 30 per cent improvement in performance in terms of output and reduction in rejects.

With innovative features including

the patented tna hyperdetect metal detector, tna intelli-read bar code verification scanning system and the tna intelli-scan visual print code verification system, the tna robag FX 3ci provides manufacturers with a complete packaging solution. In addition, tna has made it even easier to operate the machine by simplifying the film system. tna michael.lea@ tnasolutions.com www.tnasolutions.com Stand: 154

Toyo Jidoki pouch machine At Auspack, Walls Machinery will display machines from world-leading manufacturers, including Toyo Jidoki, Adaptapack, Anritsu, Fuji and Norden.

Toyo Jidoki are industry leaders with their wide range of high quality pouch filling and sealing R equipment. Toyo Jidoki’s TT-8CR will be showcased, which offers a packaging solution for a variety off products and pouch types.

Walls Machinery are proud to also be showcasing ‘Australian Made’ automated packaging solutions from Adapatapack. A range of new robotic

i ill be b on display, di l equipment will including the Shelf Ready Case Packer and Single Picking Unit.

Anritsu are world leaders in Inspection Equipment, offering quality equipment to the food and

pharmaceutical industries for over 100 years. Walls Machinery will be showcasing Anritsu’s X-ray Inspection, Metal Detector and Checkweigher.

Fuji are industry leaders in Flow Wrapping equipment, with machinery versatile to handle a wide variety of applications. The Alpha VII will be showcased on the stand, which is designed to improve productivity and reduce running costs.

PerForm Packaging Solutions specialises in the supply of a range of packaging equipment typical for end of line applications in many FMCG and industrial markets such as food, beverage and household products.

Some of PerForm Packaging Solutions’ partners include Meypack, Kliklok and Senzani. Representatives from Meypack and Kliklok will be at AUSPACK. Meypack specialises in the manufacture of sophisticated, efficient, reliable and individual end-packaging machines. Their machines are operating successfully in a large number of companies within Australia and around the world. Meypack machines are manufactured in Germany, with maintenance and service programs that Meypack carries out with its own personnel, but also with personnel from its partners.

Kliklok International has an extensive range of durable and efficient equipment that includes top load and end load cartoning, automatic product handling, wraparound sleeving, and end of line machinery.

In addition, they also offer the Woodman range of bagmakers, plus trolley loading equipment, and display card loaders.

Kliklok recently launched their new Certiwrap Elite wrap around sleever.

PerForm Packaging Solutions chrisb@performps.com.au www.performps.com.au Stand: 628

Walls Machinery 1800 500 436 www.wallsmachinery.com.au Stand: 334

Pneumatic line magnetic separator Aurora provides the FORCE10 range of highperformance magnetic separation systems to a large range of industries with niche capability in the food and diary sectors.

The FORCE10 team of specialist magnet technicians are renown in the industry for their uncompromising commitment to high quality and performance along with their extensive technical knowledge in this field. The team works with a range of global food and dairy brands to ensure the FORCE10 magnets are the highest performing, versatile, practical, and safe separators available

22 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

on the market. We have proven results in both wet and dry product applications across a range of industries in many countries ranging from New Zealand, Australia, Japan, Indonesia, China, Brazil and beyond.

The Force10 range includes separators for products ranging from powder, granular, liquid, viscous, and fragile across a range of process conditions including pneumatic transfer, gravity, high-pressure, high-temperature, high volume/bulk and ultra-hygienic.

Our team provides close support from initial

scoping and design through to project management, commissioning and on-going validation/ certification services.

We are proud to have HACCP International endorsement of several FORCE10 products and our magnet validation service.

Aurora 047 847 5315 www.aurora-nz.com Stand: 710

MA1014_000_KAE

-

1

2014-09-08T14:21:53+10:00

When only high quality clean compressed air will do

Producing clean compressed air is vital for many processes where the risk of oil contamination within the compressed air system is unthinkable.

For such demanding applications KAESER presents a powerful range of dry-running two-stage rotary screw compressors. These models not only deliver high quality and 100% oil free compressed air, but thanks to the inclusion of a tried and tested dryrunning, two-stage rotary screw airend, they also provide optimum performance and maximum efficiency - even under the toughest of conditions. And, when it comes to the life-cycle costs of these models, you will be pleasantly surprised by just how inexpensive maintenance and consumables are with KAESER. Available water- or air- cooled with drive powers up to 355 kW and free air delivery up to 51 m3/min, when only high quality clean compressed air will do think KAESER. Discover your dry-running rotary screw compressor solution today!

www.kaeser.com.au Kaeser OF Ad_Mfr Monthly Oct 14.indd 1

08/09/2014 01:20:36 PM

FD0215_024

- 24

2015-02-04T09:17:09+11:00

BEVERAGE

Beverages industry: training can b Training your staff can be the difference between a disastrous product recall and a thriving manufacturing plant, Jasmine O’Donoghue reports.

