Food&Drink

MAY 2016

MAY 2016
www.foodanddrinktechnology.com TECHNOLOGY

Health
slick
FOOD & DRINK TECHNOLOGY

The rise of healthier

cooking oils

CODE OF ETHICS UNDER THE SEA CHAIN REACTION

The role of packaging in Recording data in fish and What does the supply chain of
reducing environmental impact seafood production the future look like?
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 Contents May 2016, Volume 15, Number 8

REGULARS New sentencing

6 News & views 10 Business news guidelines page 11
12 Shelf Life 13 Ingredients 14 Processing
15 Packaging 16 Through the keyhole
41 Diary 42 60-second interview

FEATURES
11 New sentencing guidelines
Larger fines are here, warns TIFSIP’s Eoghan Daly

17 Ratty’s reflections
Richard Ratcliffe visited a recent food show, where the innovation on
display gave him hope for the challenge of feeding the world in 2050
Freeze out
19 It’s easy being lean
refrigerant
By implementing Six Sigma techniques, industry can identify areas of
waste and improve supply chain efficiencies, explains Jim Hardisty
gas leaks page 23
20 Chain reaction
Carly Wood speaks to Robert F Byrne about the supply chain of the future

22 Environmentally friendly brewery

Austrian brewery Schwechat has lowered the annual energy cost for its
refrigeration system by €30,000

23 Freeze out refrigerant gas leaks

Shaun Evers explains how the implementation of sophisticated gas
detection equipment can cut down on leaks and the associated costs

24 Production in numbers
Adrian Sunter looks at what can be measured in fish and seafood production

27 Code of ethics
Tetra Pak looks at the role of packaging in reducing environmental impact
A gentle fudge in the
28 A gentle fudge in the right direction
Carly Wood visits Fudge Kitchen to hear more about its humble
beginnings over 30 years ago, from founding MD Sian Holt
right direction page 28
30 Well oiled machine
Innovative enzyme technology increases oil yield and
protein value, explains Wouter Smits

32 Health slick
Emma Woods discusses the rise of and demand for ‘healthier’ cooking oils
and the challenges that manufacturers could face if the trend continues

34 No margarine for errors

Well oiled machine
Anders Mølbak Jensen discusses how best to improve frying performance page 30
CLASSIFIED
37 Classified 38 Suppliersʹ guide

www.foodanddrinktechnology.com May 2016 Food & Drink Technology 3

 COMMENT

Editorial
Everything Advisory Board

comes for free

W
e started a new feature this year
called Food for Thought, which
delves into the Food & Drink
Technology archive to remind us of some
of the news making headlines 10 years ago.
Something that struck me about this
month’s instalment, which you will find on
page seven, is the monumental increase in
sales of free-from foods. Now, we all know
this is a trend sweeping the industry, but
when faced with a 2016 UK sales forecast
of £531 million – compared with the £100
million 2006 estimate that we reported in
the May 2006 issue, it really highlights just
how much of a phenomenon the free-from
market has become. What’s more, Mintel
forecasts the sector to grow further, reaching
£673 million by 2020.
The growth is, of course, attributed to
a variety of factors – including a rise in
innovation (Mintel says that 12 per cent of
new food products launched in the UK in
2015 carried a gluten free claim, up from
seven per cent in 2011, for example), as
well as free-from consumers widening their
repertoires, with around half of those who
eat or buy free-from saying they are likely
to eat more of these foods in the next year.
The health halo surrounding the free-
from sector is a key driver of uptake,
Dr Steven Walker
and even champions the intolerance angle. Director General, Campden BRI
One in four (27 per cent) Brits say they
or someone else in their household avoids
certain ingredients as part of a general
healthy lifestyle, compared to one in five
(19 per cent) who report avoidance due to an
allergy or intolerance. Furthermore, the top
reason free-from users cite for eating such Fiona Kibby
food is because it makes them feel better, for Director, Society of Food Hygiene
example healthier, with two in five (39 per and Technology (SOFHT)
cent) giving this reason.
Indeed, Innova Market Insights identified
‘free-from for all’ in its top ten predictions
for 2016. “Many consumers don’t actually
need products that are free from gluten,
wheat and dairy, but are demanding them
anyway, as they believe them to be healthier,” Jon Poole Chief Executive, Institute
the company said. Although free-from has of Food Science & Technology (IFST)
featured in Innova’s predictions for the last
few years, it says the trend is now entering
the mainstream – and the figures above
certainly support that.
Industry has little choice but to respond;
the free-from boom gives manufacturers
something to work with and it gives not only
those with intolerances more choice, but Professor Lisa Jack Co-ordinator,
Food Fraud Group/Gate to Plate,
also consumers in general – a win-win for University of Portsmouth
free-from.
Carly Wood, Editor

Food&Drink
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www.foodanddrinktechnology.com May 2016 Food & Drink Technology 5

NEWS & VIEWS

FSA suspends
campylobacter
testing
The Food Standards Agen-
cy (FSA) has published an
update on its one-year cam-
pylobacter retail survey
and announced its intention
to suspend sampling.
The way the FSA has con-
ducted the testing for cam-
pylobacter levels has been to
measure the amount of the
bug on the neck skin of the
chicken – this is because this
is generally the most contam-
inated part of the bird.
However, a growing num-
ber of processors are remov-
ing the neck skin before the
birds are put on supermarket
shelves. This is good news
for the consumer because it
reduces the amount of cam-
pylobacter on the bird, but
it’s a problem for analyses.
Given that chicken samples
now contain varying amounts
of neck skin, it makes it
difficult for the FSA to
compare fairly one retailer
with another and to give
accurate comparisons with
previous quarterly results.
The agency has therefore
decided to suspend the sur-
vey for the time being while
it looks again at what sort
of testing might be done
to provide clear informa-
tion on the progress being
made by retailers to tackle
campylobacter.

Non dairy Whole-genome sequencing report

milks market
expands
While dairy alternative
drinks account for a rela-
tively limited 6% share of
total global dairy launches
recorded by Innova Market
Insights in 2015, the market
has seen ongoing penetra-
tion outside its more tradi-
tional Asian market.
This is reflected in the
static launch numbers for
the region over the past five
years, while rising activity in
Europe has taken its global
share up from 30% to 38%.
Soy milks traditionally
dominated the sector and still
featured in over 60% of dairy
alternative drinks launches
globally in 2015, either as a
main or second-
ary ingredient,
although this
has fallen from
nearly three
quarters in
2011. Almond
milks have in-
creased share
to feature in
over 28%
of launches,
ahead of rice,
coconut and
oat milks.
A new report has been published by The report examines how the increasing
speed and decreasing costs of whole-genome
the Food Standards Agency (FSA) on
whole-genome sequencing, the science of sequencing has transformed scientists’ ability
mapping the genetic make-up of micro- to investigate foodborne disease outbreaks,
organisms, and how this new technology providing faster identification and control of
can help the FSA’s work to ensure food is outbreaks.
safe and authentic.
Professor Guy Poppy, chief scientific
adviser, says, “Whole-genome sequenc-
ing is a great example of how the FSA
can use state of the art technology to
ensure that we deliver food we can trust
for UK citizens. It’s fast, precise and, if
implemented widely, cheap.
“The technology is already being
utilised by the FSA and PHE to aid
outbreak investigations; but it has a
multitude of other potential applications
in relation to food.”
Scottish food and drink report welcomed
Scotland’s food secretary The report – Building on Lochhead says, “Scot-
Richard Lochhead has wel- Success: Deepening Col- land’s food and drink
comed the publication of an laboration, Food and Drink industry has enjoyed un-
industry led report setting in Scotland – was commis- precedented economic suc-
out the actions required sioned by the Scottish gov- cess over the past few years,
to enable the country’s ernment last year and sets smashing its own ambitious
food and drink sector to out more than 30 recommen- growth and export targets.
continue to grow and pros- dations for action across key “We must stay ahead of the
per over the coming years. themes. game and one step in front of
our competitors. That is why
I commissioned this report –
to see the actions we need to
take, collectively, to build on
our remarkable success and
make Scotland the best coun-
try in the world to run a food
and drink business.”

6 Food & Drink Technology May 2016 www.foodanddrinktechnology.com


Innovation benefits cheese market
The global retail market
for cheese returned to its
long term growth trend in
2015, rising by an estimated
1% to 11.5 million tonnes,
according to a new report
from Zenith International.
The global market for
cheese is highly fragment-
ed, with the leading five
brands holding a combined
retail share of 8% by volume.
Innovation is rife as manu-
facturers endeavour to cap-
ture share, with new product
Soft drinks packaging
set for growth by 2020
The global soft drinks pack-
aging market is expected to
exceed €26 billion, growing
4% by 2020, according to a
new Technavio report.
The demand for plastic
packaging in the soft drinks
market is growing at a steady
rate compared to other
packaging materials, and is
expected to exceed €10
billion by 2020 with a 4%
growth. PET is increasingly
gaining preference due to its
light weight, low cost and
variable design availability.
The global soft drinks
packaging market by glass
is expected to exceed
€6.7 billion by 2020 – a
slow pace during the fore-
cast period compared to
other types of packaging
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launches spanning a
number of trends, in-
cluding unusual flavour
pairings, products tailor-
ed towards specific con-
sumption occasions and
low fat cheeses.
The 2016 Zenith
Report on Cheese In-
novation identifies 10
key trends and themes
driving new product
development initiatives
since 2014: cooking, dip-
ping, convenience, snacking,
solutions, with the emergence
of other packaging materials
which are considered easier
to carry, distribute, store, and
dispose of.
It is estimated that the glo-
bal soft drinks packaging
market by paperboard will
reach €6.7 billion by 2020,
growing 7%. Corrugated
boxes and containers are the
spreadables, added protein,
indulgence, lactose-free, no
melt and child oriented.
types of paperboard packag-
ing products that are experi-
encing significant growth in
the global market.
Meanwhile, the global soft
drinks packaging market by
metal will reach €3.5 billion
by 2020, growing at 2%; with
the growing trend towards
sustainable packaging, cans
are easily recyclable.
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May 2016
NEWS & VIEWS
FOOD FOR
THOUGHT
We journey back to
the headline hitting
news of 10 years ago...
In the May 2006 issue, indus-
try was celebrating the lift-
ing of the worldwide ban on
British beef exports 10 years
after it was imposed, due to
the high incidence of BSE
cases in the UK at the time.
Allergy specialist Safetoeat
(now defunct) estimated the
free-from market to be worth
around £100 million. Accord-
ing to Mintel, sales of free-
from foods are forecast to
reach £531 million this year.
Baker Perkins, formerly
APV Baker, had just regained
its historical name following
acquisition by private inves-
tors. Today, the company
continues to operate from
its two locations in Peterbor-
ough, UK and Michigan, US.
Vitafoods 2006 was pre-
paring to host 350 exhibitors
and welcome 5000+ attend-
ees. This month, Vitafoods
2016 will host more than 900
exhibitors and welcome in
excess of 16,500 visitors.
Food & Drink Technology 7
NEWS & VIEWS
NEWS IN
BRIEF
Day part dairy
Day part targeting, in which
brands pitch products for
consumption at particular
times of the day, is making
a major impact on the dairy
sector, reports Canadean.
Tanvi Savara, consumer
insight analyst at Ca-
nadean, explains, “Dairy
brands are redefining dairy
consumption occasions by
targeting new day parts to
boost consumer engage-
ment and brand loyalty. The
trend is more mainstream
in yogurt, but there are op-
portunities to expand usage
occasions for milk and
cheese by targeting late
evenings and after dinner.”
NPD boom for
nutrition market
This year is set to herald a
major innovation boom in
the nutraceutical indus-
try, according to a survey
carried out for Vitafoods
Europe 2016.
Researchers questioned
exhibitors and visitors
who attended 2015’s
event about their plans for
launching new products
over the coming 12 months.
Among exhibitors, 92%
said they would launch at
least one new product, with
21% planning to introduce
10 or more and another
19% promising between
five and nine.
Mixed fortune
for white milk
A dwindling consumption of
white milk in the West will
hit North America the hard-
est, says Canadean, with a
loss of two billion litres by
2021 – a negative CAGR
of almost 2%. This is due
to reduced occasions for
drinking white milk and a
global trend for health and
wellness, which is particu-
larly prevalent in the West.
Emerging markets are
expecting an increase in
white milk sales by 2021,
led by the Middle East and
North Africa region, where
the market will expand at a
CAGR of 4.9%.
8 Food & Drink Technology May 2016
According to the 2016 Brit-
vic Soft Drinks Review, the
soft drinks category still
remained a critical one for
the UK grocery channel in
2015, despite an unprece-
dented level of change in the
grocery sector.
At £5.5 billion, the soft
drinks category was largest
across grocery and continued
to be purchased by 100% of
UK households, with over
200 soft drinks being bought
New degree apprenticeship
A Food Science and Tech-
nology Steering Group,
led by the National Skills
Academy for Food & Drink
(NSAFD), has unveiled the
standard for the UK’s first
degree level apprentice-
ship in Food Science and
Technology.
Aluminium recycling rates
The national recycling rate
for all aluminium pack-
aging now stands at 55%
(previously 48%) and the
estimated recycling rate for
aluminium drinks cans is
69% (up from 60%), but the
figures could be even high-
er, indicates the Aluminium
Packaging Recycling Or-
ganisation (Alupro).
According to packaging
Tough
times for
soft drinks
every second. However, with
43% of all soft drinks sold on
deal and underlying volume
growth in the category of
+1.1%, overall value in gro-
cery in 2015 fell by -0.9%.
While at a total soft drinks
level sales were flat, specific
areas of the market were able
to capitalise on evolving con-
sumer trends. Winners were
segments that focused on
health and functionality.
A ‘better me’ mindset was
In a move to address the
UK’s current shortage of
food scientists, the steering
group has spent nine months
working with NSAFD to
develop a level six food
industry technical profes-
sional degree apprenticeship
standard.
Research suggests that
25% of food scientist and
food technologist vacancies
remain unfilled due to a lack
of available talent.
Justine Fosh, chief ex-
ecutive of NSAFD, says
“Currently the only rec-
ognised way to become a
waste recovery data, the
‘business’ recycling rate for
all aluminium packaging ex-
ceeded its 2015 target (49%),
reaching 76,027 tonnes.
However, research con-
ducted to determine how
much is reprocessed or ex-
ported revealed at least
10,000 tonnes of qualifying
used aluminium packag-
ing did not go through the
www.foodanddrinktechnology.com
responsible for the growth in
water (£524 million +11.7%)
and functional water (£167
million +4.2%), and energy
drinks continued to capital-
ise on desire for an increased
level of functionality, with
+4.6% growth. This mind-
set, together with increased
spotlight on sugar, led to the
continued rise of low calorie
products (£1.5 billion +2.3%)
versus their standard counter-
parts (£4 billion -2.0%).
graduate food scientist is to
attend full time university.
With the dwindling num-
bers of students studying the
subject, the pipeline will not
be sufficient to meet indus-
try needs. The development
of this standard is a direct
response from the industry
for the industry.”
The NSAFD is now giv-
ing food and drink business-
es the opportunity to shape
the standard for the level
six food industry technical
professional degree appren-
ticeship as part of a public
consultation.
packaging recycling notes
system in 2015, meaning an
estimated 86,200 tonnes was
actually collected for recy-
cling, equating to an overall
55% recycling rate for 2015.