G

iven the present economic environment, it’s not unheard of for training to fall to the wayside, but the Australian Beverages Council is keeping it on the agenda and addressing areas for improvement in the industry with their training events. Food Magazine spoke with Colin Felder, Technical & Regulatory Manager at the Australian Beverages Council, to find out more.

There’s no denying that technology moves fast and it will continue to do so. Keeping your eye “on the ball” through ongoing training can be both a preventative tactic, and aid in innovation.

“If you take your eye off the ball, technology will either catch up with you or there’ll be something which pops through the system, which may lead to a recall,” Felder says.

In previous years, the Council identified a need for a training course which covered the beverage supply chain and introduced the integrated regulatory, quality and safety programs of the beverage industry in Australia, New Zealand and beyond.

“Unfortunately the way the education system and the courses that are being offered at the moment, often you’re not getting a good commercial background, you’re just coming out with specialists.”

Felder found a lot of the attendees for the 2014 Manufacturing Beverages One course were plant operators, or

CASE STUDY:

A look inside Asahi Beverages Alison Goss, Head of Culture & Capability, Asahi Beverages

A

s Head of Culture & Capability, Alison leads a team of specialists whose primary role is to establish frameworks and partnerships which enhance the way Asahi develops its team members.

In addition, there are a team of site-based training coordinators who work in conjunction with local sites to manage day-to-day logistics.

Why is training important for a beverage manufacturer?

In our industry the skills of our people are a key competitive advantage – it is with this philosophy that we commit significant resources to the development of our people. It is only through having a team of skilled and engaged people that we continue to create great products, in a competitive market.

What training do Asahi employees receive?

Asahi Beverages commits a significant investment 24 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

to developing our people. We leverage a blend of development options: formal training, through to on-thejob coaching, and whilst much of the training is delivered using our internal team, we additionally partner with external groups for specialist topics. Apart from during our peak season, when production is at its highest levels, you could find development of some variety happening during any given week across our business.

management and leadership skills. Training may be targeted to either current roles, or for future development.

How is this training delivered and why?

Our approach to training delivery is to select the method best suited to the group and the topic. This will involve one-to-one coaching, small group training, online, and self-paced content.

How does this training benefit the business?

Investing in the skills and capability of our people contributes to achieving our strategic goals in a variety of ways. Engaging a team who are skilled and capable drives efficiency in our operations. Development is a key driver of retention, and minimising turnover contributes towards minimising our operational costs.

Our ability to develop talent from within our business contributes to building our reputation, which attracts and retains people over the long term to ensure we have

What topics or areas does training typically cover?

Given the complexity of our operations, training and development covers a variety of topics including technical job skills, health & safety, interpersonal skills,

Who receives the training?

Available development offerings are segmented by role, and for training related to developing for future career opportunities is limited dependent on the individual’s interest and potential career progression.

FD0215_025

- 25

2015-02-06T10:20:13+11:00

BEVERAGE

n be a game changer people who’d come out of the packaging industry and didn’t have an understanding of ingredients and the things that go into the total manufacturing of a beverage.

“Then there is newer graduates coming out of things like food science and walking in. They need to know what the actual language of beverages is.”

Felder says sometimes these graduates “don’t understand and sometimes can’t communicate the quality assurance and packaging roles and legislative roles that they need to in order to have a good understanding of the whole industry.”

“To actually be able to take a basic bottled water plant and give them the opportunities to put simple additions to the plant and upgrades gives them a opportunity than just sitting around and playing with different labels, for example.”

Smaller operators Training can especially be a struggle for the smaller operators.

“We’re finding that even the smaller operator, because everything is down at such a small margin you can’t actually afford to have your key plant operators out of the factory for three days, for example, and probably by the

time you have your travel, you’ve probably lost them for a week for three days of training.”

In response to this, the Council is looking at putting together a module system which can be done online for specific needs.

But it doesn’t end with the Australian Beverages Council, with a lot of the larger members of the beverage industry, such as Asahi Beverages, opting for in-house training.

Australian Beverages Council 02 9662 2844 info@australianbeverages.org

Spotting the gaps Although the Australian Beverages Council is currently in the process of reviewing the industry’s areas of need, Felder predicts the big challenges in 2015 will be new ingredients and the shift in bottled water towards lightly sparkling.

“We’re looking at new ingredients, especially with the advent of less sugars and the increasing role of natural sweeteners,” Felder says. “Stevia is obviously a bit part of that.”