New export
guidance
published
New food and drink
export guidance has been
issued to manufacturers to
help existing and would-
be exporters to compete
in the competitive global
marketplace.
Exports – Five Steps to
Food and Drink Exporting
Success was developed by
the Food and Drink Feder-
ation (FDF) and Food and
Drink Exporters Associa-
tion (FDEA) as part of an
enhanced partnership to
help more of Britain’s 6,500
producers to export. The
guide provides useful in-
formation and tips on how
food and drink manufactur-
ers can begin exporting to
foreign markets, including
details of necessary research
and how to create exporting
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opportunities and contacts.
FDF has set an ambition
to grow value added food
and drink exports by a third
to achieve a total value of £6
billion by 2020, with regular
joint activity and promotions
between FDF and FDEA a
key strand of FDF’s efforts to
achieve that ambition.
LOGISTICS MANUFACTURING MERCHANDISING
Brits snacking less
UK consumers have cut
down on consumption of all
snacks over the past year,
according to new research
from Mintel.
The findings highlight
that chocolate, which in
2014 was Britain’s most
eaten snack tied with
fresh fruit, has fallen
as a snack choice by 9%
over the course of a year.
Whilst over two thirds (68%)
ate the snack in the month
to December 2014, a year
later in December 2015 just
59% said they ate the treat
between meals.
What’s more, in the same
time frame, the number of
Brits snacking on crisps and
crisp style snacks fell from
67% to 57%, the proportion
snacking on sweets dropped
from 40% to 29%, those
snacking on cakes and sweet
baked goods declined
to 39% from 51%
and an 11% drop
in usage was seen
PHARMA
May 2016
NEWS & VIEWS
in the pie, pastry and sausage
roll segment with just 25% of
consumers snacking on these
products in the month to
December 2015.
However, it’s not just ‘un-
healthy’ treats which are
seeing a drop in consump-
tion. Although still Britain’s
favourite snack, the num-
ber of consumers eating
fresh fruit outside of meal-
times dropped from 68% in
December 2014 to 61% in the
month to December 2015,
and the proportion snacking
on fresh vegetables dropped
from 32% to 21%.
However, Brits are far
from snack-free. Overall,
95% of Brits ate snacks in the
month to December 2015,
down by just 2% in 2014.
Food & Drink Technology 9
BUSINESS NEWS
BUSINESS
BITES
Ardagh Group has en-
tered into an agreement
with Ball Corporation
and Rexam to purchase
certain metal beverage
can manufacturing assets
and support locations in
Europe, Brazil and the US.
Palsgaard achieved CO2
neutrality at its Danish
plant during 2015 and
has reconfirmed plans to
achieve a zero carbon foot-
print worldwide at all pro-
duction plants by 2020.
Tetra Pak has acquired
Laude, which designs,
develops and manufac-
tures plastic moulds used in
hard and semi hard cheese
production.
RPC Bebo Kristiansand has
been renamed RPC Bebo
Food Packaging to un-
derline its ability to provide
a complete packing solu-
tion, comprising both the
pack and filling system.
Admix is expanding its
customer base in Europe
after its acquisition of In-
Mix Flow Technology, a
Danish mixing equipment
company.
Glass manufacturer and
contract bottler Encirc
Beverages has installed
a second drinks blend-
ing stream at its facility in
Elton, Cheshire, UK, dou-
bling its capacity to blend
beverage products.
Filling and packaging spe-
cialist Krones has pur-
chased 60% of the shares
in System Logistics, a
supplier of solutions for in-
tralogistics, material flow
technology and warehous-
ing, based in northern Italy.
A £1.2 million investment
will enable fresh food pack-
aging manufacturer Lin-
pac to produce a further
200 million expanded poly-
styrene trays each year.
10 Food & Drink Technology May 2016
Second location for Nagel Nederland
Nagel Nederland will soon
operate in the Dutch food
logistics market from a sec-
ond location in Waalwijk.
Since the beginning of
April, the subsidiary of
the Nagel-Group has been
working towards this with
fresh logistics company
Kivits Drunen, which will
undertake collections, tran-
shipment services and dis-
tribution in the southern
and western regions of the
Netherlands.
Construction starts on AD plant
UK food waste recycler Re-
Food has started construc-
tion on its new £32 million
anaerobic digestion (AD)
plant in Dagenham, Essex.
As part of a long term in-
vestment programme, the
gas to grid (G2G) facility will
create up to 60 new jobs in
the local area.
LoeschPack sets up in
Switzerland
LoeschPack has established
its new subsidiary in Swit-
zerland, based in Koblenz.
By establishing the Loesch-
Pack Design and Develop-
ment Centre Switzerland –
known as LoeschPack DDC
Switzerland – the company
is underscoring its ambitious
aims for the positioning of
its F-Series horizontal flow
wrapping platform, as well as
making a firm commitment
to Switzerland as an indus-
trial base.
The applications devel-
oped by LoeschPack DDC
Switzerland will be manu-
factured at the mother plant
in Altendorf, in the Upper
“With this strategic re-
alignment, we are adapt-
ing our network to changes
in the food logistics sector
while simultaneously making
Capable of recycling
160,000 tonnes of food waste
each year, ReFood Dagen-
ham will be able to gener-
ate more than 2,000 m3/hr
of methane gas. Using G2G
technology, this will be up-
graded to reflect the qualities
of natural gas – allowing it to
be injected directly into the
national gas grid and used
to power more than 10,000
homes across the region.
The plant will be located
at the London Sustainable
Industries Park in Dagen-
ham Dock and is expected
to open in summer 2017.
Franconia region of south-
ern Germany, where they
will be integrated into wide
ranging packaging systems
for chocolate, chewing gum
and baked goods. The new
subsidiary will also offer the
possibility to expand devel-
opment and design capacity
through strategic develop-
ment projects.
www.foodanddrinktechnology.com
considerable improvements
to our presence in the Neth-
erlands,” explains Björn
Schniederkötter, COO of the
Nagel-Group.
Mitie secures
waste contract
Mitie has won a contract
with soft drinks manufac-
turer Lucozade Ribena
Suntory to provide a com-
plete waste management
service for its UK sites,
including the manufactur-
ing site at Coleford in the
Forest of Dean and the UK
headquarters in Uxbridge,
London.
Mitie will be responsible
for capturing all elements
of waste and recyclables
process across the estate, in-
cluding dry waste and skip
services through all chan-
nels of the waste hierarchy
– waste reduction, re-use, re-
cycling and energy recovery.
Already a high achiever in
waste management practices,
Lucozade Ribena Suntory’s
current recycling perfor-
mance at the Coleford site is
over 99%.
Darren Kenney, sales di-
rector at Mitie’s waste busi-
ness, says, “Mitie are very
pleased to work in partner-
ship with Lucozade Ribena
Suntory, not only to maintain
their zero waste to landfill
status but to drive towards
achieving 100% recycling.”