Felder says that with the growing bottled water market trending away just from bottled water into lightly sparkling, some smaller operators are needing to adapt.

“We’re teaching them things like the basics of carbonation so they can expand the plant and take extra opportunities there in the market and expand away from their standard still bottled water into the sparkling, which they’re upgrading the plants to do.”

a strong pipeline of talent progressing through the organisation.

How do you identify areas for training?

As both the market and our business evolves, so too does the need for development solutions to evolve in response to these needs. New technology brings with it the need for different skill sets. Changes in the way our organisation operates will often be underpinned by targeted development programs. These changing needs are identified in conjunction with leadership teams as part of our talent review processes.

What industry/market trends do you anticipate that the beverages industry will need to respond to in 2015 that will require further training?

The beverage industry continues to see technology advancements in response to a desire to increase operational efficiency; with this will come the need to continue to develop skills and capability.

Additionally, changing consumer expectations about product preferences sees an ongoing need for people with the skills to develop and manufacture new products. www.asahipremiumbeverages.com

If diversity’s what you’re looking for: the Varioline packaging system from krones. www.krones.com AUSPACK 2015 Melbourne, 24 – 27 March Stand 555

www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 25

CC-en30-AZ032 01-15 indd 1

07 01 15 13:16

FD0215_026

- 26

2015-02-04T08:40:42+11:00

DAIRY

An Australian first:

Saul Sullivan in Udder Delight's white mould room.

MAKING A RAW CHEESE WORK

Raw milk has attracted some unfavourable publicity recently but it hasn’t deterred a master cheesemaker from South Australia, who has unearthed a rare bacteria in the Adelaide Hills and used it to create a unique raw milk cheese. By Jack Baldwin.

T

hree years ago, Saul Sullivan, master cheesemaker of Udder Delights, set out to create an impossibility. He wanted to make a raw milk blue cheese in a country where the regulations strictly forbid it.

“I remember the auditor’s first comment was, ‘what?

Are you nuts?’ I went home to my wife Sheree, she’s a cheesemaker too, and she said it can’t be done. Everybody in the regulating authority said it can’t be done,” Sullivan says.

“Even when we went to our mentors in Europe, who I would consider some of the world’s elite cheese makers, they said the regulations won’t allow you to make it.

“That was like a red flag to a bull. I thought this is just the challenge I need. This is what I’ve been doing this for.”

Sullivan decided to put his own name on the line.

King Saul, as he called it, was to be a reputationmaking product for Udder Delights that holds its umbrella over an entire brand.

King Saul began with Sullivan’s fascination of raw milk cheese. He says that common opinion holds the 26 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

raw cheese coming out of Europe to be generally superior to the pasteurised products made in Australia.

In a strange twist to the regulations, European raw milk cheese can be sold in Australian stores, even though manufacturers here are generally forbidden from making it.

Sullivan travelled across Australia and Europe, looking for scientific answers as to why unpasteurised milk yielded better results in cheese. The consensus was that pasteurisation killed off ‘the flavour’.

“I used to go to the experts in Australia and ask, ‘what are you killing off?’ No one could actually tell me, besides the potentially hazardous bugs that are living in the milk. What it actually is, there are natural flavours that come through in the taste of a raw milk cheese,” Sullivan explains.

“I had to speak to a professor in France about it.

Everyone else was very cagy about why the European raw milk cheese tastes better. The professor told me about a non-pathogenic bacteria called Hafnia alvei that lives in the very cleanest terroirs around the world.”

The prestige of having the only raw blue in Australia has boosted the business' profile.

FD0215_027

- 27

2015-02-04T08:46:17+11:00

DAIRY Extensive micro-testing Hafnia alvei can be found throughout cheese regions such as Bordeaux and Roquefort. Sullivan began his search across the Adelaide Hills farms that Udder Delights sources its milk from, using extensive micro-testing of the soil in an attempt to track down the bacteria.

They found Hafnia alvei occurring naturally in the Mount Torrens region - the very same strain found in Europe.

He explains that it works like a sponge, living in the dirt, the grass, the hay, the fields, the flowers and waters, collecting the naturally occurring flavours of the environment it resides in.

Cows consume all of that, and the Hafnia alvei ends up in the milk. Pasteurisation typically kills it, but in raw milk cheese, the bacteria survive and their ‘sponge’ is wrung out over time. It gradually releases the natural flavours, the terroir, in to the cheese.

“As the cheese is maturing, it keeps breaking down the fats and lipids, the proteins, and it will continue to release these flavours and they will intensify. It’s like a honeybee. You can put a hive around a Eucalyptus Gum or an Orange Blossom and you’ll get that flavour in the honey.”

Having found the secret ingredient, Sullivan set about research and development of how to implement it in to his cheese. The dairy authority had granted him a one-off permit to research raw milk blue, but the regulations aren’t conducive to making such a product.

“You need less than 39 percent moisture. You need your pH to be below five. It has to have 90 days maturing at above 10 degrees. These are all things that a blue vein cheese does not like.”

Cheese safety Over two and a half years, Sullivan worked on developing methods to create King Saul in line with the regulations. He had laboratories poring over Hafnia alvei and testing the safety of his cheese.

“The laboratories were saying to me, ‘man, you want to patent this stuff,’ but I can’t - it exists naturally. You can’t trademark a region.

You can’t trademark Hafnia alvei. All you can

trademark is the way that you use or adapt it.

“Our intellectual property is specific to the dairy industry. We know how it works and responds with milk and feed, and I believe there are areas regarding the bacteria that we stumbled across that would take people years and years to work out.”

He is fairly confident their techniques will not be replicated - or at least the cheese can’t be.

Working to the limitations of the Food Standards regulations, the final product has taken on a fairly unique character.

After two and a half years of research, King Saul was complete.

Sullivan describes his Edison moment - ten thousand tries before he finally nailed it. One day, he put the cheese trier in a King Saul wheel and had a taste.

A trusted partner in quality for 60 years

DTS Facta can provide analysis, consulting and training support to assist with allergen risk management across Asia Pacific.

Microbiology | Chemistry | Food Forensics | Allergens GMO | Milk Analytical Services | Customer Risk Mitigation Services | Indoor Air Quality | Water Quality

Our laboratories use internationally accepted methods to determine the presence of allergens and has the broadest range of accredited analysis in Australia and New Zealand.

Let DTS Food Laboratories provide support for your allergen risk management program.

Why not make DTS your trusted partner in quality?

NATA accredited since 1961, DTS is passionate about understanding the needs and requirements of its clients and their markets. We work by forming partnerships to become an integral part of our client’s business and supply chain through the provision of a comprehensive range of analytical and assurance services.

Contact: E: sales@dtsfoodlabs.com.au W: dtsfoodlabs.com.au Sales Office: Melbourne, Sydney, Brisbane Labs: Melbourne, Brisbane

www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 27

FD0215_027

- 28

2015-02-04T08:42:42+11:00

DAIRY

Raw milk and cheese regulations in Australia

R

egulations on raw milk production and sales are governed by Food Standards Australia New Zealand (FSANZ). The regulations are strict but fairly fluid and proposals for change can be submitted to the FSANZ board.

• The last core set of rules was introduced in March 2012, which allowed for the production and sale of non-pasteurised hard to very hard cooked curd cheeses.

• Cheeses and curds must be heated to a minimum temperature of 48°C, stored for a minimum of 120 days and contain a minimum moisture content of 39 percent.

• The latest proposal is currently undergoing assessment and could pass this year, subject to approval from the Federal Government. It would allow for more raw milk products to be produced and sold if they meet the right conditions.

• Raw milk for cheese must be sourced from healthy, non-diseased cows.

• Potable water must be used for processes related to the cows, including washing the cows themselves and milking equipment.

• Milk must be cooled to a maximum temperature of 6°C within two hours of milking.

• While being transported, the milk must be kept separate from non-raw milk and under 8°C. • Cheese cannot be made from raw milk that was milked more than 24 hours from the start of processing.

• Before processing, all milk must be tested for contamination. Microtesting for salmonella, campylobacter and staphylococcal amongst others must be undertaken.

Raw cow’s milk for drinking is forbidden from sale and consumption in Australia.

There are loopholes – it can be sold as Bath Milk for ‘cosmetic use’, with warnings against consumption, however this is controversial after it was recently linked to the death of a three year old. Victoria has introduced a new regulation requiring a gag-inducing chemical too be be mixed in i with all raw milk sold in Victoria. Raw goat’s milk for drinking drinki k ng is legal to sell in ffour o r states of Australia. ou

“It blew my mind. I knew we had something phenomenal there. That afternoon I had the phone call with the dairy authority and they said to me, ‘Yes Saul, but you’ve only been given approval to research and develop.

There has been no approval - and we cannot that guarantee that this will ever be able to be sold.’”

On the chance that he did get approval, Sullivan had to prepare for the launch. If the micro-testing came through with a good result and the authority approved it, the release had to happen straight away. The labels had been hand illustrated in France, the boxes for the product were all handmade.

There are less than a handful of raw milk cheeses made and approved for sale in Australia. The others are all hard-pressed cheeses - there’s no living bacteria or mould in them, which is the main reason there had been no legal raw blue cheese in Australia. If Sullivan got his approval, it would not only be the first raw blue vein cheese made in Australia, but the first living raw milk cheese.