New sentencing
guidelines
F
or the first time, food safety
offences have been included in the
Sentencing Council Guidelines, a
major development for the UK food
industry.
The new guidelines for Health and safety
offences, corporate manslaughter and food
safety and hygiene offences came into effect
on 1 February 2016 and will act as a deter-
rent for less responsible operators.
Initial reactions suggest that these meas-
ures have been broadly welcomed by the
food industry and this was backed up by the
audience at our recent food law conference
in March.
What’s new?
An important change is that the courts now
have a detailed framework for calculat-
ing fines, expressed in easily understood
financial terms. In turn, this should provide
a strong incentive for food businesses to
comply with the law.
When looking at how to prosecute food
businesses, previously, the courts would
consider many of the elements within the
guidelines, but due to a lack of focused
sentencing advice, the resulting penalties
were extremely variable and often appeared
inconsistent. As a result of the new guide-
lines, the main changes for food safety
offences include:
• A definition of the most serious level of
harm that includes the risk of an adverse
effect as well as the actual occurrence of
a serious adverse effect
• A reduction in the mitigation factors that
‘
can be considered in sentencing
• Inclusion of harm arising as a result of
The new guidelines require the courts to establish the
offence category by assessing culpability and harm
www.foodanddrinktechnology.com
Larger fines are here, warns Eoghan Daly,
TIFSIP’s policy and technical advisor
provision of misleading information
about a food’s compliance with religious
or personal beliefs.
The new guidelines require the courts to
establish the offence category by assess-
ing culpability and harm. Culpability is
assessed on a scale from low, failings were
minor and occurred as a minor incident; to
very high, deliberate breach of or flagrant
disregard for the law. Harm, meanwhile, is
assessed in regard to a combination of the
likelihood of harm and the seriousness of
the harm or risk of harm.
Once both factors have been determined,
a further consideration is then given to the
number of workers or members of the pub-
lic that were exposed to the risk of harm or
suffered actual harm.
The process
The next stage of the process requires
the courts to determine the appropriate
fine linked to the organisation’s size and
turnover:
• Micro – turnover not more than £2 million
• Small – turnover between £2 million and
£10 million
• Medium – turnover between £10 million
and £50 million
• Large – turnover greater than £50 million.
This provides the starting point, but after
determining the turnover the courts must
then consider further adjustments dependent
on aggravating or mitigating factors. The
guidelines include a non exhaustive list
of such factors and emphasise that recent
relevant convictions are likely to result in
businesses.
‘
a substantial increase in penalties for food
NEWS FEATURE
In certain cases, the courts may move
the adjustment outside the identified cat-
egory range and the aim is to have a real
economic impact so that management and
shareholders appreciate the need to comply
with the law.
Fair penalties
While modelling, based on the guidelines,
suggests that fines for large and medium
sized businesses will increase, there is
uncertainty about the impact on small and
micro businesses. The Sentencing Council
will therefore need to monitor penalties
carefully to ensure that they are fair and
proportionate.
Information from enforcement officers
suggests that small businesses are the most
common recipients of fines. While linking
small businesses’ fines to turnover main-
tains a consistent approach, there is a risk
that, due to low turnover, a deterrent effect
might not be achieved.
Compliance with the law is the aim and
seeing a fine as ‘just another business cost’
should never be a good option. Conversely,
a good history of past compliance should
give some degree of mitigation in case of
failure.
While it is recognised that the majority
of food businesses work hard to comply
with the law, there are some who do not
properly invest in food safety and hygiene.
Where there are cases that demonstrate food
businesses have put profit before protecting
health and wellbeing, a strong signal is
needed in the form of a deterrent penalty.
It is still early days, and as such, difficult
to predict the impact of the new sentencing
guidelines – but it is our opinion that they
will better incentivise businesses to ensure
good standards of food safety and hygiene,
as well as properly protecting people from
harm. ■
May 2016 Food & Drink Technology 11
SHELF LIFE
Improved
Coke Zero
to launch
Coca-Cola Great Britain
(CCGB) has announced
that a new and improved
sugar-free Coca-Cola will
be in stores this summer.
The next step in the com-
pany’s strategy to help
people reduce their sugar
intake, Coca-Cola Zero
Sugar – which will replace
Coca-Cola Zero, which was
launched in 2006 – will taste
more like the original Coca-
Cola, but without sugar, and
will be supported by a £10
million marketing campaign
designed to get more people
to choose no sugar.
The move is a deliberate
attempt to change the mix
of the company’s portfolio
between sugar
and no sugar
drinks and is
the latest ac-
tion to result
from the com-
pany’s £30
million refor-
mulation and
new product
development
programme.
Britvic overhauls juice
drink brand Drench
Britvic has re-
vamped its juice
drink Drench,
with new packag-
ing and a refor-
mulated recipe.
The refresh of
the brand will see
the launch of new
500ml packaging
with a modern de-
sign, supported by
a communications
campaign to drive
consumer aware-
ness of the new products.
The new and improved
recipe, which includes
no artificial sweeteners,
colours or flavourings,
12 Food & Drink Technology May 2016
It’s crunch time for granola
Premium granola producer
Cereal Lovers has launched
new snacking granola,
CrunchTime Nuggets.
This sees the establish-
ment of a new category in the
healthy sector, using produc-
tion innovations to reduce
sugar, enhance crunch and
bake ingredients together for
healthier digestion and more
complex flavours. It comes
in three variants: Chocolate,
Sunshine and Forest.
Creator Jenny Fox-John-
son says, “Baking them as
Kopparberg expands
frozen cider range
Kopparberg has
unveiled the latest
addition to its Fro-
zen Fruit Cider range
– Kopparberg Frozen
Mixed Fruit Cider.
The latest variant,
which joins existing
flavours Strawberry &
Lime and Elderflower
& Lime, has an ABV
of 4%.
Packaged in a metal-
lic pouch, the cider should
be frozen for eight hours,
squeezed into a glass and en-
joyed with a spoon or straw.
benefits from a combination
of juices and spring water.
Through its continued
use of naturally sourced
stevia sweetener, the
liquid has also been re-
formulated to contain
less sugar than be-
fore. As a result, the
front of pack traffic
light labelling on the
new variants will be
amber.
Available now, the
new flavours – Peach
& Mango and Straw-
berry & Lime – will
join the reformulated
Pear & Blueberry
variant.
Chai
flavoured
milk
Drink Me Chai is enter-
ing the ready to drink
market this summer
we do and on the machin- with the launch of its
ery we use, we are able to Iced Chai Latte.
mechanically alter textures, With no other chai
and by setting the bak- offering in the UK fla-
ing times and temperatures voured milk market,
throughout baking we can Drink Me Chai is keen
again manipulate texture and to exploit the growing
the taste as well.” sector, currently valued
at £42 million, and the
increasing popularity of
the chai flavour profile.
The drink is a low fat,
Jodie Alliss, senior low sugar blend of tea,
marketing manager at milk and ex-
Kopparberg, comments, otic spices
“Following the success- b e s t
ful launch of our Frozen served
Fruit Ciders in 2015, chilled,
we’ve seen widespread but with
demand from our con- a nine-
sumers to expand the month
range even further into ambient
2016. That’s why we’re shelf life.
excited to be offering It is avail-
the Mixed Fruit variant, our able now
latest premium product that in 330ml
gives Kopparberg consumers screw cap
even more drinking alterna- bottles.
tives this summer.”
Trilogy of American
inspired relishes
Food and drink 320g (315g for the New
importer Empire York Deli Pickle Rel-
Bespoke Foods has ish) easy squeeze
launched a trio of plastic bottles.
American inspired Nick Thomas,
relishes in the UK, sales and mar-
from condiment keting director
giant French’s. at Empire
The new arrivals Bespoke Foods,
are all ultra versatile says, “We’re
and perfect for burg- thrilled to in-
ers, chops, sausages, troduce this US
steak, sandwiches and inspired range
wraps. of relishes by
The three variants are: French’s into the
Texas Jalapeño Tomato convenience and
Relish, Californian Sweet speciality sectors
Onion Relish and New in time for the sum-
York Deli Pickle Relish. mer months and
The new lines come in core BBQ season.”
www.foodanddrinktechnology.com