“We were waiting on the final approval from the

Labelling at Udder Delights.

28 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

FD0215_029

- 29

2015-02-04T08:43:39+11:00

DAIRY

Dairy Authority, from the CEO. Sheree and I were out to lunch and an email came through with the letter of approval to release the product for public sale.

“We were so excited. I ordered a bottle of champagne, and because I was so emotionally overwhelmed, I went to the toilets and had a bit of a cry. I try and be a macho man but I was so overwhelmed I had to get up and have a tear in the toilet. I felt like I had just won the lottery.”

Years of experience Despite any anxiety that the regulations caused Sullivan in the development of King Saul, he respects the fact that they exist.

“It really is amazing to see and understand what is in raw milk. I definitely am a very big advocate of pasteurised milk for human consumption. Particularly when playing with raw milk cheese, it really is and should only be left up to extremely experienced individuals.”

Sullivan says that in the end, even passing all of the regulations and microtesting requirements, it was only his title of master cheesemaker and the years of experience behind it that got King Saul over the line.

“There was the bath milk episode recently…one is a completely illegal, unregulated industry; the other is not. It’s

like buying unregulated pharmaceuticals for your children - you just don’t do that.

“I am a big advocate for the manufacturing of raw milk cheese because it can be done safely. But it needs to be done with respect and responsibility. The discerning foodie in Australia is demanding and deserves a better quality cheese.”

Udder Delights released the first run of King Saul in December - 160 of the

Much like Grange did for Penfolds, Udder Delights is betting their reputation will be made on their most premium, small run products.

250 wheels produced in their first batch.

It’s sold as a premium product at $150 for a 500g wheel. According to Sullivan, that barely covers the cost of production and research - he himself was essentially working for free.

“What I will say is this: we’re just packing, packing, packing pallet loads of cheese. King Saul has already had a phenomenal halo effect on the Udder Delights brand. We’re up 100 percent for November and December and we can’t keep up with orders.”

Saul Sullivan and his wife Sheree.

It appears the prestige of having the only raw blue in Australia has boosted the business’ profile beyond the one product - not only have their other cheeses reaped the benefits of trickledown research and development, but the company’s wider reputation has been boosted as well.

“Orders are so much bigger - they’re at least 100 percent above what we had last year. It spiked with the launch of King Saul. I know you get a spike for Christmas - this is like a triple spike. It’s

completely unconventional in the terms of the rhythm of our business.”

Much like Grange did for Penfolds, Udder Delights is betting their reputation will be made on their most premium, small run products.

[This article is reproduced courtesy of The Lead South Australia www.theleadsouthaustralia.com.au] Udder Delights 08 8388 1588 udderdelights.com.au

SUMMIT MATSU PROVIDES RELIABLE COOLING SOLUTIONS FOR FOOD PROCESSING FACILITIES AUSTRALIA WIDE

matsu.com.au | 1300 CHILLERS

SUMMIT MATSU CHILLERS IS AN ESSENTIAL PART OF THE CHOCOLATE COOLING PROCESS AT TUSCANY CHOCOLATES IN MULGRAVE NSW. PROVIDING AUSTRALIAN CONSUMERS WITH TONNES OF CHOCOLATE ANNUALLY. www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 29

FD0215_030

- 30

2015-02-04T09:10:44+11:00

MOTORS & DRIVES Left: The cocoa paste is compressed by a dedicated worm gear unit powered by a helical geared motor.

Below: The raw mixture must be re-ground in a rolling machine. A conveyor belt transports the mixture there.

FROM COCOA TO

chocolate

Uncovering the driving force behind Zotter Schokoladen’s chocolate factory.

T

hose in the business of chocolate manufacturing know of many steps are necessary to make chocolate from cocoa beans. During the process, ingredients and mixtures in various states remain in nearcontinuous motion for hours and days on end, which requires reliable drive systems.

Chocolatier Josef Zotter strives to stand apart and sustainable production is his prime objective.

His factory in Riegersburg in the South of Austria relies on renewable energy and generates most of it from burning in-house waste products. As the only chocolate manufacturer in Europe to exclusively use organic fair trade materials, fair treatment – of both farmers and consumers – is equally important to Zotter.

The Zotter masterminds introduce a wide variety of ingredients every year, currently offering bars and other sweets in 365 different varieties. These range from pineapple, lemon, celery, asparagus, coconut and cheese.

Keeping it classic Regardless of exotic flavours and new creations, classic chocolate remains an indispensable ingredient for a large part of the product range. For years now, chocolate has been produced in-house according to Zotter’s recipes, which is quite unusual for a small manufacturer.

For years now, the facility has been using geared motors from NORD Drivesystems for

conveying, mixing and pumping tasks. Swiss process engineering expert Bühler was responsible for the design and implementation of the chocolate production facility.

Cocoa beans delivered to the factory are cleaned and then roasted for several minutes at temperatures above 100°C, and subsequently sterilized under steam pressure. Conveyor drives with 0.75 kW rated power ensure transportation between the cleaning, roasting, and sterilising stations.

The next step is a crusher, where the cocoa nibs are de-shelled. A grinder then turns the nibs into liquid cocoa paste, which is piped to a mixer. The pumps required for this stage feature 4 kW geared motors.

Above: Helical geared motor

The single-shaft conche reduces the water content which ensures a silky consistency Inside the mixer, sugar and – for some recipes – dried milk is added to the cocoa paste.

On top of that, extra cocoa butter is added from neighbouring tanks which are equipped with several 1.1 kW pump drives.

Mixing the cocoa mass with the other ingredients results in a pourable mass, which is ground in a rolling machine in order to achieve a fine texture. A dedicated worm gear unit powered by a 4 kW helical geared motor then ensures compression.

30 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

Left: Belt drive during conche loading.

Larger bearings Based on the current NORDBLOC.1 design, this drive features an innovative construction: The gears are introduced and mounted through the bearing bores. While the axis-toaxis distance is the same as in conventional

FD0215_031

- 31

2015-02-04T09:11:27+11:00

MOTORS & DRIVES

helical gears, the NORDBLOC.1 design allows for using larger bearings in an overlapping offset configuration.

The shafts are also larger than in other market-standard one-piece systems. Thanks to the larger bearings, the drive systems are considerably stronger and more durable, since wear through radial and axial forces is further minimised.

The larger shaft journals allow for a very flexible implementation of customer specifications, for example regarding shaft diameters or the shape and length of the shaft studs.

Conveyor drives then transport the solidified intermediate product through five rolling machines, where it is gradually refined. Only then does the mixture arrive at the last step of chocolate production.

Developed by Bühler, the single-shaft conche is used to reduce the water content, which ensures a smooth, silky consistency. Bitter compounds are evaporated through sophisticated temperature monitoring while the desired aromas remain.

Depending on the recipe, the chocolate mass is agitated for up to 48 hours at increased temperatures in a liquid state, until a product with the finest glaze and the desired aromatic profile is created.

The agitator arms are moved by a space-saving direct drive. The parallel shaft geared motor used for this purpose provides a rated power of 55 kW. The conched mixture is evacuated via a pump system driven by a helical geared motor.

In chocolate production, machines such as grinders, mixers, and agitators as well as many conveyors and pump lines rely on robust drive technology. Josef Zotter’s factory uses various geared motor types from NORD accomplish a wide range of these tasks.

NORD Drivesystems 03 9394 0500 www.nord.com.au

Ingredients and intermediate products are moved from tanks and from one machine to the next by means of several pump drives; shown left: conche evacuation.

Right: Parallel shaft geared motor driving the conche.

direct-fired fryer A range of fryers available for snacks, prepared foods, meat/poultry foods, batter/breaded products, fried pies and an assortment of other products. key benefits: » High efficiency heat exchanger, serpentine tube design

» Lower installation and operating costs

» Designed to accommodate ease of sanitation and general maintenance

what we offer: » Variety of sizes and belt configurations

AUSPACK

to meet your individual needs

» Heavy-duty construction utilizing the latest in

stand #154

combustion, conveyor and control technology

» A complete line of equipment accessories paul irwin » regional sales manager » tna australia pty ltd » p: +61 (3) 9839 2300 » m: +61 412 366 351 » f: +61 (3) 9839 2399 » info@foodesign.com Stay in touch with tna Follow us @tnasolutions

Search tna solutions

YouTube Channel tnasolutionsmedia

Search tna packaging solutions

www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 31

FD0215_032

- 32

2015-02-04T09:21:37+11:00

FOODSECTION

Australian wine exports rise in volume and value For the first time since the GFC, Australia saw a rise of 1.9 percent in the value of wine exports in 2014, Jasmine O’Donoghue reports.

T

he total Australian wine export volume increased to 700 million litres and total value increased to A$1.82 billion and the average value of exports remained steady at A$2.60 per litre, according to the Wine Export Approval Report December 2014, released by the Australian Grape and Wine Authority (AGWA).