Two in one
Salt of the Earth has
launched Umamix Bold
for multiple applications
in the food manufacturing
and food service industries.
Designed to simultaneously
reduce sodium and boost
flavour, it is a new addition
to the company’s recently
developed Umamix line.
The all natural ingredient
Grape juice boosts beverage offering
Welch’s Global Ingredients
Group has strengthened
its product portfolio with
100% Niagara grape juice
– a golden American super-
fruit juice that promises a
sophisticated flavour pro-
file and naturally nutritious
polyphenols.
Crisp, sweet, light and
refreshing, it joins the deep
purple Concord grape juice
Stabilising milk protein
Premium Ingredients has
launched a new range of
stabilisers for acidified
dairy beverages based on
soy-polysaccharide fibre.
They are an alternative to
other stabilisers prepared
with pectins, improving
their functionality in stabi-
lising milk protein, cost and
availability.
Premigum XLB-15032,
Premigum XLB-16022 and
Premigum XLB-16023 allow
www.foodanddrinktechnology.com
contains a combination of
sea salt, tomato concentrate
and mushroom and seaweed
extracts.
It also helps to eliminate
the use of monosodium glu-
tamate (MSG) in savoury
foods.
Non GMO and MSG free,
it does not contain any artifi-
cial colours, preservatives or
e-numbers. It enables a clean
label claim and helps compa-
nies in their efforts to launch
healthier products.
A successful trial conduct-
ed with a processed meat
company in Israel showed
that replacing salt with
Umamix Bold in sausages
can improve flavour and
easily decrease sodium by up
to 30%.
in the company’s range,
giving beverage, confection-
ery, dairy and alcohol brands,
as well as contract manufac-
turers, access to a choice of
two contrasting fruit juice
concepts.
Containing no added sugar,
colours or flavours, it offers
bolder and more floral fla-
vour notes than other white
grape juices. Nevertheless,
beverage companies
to create new products
with a lighter texture
due to the properties
of the soy-polysaccha-
ride fibre, compared
to traditional solutions
based on pectin or
CMC. Moreover, the
synergy between the fibre
and the pectin offers greater
stability using lower doses of
the latter.
In addition, they are pre-
sented as an alternative to
pectin in periods of rising
prices or market shortages,
with current forecasts point-
ing to an increase in the cost
of the raw material which
will be maintained for an
extended period of time.
Eastern promise
EHL Ingredients has
launched four new Asian
herb and spice blends
following the surge in
popularity of Thai and
Chinese dishes.
The new range includes
Thai Seven Spice, Spicy
Thai Fish Seasoning, Chi-
nese Five Spice and Aromatic
Oriental. The versatile spice
blends can be rubbed onto
meat or fish, used in vege-
table dishes or incorporated
into formulations to recreate
authentic Asian meals and
accompaniments.
The seven spice blend is
a combination of crushed
chillies with paprika, cumin,
ground coriander, turmeric,
fenugreek, ginger and
celery; while the spicy Thai
the Niagara grape juice taste
remains light enough that it
is perfect for blending with
other juices in a way that
complements them, rather
than overshadowing them.
Welch’s has also added the
Niagara grape to its Fruit-
Worx range of real fruit in-
clusions for bakery, nutrition
bar, confectionery, snack and
breakfast cereal applications.
Cleaner gluten free crust
Beneo has developed a way
to combine its rice flour and
rice starch ingredients to
create a gluten free, yeast
raised pizza crust.
It uses two of Beneo’s
speciality flours: the newly
wet milled rice flour Remy-
flo R7 90 T CP and the brown
rice flour Remyflo C 200,
instead of standard white
flour.
The rice flour/starch mix
May 2016 Food & Drink Technology 13
INGREDIENTS NEWS
seasoning brings an authentic
flavour to baked, grilled and
fried fish dishes.
Chinese five spice is
a subtle combination of
fennel, cassia, star anise,
clove and black pepper, and
encompasses different tastes
– sweet, sour, bitter and
spicy. Finally, the aromat-
ic oriental dry marinade is a
multipurpose, authentic mix
of star anise, ginger, fennel
and cinnamon.
The new launch follows the
successful introduction of
FruitWorx Concord grape
inclusions a year ago.
enables the ingredients list-
ing of a standard gluten free
pizza to be reduced from this:
water, rice flour, modified
rice starch (INS 1403), potato
starch, olive oil, evaporated
cane sugar, tapioca flour,
potato flour, fresh yeast, salt,
xanthan gum (INS 415) and
calcium sulfate (INS 516) –
to this: rice flour, water, rice
starch, oil, sugar, salt and
hydrocolloid yeast.
PROCESSING NEWS

Heavy duty containers launched Safety system expands

Plastic pallet supplier Ex-
porta Global has launched
a range of heavy duty
attached lid plastic con-
tainers with long life colour
intensity.
Available in 45 and 60 litre
capacities, the containers
feature an integrated lid and
reinforced flat base, which
supports automation.
They are available in blue,
red or green, are stackable
and feature a nesting ratio of
75%. Other features include
tamper evident seals, ergo-
nomic handles at both ends, a
removable card window and
ID label surface with card
slot.
Fresh approach
Paramount Packaging
Systems has announced
the launch of an Alpha VII
FW3710BS/B back seal
flow wrapper, that has
been adapted for reliable,
high speed operation on the
mobile field harvesting
rigs widely used by fresh
produce growers.
Mounted on a robust stain-
less steel support frame to
ensure stability and rigidi-
ty when sitting on the har-
vesting rig, it can be easily
Dale Paterson, Expor-
ta Global group managing
director, says, “These are
designed to be very price
competitive with an excel-
lent nestable ratio support-
ing palletisation and storage,
particularly where space is
at a premium. They are suit-
able for transporting a vari-
ety of goods, including food
produce.”
repositioned when the sides
of the rig are folded up
for transportation between
fields, and even countries. It
also has an integrated ink jet
coder and labeller.
Developed for wet envi-
ronments, the system fea-
tures a hygienic design to
help prevent dust and dirt
accumulation, meets full
washdown requirements and
incorporates water drainage
channels from the infeed.
The machine, which oper-
ates up to 120 packs per min-
ute with a low maintenance
box motion sealing system,
has a convenient ‘plug and
play’ two-part infeed which
allows it to be used with dif-
ferent types of rig and across
a variety of applications.
Icicle Technologies has an-
nounced the integration of
inventory management into
its advanced food safety
management system Icicle.
Though not typically
associated directly with food
safety, inventory manage-
ment can provide an extra
layer of oversight for food
safety to make sure that
traceability is being properly
enforced.
As Icicle is built to fit
within a facility’s existing
operations, adding two more
attributes (quantity and
Leak testing system for MAP
A new, fully automated leak
testing system has been
developed by Mocon com-
pany Dansensor to help
food processors ensure that
individual modified atmos-
phere packages (MAP) are
not going out the door with
undetected micro leaks.
The LeakProtego online
system has been engineered
to test for potential leaks at
levels lower than previously
possible. This is of particular
significance for processors
who are pushing the shelf life
envelope.
location) when scanning lot
numbers for traceability was
a natural development of the
system to meet the needs of
users. This comprehensive
inventory management sys-
tem allows users to look at
any particular ingredient and
see how much is available,
where it is, how it’s being
used and where it went.
Inventory controls can also
assist companies in reducing
food waste through advanced
automation, as well as com-
bat food fraud with checks
and balances.
It uses a patent pending
sensing system with CO2 as a
trace gas to detect leaks down
to 50 microns. The technol-
ogy relies on modular units,
each of which can test up to
12 packages per minute.