Over the last 12 months, Australian wine was exported to 121 destinations by 1,329 exporters and in contrast to 2013, the majority (893 exporters) recorded volume growth. The increase in volume was aided to some degree by the depreciating Australian dollar but a huge Spanish crush in 2013 put downward pressure on bulk wine prices, which continued to decline by 2 percent to A$0.99 per litre. Bulk wine export volumes increased by 8 percent to 402 million litres.

In contrast, the average value of bottled wine exports grew 7 percent to A$4.85 per litre, the highest it’s been in a decade. This was driven by both demand for Australia’s premium wines (above A$7.50 per litre) in North America, Europe, and much of Asia and a decline in bottled exports under A$5 per litre, with more wine shipped in bulk containers to be bottled in-market.

AGWA’s Acting Chief Executive Andreas Clark said the premium price segments saw the strongest growth throughout the year.

“It’s encouraging to see the value of Australian wine exports in positive growth for the first time since 2007 and increasing demand for our premium wines was a major contributing factor to that growth.

“We’ve seen rises in wine exports in all premium price segments: the A$7.50-$9.99 price segment increased by 5 percent to 15 million litres and by 15 percent in the A$10.00 and above segment to 17 million litres.

“The ultra-premium above A$50 segment grew 55 percent, hitting a record A$107 million.

While the segment only accounts for 0.8 percent of the total volume, it contributes 8 percent of the total value of bottled exports.”

Wine exports in the above A$10 were at A$356 million, just below the record high of A$371 million set in September 2007.

Australian Grape and Wine Authority 02 9361 1263 agwa.net.au 32 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

FD0215_033

- 33

2015-02-04T08:15:03+11:00

ON THE SHELF

1

2

3

4

5

6

1 - Latasha's Kitchen Indonesian Turmeric Kari Paste

2 - Barilla's 'Family Favourites' Pasta Sauce Range

3 - NOSHU Guilt Free Donuts

A nutty, hand blended paste with fresh ingredients, spices and herbs - ideal with chicken, turkey, lamb and seafood. LK Tumeric Kari Paste has multiple uses, and is great as a marinade or for use in Indonesian fried rice.

Manufacturer: Latasha’s Kitchen Shelf Life: 2 years Packaging: Glass Jar 180g Website: www.latashaskitchen.com.au

Barilla's new 'Family Favourites' pasta sauce range introduces three new sauces: Cheese & Tomato Pasta Bake, Red Wine & Garlic and Spaghetti Bolognese, all made from natural ingredients, are gluten free and have no added preservatives.

Manufacturer: Barilla Shelf Life: 18-22 months Packaging: Slim-line 575g jar Website: www.barilla.net.au

NOSHU’s baked, gluten free, no added sugar, naturally sweetened cake donuts are made without grains, seed oils or sugar. The range includes; dark chocolate & raspberry, caramel spice and banana and coconut.

Manufacturer: NOSHU Foods Shelf Life: 28 days Packaging: Individually wrapped 45g, in retail POS box of 12 Website: www.noshu.com.au

4 - Chris' Dips Heritage Range

5 - The Australian Brewery's Chilli Jam

6 - Slow Cow

Chris’ Dips launched a naturally packaged range of Heritage dips sold in handmade European terracotta pots. The premium dip range offers eight flavour combinations such as Smoked Gouda & Almond, Classic Greek Tzatziki and Blue Cheese, Fig & Pistachio.

Manufacturer: Chris’ Dips Packaging: Terracotta Pots 170g Website: www.chrisdips.com.au

Not as sweet as your standard sweet chilli sauce and a little bit hotter, Australian Brewery’s chilli jam is the perfect balance between sugar and spice. The Australian Brewery’s chilli jam compliments any type of meat or salad dish and uses real ingredients for a bolder flavour range.

Manufacturer: The Australian Brewery Shelf Life: 12 months Packaging: Glass jar 375g Website: www.australianbrewery.com.au

Slow Cow is a functional beverage and claims to be the only drink in Australia to deliver a therapeutic dose of L-theanine.

Slow Cow contains no calories, no caffeine, no sugar and no preservatives.

Manufacturer: Boisson Slow Cow Shelf Life: 2 years Packaging: 250mL slim line can Website: www.drinkslowcow.com.au

www.foodmag.com.au | Feb/Mar 2015 | Foodmagazine 33

FD0215_034

- 34

2015-02-06T09:54:26+11:00

LAST WORD

Food processing: Efficiency is key Australian food manufacturers should focus on sustainability and energy performance, Craig Roseman tells Kevin Gomez.

AUSTRALIA is often viewed as a key food supplier to Asia with the ability to sell premium products into these markets.

For that to happen, the country’s food industry needs to get its manufacturing process and automation strategies right, says Craig Roseman, Schneider Electric Australia’s National Segment Manager for Food & Beverage.

What are the biggest technology challenges facing food manufacturers in Australia?