Lubricant for refrigeration compressors

ExxonMobil has devel-
oped a synthetic oil for
carbon dioxide cooled
industrial refrigeration
applications.
Mobil SHC Gargoyle
80 POE has been designed
for the lubrication of com-
pressors and is particularly
suitable for reciprocating
compressors using carbon
dioxide as a refrigerant,
which are found in appli-
cations ranging from food
preparation and freezing
operations to cold storage.
The new lubricant has
been formulated using polyol
esters (POE) to enhance
lubricity, wear protection
and chemical and thermal
stability.
As part of its development,
the lubricant was tested on
four reciprocating com-
pressors over 18 months in
a major food preparation
facility in northwestern
France. The facility switched
to Mobil SHC Gargoyle 80
POE from a conventional
POE based oil and found the
new product delivered lower
oil carter and piston tem-
peratures and lower energy
consumption.

14 Food & Drink Technology May 2016 www.foodanddrinktechnology.com

 PACKAGING NEWS

From glass to carton packs for wine range

Wine specialist South Wine Company
(SWC) is expanding its range of pack-
aging and is now making its Odyssey
brand wines available on the Russian
market in aseptic carton packs.
The company has opted for packag-
ing and filling technology from SIG
Combibloc; four of its own home grown
semi-dry wines are now offered in the
combiblocSlimline 1,000ml carton
pack. SWC’s wines have previously
been available in glass bottles only.
“We decided to make our wines avail-
able in carton packs from SIG Com-
bibloc,” says Vyacheslav Merkulov,
deputy managing director of SWC. “We
are convinced that this packaging pre- The company has installed a CFA
serves the high quality of our wines and 310 filling machine from SIG Com-
perfectly suits the convenience require- bibloc to fill the combiblocSlimline
ments of modern consumers.” carton packs.

New glass range Art inside and out

Origo Glass, a pro-
ducer and supplier
of glass bottles for
the craft beer indus-
try, has announced a
new product range
for craft brewers.
The range has
added flint and green col-
our options to the previously
available amber in the light-
weight 500ml standard
bottle. A new 330ml option
New look for Schweppes
Tonic water brand Sch-
weppes is revamping its
pack design by launching a
bold new look to showcase
its premium credentials to
adult consumers.
Its one litre mixers are now
available with striking black
labels which demonstrate the
brand’s long standing herit-
age as the ‘creator of bubbles
since 1783’. The new design
is also peppered with adult
wit and humour to appeal to
consumers aged 30+ looking
for intriguing brands that suit
their lifestyles.
The move is the first in a
series of investments planned
weighing only 200g is also
now available in green and
amber. Origo’s bottles are
manufactured to guarantee a
sustainable product.
for the Schweppes brand in
2016, which promises to be
the brand’s biggest campaign
in 20 years. Wider plans also
include reintroducing the
Russchian variant, currently
known as Citrus Blend.
Simon Harrison, commer-
cial director, Schweppes and
new brand development at
Coca-Cola Enterprises, says,
“Schweppes is an iconic
brand that will benefit from
a bold new look that drives
home the brand’s unique
heritage, distinctive sharp
taste and premium quality.
“With mixers perform-
ing well, we have impres-
sive plans for
Schweppes this
year, and this is
the first in a line of
activations that will
encourage trial and
build brand loyalty
by emphasising
Schweppes’ taste
preference, distinc-
tive British style
and sharp sense of
humour.”
rlc packaging group has
recently started producing
eight new chocolate boxes
with elaborate finishing
for Swiss chocolate brand
Cailler by Nestlé.
The boxes are
designed with up to
14 UV printing inks
using underprinting
and overprinting,
and feature various
types of finishing,
including hot foil
printing in glossy
gold or embossing.
The surface has a
slightly rough feel
and attracts atten-
tion with a subtle
sparkle thanks to the
use of Iriodin pigment. This
does not affect the colour
brilliance and diversity in
European first for milk
RPC Promens Consumer
Nordics has developed a
one litre milk bottle made
entirely from a non oil
based bio polymer, pro-
duced from sugar cane.
An additional feature that
is now being developed, and
which is believed to be a first
in the European market, will
see the polymer mixed with a
special mineral filler. This re-
duces the amount of polymer
required for each bottle with-
out impacting on its strength
and performance, which will
further enhance its positive
environmental profile.
In its first commercial ap-
plication, the new Modul
bottle has been selected by
Swedish dairy company
areas with photos or coloured
surfaces.
The folding box design
was created by artist Mari-
anne Dubuis. Using the tra-
ditional découpage cut
out technique, she
created handmade
silhouettes depicting
different details re-
lated to Cailler choc-
olate. These motifs
include grazing dairy
cows and a view of
Maison Cailler com-
pany headquarters.
rlc then transferred
these images to the
packaging surface
through relief and
blind embossing.
The packaging is also embel-
lished with the company logo
in hot foil embossed gold.
Skånemejerier for its range
of non homogenised milk.
The one litre white blow
moulded Modul bottle is
available with a choice
of closures and features a
four-sided label applied by
RPC Promens.