I believe the main challenge of the Australian Food & Beverage industry now more than ever is to produce better, with fewer resources.

One of the foremost reasons is the growing consumer knowledge of production processes. This is increasing the demands they are making for safer, healthier, tastier and more ethical products, which is putting pressure on an already highly regulated industry. Additionally, the method in which you inform consumers about product quality and specifications should be clear.

Honesty is often the best policy in this case. How companies communicate with consumers and regulators is especially important as enforcement of regulations continues to rise. Another challenge facing companies is the need to adapt to new distribution channels created by the digital transformation of society.

Producing better in order to adapt to a fluctuating environment and new regulations enforcement is also a key consideration for manufacturers in this industry.

Producing in a considered and thought-out approach has always been key to reduce the amount of resources necessary for production. The idea that less is more is becoming increasingly important in order to combat the growing power of direct retail and to reach significant market share. Correct allocation of resources allows for energy and capital to be implemented in other areas where it is needed, this is especially important as food and beverage companies face fiercer competition in Australia and internationally.

Using less resources is also key in minimising the environmental footprint of operations, which helps meet consumer and stakeholder’s growing sustainability concerns.

What should Australian food manufacturers be focusing on in terms of process control, automation and energy?

In my opinion the focus should be on: Sustainability and Energy Performance Assessing the use and waste of resources is particularly important. Energy, but also WAGES (water, air, gas, electricity and steam) and products are good examples of this. In a production context, implementing collection systems (automated when necessary) to generate KPIs will allow businesses to view and benchmark poorly performing processes or machines and deploy continuous improvement actions.

34 Foodmagazine | Feb/Mar 2015 | www.foodmag.com.au

Manufacturing Efficiency Implementing Manufacturing Operation Management software to increase the production flexibility while improving the overall performance is another key focus for companies for a number of reasons.

• Financially, improving overall equipment effectiveness to reduce the cost of goods sold and increase capacity utilisation can reduce inventory to improve return on assets.

• Higher customer satisfaction by delivering the brand promise of variety, food safety, quality, delivery time, labelling.

• Improved food safety by documenting that critical control points were correct during production. This adds accountability to the process and includes operator action and the use of materials from raw to end products.

• Compensating for an aging workforce as systems contain embedded expertise to guide new staff in their tasks wherever they perform it.

The benefits of such systems are even higher when they are applied across plants. This gives the management a real-time visibility of the performance and the capability to drive it.

Using more powerful packaging machines also allows more flexibility (packaging change on the fly, modification of lines in a few minutes).

Using completely transparent automation architecture based on Ethernet to increase the capability to manage the production assets in a proper way extends machinery lifetime and aids in predicting potential future failures.

Power Quality Power availability is key for production performance.

However, a Food and Beverage production plant is a living, evolving asset, in order to face the new customer

requirements. These modifications can have an impact on power quality and can cause significant downtime in a plant - this can occur even if power factor correction measures are implemented when designing the facilities.

Bad power quality can also lead to device failure.

Supply Chain Optimisation Supply Chain complexity is also a challenge for Food and Beverage companies. A focus on decision making tools for supply chain optimisation will be key for next year’s performance. These decision making tools must work both on a strategic dimension and operation dimension.

What innovative technologies and products can food manufacturers expect to see over the next year or two?

Mobility and workflows will have a significant impact over the next year. These applications will allow users to interact from any place where cyber security measures are implemented - whether from the machine at the shop floor, the office or from home - with the right level of information and guidance. The workflow will provide embedded expertise to compensate for lost expertise with older staff retirement.

Cloud and Big Data analysis will also contribute strongly to the understanding of the phenomenon occurring in complex manufacturing environments and improve knowledge and efficiency of the process.

Last but not least, the capability to connect smart and communicating devices in the production environment will improve the capability to diagnose issues and increase production flexibility, adapting production systems to specific production batches.

Schneider Electric www.schneider-electric.com

FoodAwards_2015_FP

-

1

2015-01-22T13:59:23+11:00

11th Annual Food Magazine Awards

Call For nominations!

Nominations close 1 April 2015 A total of 16 awards will be up for grabs on the night, highlighting innovation and excellence in the industry.

Submit your entry for the chance to have your success and hard work recognised at a glamorous gala event.

All finalists will be profiled in Food Magazine and on the website. They will also be given two free tickets to the gala dinner where the winners will be announced.

For more information on the awards and to nominate in any of the 16 categories please visit our awards website.

www.foodmagazineawards.com.au Platinum Sponsor

Sponsors

FD0215_000_WIL

-

2

2015-01-27T13:30:08+11:00

Excellence re Excellence re

Excellence re