www.foodanddrinktechnology.com May 2016 Food & Drink Technology 15

CASE STUDIES
Through the keyhole
Food & Drink Technology reviews recent installations at
food and drink manufacturing facilities
Dual sealing system
Following a request from an ingredients
supplier to a global soft drinks company
for extra protection from cross product
contamination during the case sealing
process, Endoline Machinery developed
a case sealing system which both glues
and tapes filled cases – the new dual
sealing system.
Utilising Festo pneumatics and Allen
Bradley components, Endoline brought
the technologies from its existing tape
and glue sealing machines together to
design the new system. The entire ma-
chine frame and side drives were altered
to accommodate both the folding and
gluing assemblies along with the taping
system. The machine also has a special
switch to disable the glue, and with the
easily removable tape units it can be run
to seal with both tape and glue or just
one type of seal.
Once a filled box runs into the system,
the dual action hook closes the rear flap
before glue is applied and the outer flaps
are closed. The glued case then moves
under the taping head for final sealing.
With a daily output of over 10,000
cases, the machine is achieving a per-
fect seal on cases ranging from almost
empty to 25kg in weight.
Fruit and nut efficiency
A 14 head Ishida CCW-R multihead
weigher is enabling German fruit and
nut snack specialist Farmer’s Snack
to meet increasing demand for pocket
sized packs.
The multihead weigher forms the
core element of a new packing line,
installed by Farmer’s Snack after win-
ning a major contract from a discount
retailer. The line primarily handles the
weighing and filling of pocket sized
16 Food & Drink Technology May 2016
bags with a fill weight of 40g, but is also
able to pack 150g flat bags.
The weigher meets specifications with
regard to speed and can process up to
140 bags per minute. Maximum weigh-
ing accuracy is 0.1g and the standard
deviation (weighing consistency) for a
filled bag is well below 1g.
“Compared with our other multihead
weighers those are particularly good
figures, which we can achieve with just
a few adjustments,” says Boie Karstens,
a member of the management team at
Farmer’s Snack. “We were also pleas-
antly surprised
by how well
the weighing of
sticky snacks
works.”
He expects
the multihead
weigher, which
operates in two-
or three-shift
mode, to pay
for itself within
three years.
Warehouse management
Warehousing and logistics software pro-
vider Indigo Software has been awarded
a contract by brewer Greene King to
implement Indigo WMS with voice
picking across its network of UK
distribution centres.
The investment is regarded as essen-
tial to enable larger volumes of product
to be securely moved around the busi-
ness and onto customers as efficiently as
possible. The project to imple-
ment Indigo WMS will ensure
better use of Greene King’s
warehousing network and is
expected to deliver a tangible
return on investment across
the supply chain.
As well as providing
extensive warehouse man-
agement and traceability
functionality, Indigo also
offers voice directed pick-
ing, the ability to handle
multiple warehouses and
movement between sites,
plus direct integration with
Greene King’s existing ERP solution.
The brewer’s critical success factors
will see key supply chain improvement
objectives met, including the reduction
of wastage through better stock control,
shelf life management and overall stock
accuracy across the business.
Consistent product quality
for ice cream manufacturer
Ice cream manufacturer Ben & Jerry’s,
a wholly owned subsidiary of Unilever,
maintains quality procedures for key
performance indicators that ensure con-
sistent product quality for every pint
produced. To track quantitative data, the
company had previously been using a
paper based system, which was not only
slow and inflexible, but also costly in
terms of man hours required for calcula-
tion and analysis. Ben & Jerry’s needed a
fast and reliable way to collect and ana-
lyse the vital quality data of its products.
It decided to deploy the InfinityQS
ProFicient enterprise quality hub to
streamline its quality control procedures.
Powered by a statistical process control
analysis engine, the system easily
automates data collection and integra-
tion from terminals on the shop floor,
while its real time monitoring and
analysis functions enable the quality
department to acquire manufacturing
intelligence by tracking variability
across each production line.
By measuring, monitoring and con-
trolling four main product attributes
– weight, volume, air addition and inclu-
sion amounts – as the pints come off the
production lines, quality teams can work
with production to quickly make adjust-
ments in real time as products or pro-
cesses approach specification limits. ■
www.foodanddrinktechnology.com

T
wo things struck me about this
year’s Food & Drink Expo and its
sister shows, held at the NEC in
Birmingham in April: firstly there
was a greater degree of real innovation
than in recent years – clearly the nation is
prospering again; and secondly the extent
to which that innovation seemed to be very
much focused on drinks, and especially
the up market alcoholic liqueur and spirit
sectors.
I spoke to the Thunder Toffee Vodka team
who said that at the last count, their distribu-
tor was dealing with 137 gin distilleries in
the UK; that must be nearly as many as in
Hogarthian times when gin was safer to
drink than London water. One gin in par-
ticular at the show took my fancy – Pinkster
– naturally coloured from the raspberries
used in the distillation process. Two artisan
bottlers from near York were demonstrat-
ing lovely gin based liqueurs using dam-
sons, rhubarb and gooseberries (Raisthorpe
Manor), whilst colleagues at Sloemotion
were using the spirit infused sloes as an
ingredient in fruit chocolates and chutneys
– how’s that for waste minimisation? Let’s
pick that up in a moment.
Others worthy of mention were the Sweet
Potato Spirit range and the QuarterPast
syrups (in the hot drinks sector) from New
Zealand. Two exhibitors had taken the cus-
tomer involvement approach with great
pieces of innovation; no doubt capitalising
on the nation’s fascination with getting
back in their kitchens on the back of TV
programmes such as Masterchef. The Big
Cheese Making Kit producer claims that
the consumer can make cheese from milk
in an hour (I didn’t see this put to the test),
“The question has to
be asked, do good
nutrition and sustainability
sit comfortably with
each other?”
www.foodanddrinktechnology.com
Feeding
the planet
Industry stalwart Richard Ratcliffe visited
a recent food show, where the innovation
on display gave him hope for the
challenge of feeding the world in 2050
while Smithy Mushrooms used the show as
a vehicle for launching mushroom growing
kits – not any old mushrooms, but exotics
like shitake and oyster pinks. I wonder what
the repeat sales would be on either of these
‘consumer involvement’ ideas. Could be
fun the first time, but then I can see people
slipping back towards ‘convenience’.
Waste not, want not
Going back to the use of the infused sloes
in chocolates by Sloemotion, the IFST din-
ner and conference across the road from the
NEC at the National Motorcycle Museum
was themed around ‘Food Sustainability:
Waste not Want not’.
Whether it’s the use of sloes (tickling the
edges) or the donation by the likes of Pret
a Manger of surplus sandwiches to chari-
ties helping the homeless, the figures for
food waste are absolutely staggering.
Professor Tim Benton of Leeds
University estimates that we
‘waste’ 1.3 million tonnes of
food annually in the UK, and
globally 33 per cent of
food grown and pro-
duced is wasted. Set
that against the back-
ground of feeding
the world population
in 2050 of two billion
more than today and the
challenge, which I have
talked about in this col-
umn previously, is enormous.
“11 billion people cannot eat
RATTY’S REFLECTIONS
the way we eat today and it is unlikely we
can grow enough food to meet demand sus-
tainably,” said Benton.
The IFST assembled a remarkable
team of expert speakers from many of
the organisations working on this biggest
problem ever faced by the human race,
including FareShare, Linking Environment
and Farming, WRAP and the Institute of
Grocery Distribution (IGD).
WRAP has launched an ambitious action
programme to cut the resource needed to
provide our food and drink by 25 per cent
over 10 years, and reduction in food waste
plays a big part in this. The question has
to be asked, do good nutrition and sustain-
ability sit comfortably with each other?
Put another way, could we eat less and eat
better?
Alan Hayes of the IGD presented the
institute’s approach: designing waste out
of the food chain, recognising the impor-
tance of nutrition through reformulation
(eat less, eat better) and the commitment to
17 sustainability goals through a number of
partnerships.
One cannot begin to offer a description
of everything going on in the sustainability
field in an overview such as this, but that
so much effort is being directed towards
solutions is encouraging. The innovation
coming through at the food exhibitions I
had witnessed the previous day at the NEC
gave me a glimmer of hope for the future
and for joined up thinking, which will be so
essential if we are to feed the planet for the
next generations. ■
May 2016 Food & Drink Technology 17
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18 Food & Drink Technology May 2016 www.foodanddrinktechnology.com


It’s easy
being
lean
By implementing Six Sigma techniques and lean
processes, industry can identify areas of waste and
improve supply chain efficiencies, explains Jim Hardisty
ix Sigma is not a new concept. The
term was first introduced in 1986
by Motorola engineer Bill Smith
as a set of techniques and tools for
process improvement. Today, Six Sigma
techniques are used by many industrial
sectors as a means to remove any defects or
wastes in their products and services, and
improve the quality of business processes
from manufacturing to transactional.
Eight wastes of lean
Each Six Sigma project carried out within
an organisation follows a defined sequence
of steps and has specific value targets, for
example: reduce labour, improve lead times
and increase profits.
When we’re approached by a new cus-
tomer looking to improve their business
processes, in our first consultation we dis-
cuss what Six Sigma refers to as the ‘eight
wastes of lean’:
• Transport – moving people, products and
information
• Inventory – storing parts and documenta-
tion ahead of requirements
• Motion – bending, turning, reaching and
lifting
• Waiting – for parts, instructions and
equipment
• Over production – making more than
immediately required
• Over processing – using tighter tolerances
or higher grade materials than necessary
• Defects – damage, scrap and incorrect
documentation
• Skills – underutilising capabilities and
delegating tasks with inadequate training.
Reportedly, Six Sigma reduced
Motorola’s manufacturing costs by just
shy of £1 billion between 1987 and
1994 and saved the company £10 billion
www.foodanddrinktechnology.com
over the last 11 years.
By using a Six Sigma approach, we can
utilise skills that most businesses pay sig-
nificantly for as a consultancy service to
identify areas of waste in their supply chain.
Types of waste we commonly identify
include the use of throw away packaging,
eg shrink wrap, surplus labour, damaged
products, inefficient vehicle fill and the
use of one-trip wooden pallets rather than
returnable plastic ones.
Barriers to success
The biggest hurdle when implementing Six
Sigma is that change is required. Many
businesses show reluctance to introducing
new processes, particularly in fast moving
environments where they require full team
support and collaboration. In many business
scenarios, however, it’s often a company’s
false perceptions that prevent them from
instigating change.
We’ve come across businesses that think
if you add in a back haul rate to return plas-
tic pallets and boxes for reuse then it can’t
possibly save them money; but they don’t
appreciate the cost of their current system.
Most Six Sigma projects pay back within
a 12-18 month period; some ultimately pay
back a lot quicker.
Six Sigma success
Goplasticpallets.com has already helped
several businesses in the food and drink
industry improve supply chain efficiencies
by switching from one-trip packaging to
returnable transit packaging. Here is a
typical scenario.
A customer manufactures ready meals in
its factory kitchen and warehousing facility;
it packs a specific number of ready meals
per cardboard box and palletises them for
SUPPLY CHAIN MANAGEMENT
Jim Hardisty
storage and distri-
bution through its
frozen store. The
goods are picked in whole packs and sent
using the customer’s own transport to shops
and garden centre stores across the country.
These stores receive deliveries multiple
times a week depending on the time of year
and how busy they are. The waste element
of this supply chain is the cardboard outer
boxes and the breaking down of smaller
selling SKUs into new cardboard boxes for
delivery to store. The customer is sending
out in excess of 1.1 million outer card-
board cases, which are dispatched daily.
The cardboard box costs on average £35p,
so £385,000 per annum, with additional
recycling costs at each store, as well as the
cost for replacing damaged boxes.
Our recommendation would be to intro-
duce reusable folding containers by replac-
ing the cardboard outer box with a plastic
tray. As each store receives at least two
deliveries a week, the distribution time
would reduce to a maximum of five days.
The tray being folding and ventilated means
that they would have better airflow in the
cold store and save space at both distribu-
tion centres, as well as the shop premises
where space is a premium.
Based on this scenario, introducing
returnable folding boxes could save the cus-
tomer circa £150,000 in the first year, with
a potential five-year saving of £1.2 million.
Other savings include maximised vehicle
fill, less time for assembling cardboard
boxes, less damaged products and lower
recycling costs. ■
Author
Jim Hardisty is managing director of
Goplasticpallets.com
May 2016 Food & Drink Technology 19
SUPPLY CHAIN MANAGEMENT
Chain reaction
What are the limitations of
‘traditional’ supply chain
management solutions?
Traditional supply chain management solu-
tions are neither real time nor multi enter-
prise; they are bounded by the four walls
of the enterprise, whereas today’s supply
chains extend to include customer, co-
packer and supplier networks.
Traditional demand planning systems
employ time series analysis to create fore-
casts based solely on prior sales. We all
know that history is a poor predictor of
future sales, especially in volatile markets.
The increased reliance on promotions and
innovation to drive growth further com-
pounds the problem.
New items lack the two years of history
required for time series analysis, and pro-
motions by nature are designed to ensure
that history does not repeat itself. No one
should have to wait for two years to forecast
a product. Furthermore, traditional planning
systems are essentially mechanical calcula-
tors without the ability to learn.
How have innovations in recent
years affected supply chains
and what benefits can new
technologies afford them?
Demand sensing technology helps over-
come the shortcomings of traditional plan-
ning systems by using current information
from across the supply chain to create accu-
rate forecasts that are in tune with market
realities. This has become especially impor-
tant as retailers shorten lead times, increas-
ing volatility and shifting the burden of
carrying inventory towards manufacturers.
20 Food & Drink Technology May 2016
Following the recent merger between
E2open and Terra, Carly Wood speaks to
Robert F Byrne, VP and GM, forecasting solutions
at E2open, about the supply chain of the future
Demand sensing’s automated pattern
recognition algorithms analyse current sig-
nals from across the extended supply chain
to determine what data is predictive and cre-
ate the best possible forecast. Figures from
E2open’s Forecasting Benchmark Study –
encompassing more than $200 billion in
sales from 14 multinational manufacturers
– show that demand sensing cuts weekly
forecast at the SKU level by 37 per cent.
Talk us through the journey of
demand sensing, since Terra
invented the concept in 2002
until now – what changes has
the industry seen and how has
demand sensing adapted in line
with those?
Terra invented demand sensing in 2002 and
was the first to systematically use current
demand signals to accurately predict near
term demand. As retailers started to share
daily data, demand sensing became multi
enterprise. The system was enhanced to
automatically analyse a myriad of data
inputs, including point of sale and retailer
warehouse levels to determine what is pre-
dictive and create an even better forecast.
In 2012, long-term demand sensing
was introduced to rethink demand plan-
ning using our automation expertise and
pattern recognition technology, streamline
manual processes and improve planner
productivity.
Campbell Soup was the first company
to adopt demand sensing in 2003. Three
years later, Procter & Gamble started
its global deployment. Today, it is being
used to plan more than $200 billion of
products in over 160 countries for some of
the world’s largest companies.
How does supply chain efficiency
contribute to ambitious waste
reduction targets?
Waste in the supply chain is most frequently
a result of the gap between intended sales
and actual sales. Having an efficient (ie
demand driven) supply chain is the major
step in reducing waste. Becoming demand
driven means two things: improving the
quality of your demand signal, and reducing
your lead times.
For food and beverage companies,
exceeding shelf life is often the largest driver
of waste. Companies need to both reduce
overage inventory and improve freshness (ie
lower average days on hand). Waste reduc-
tion therefore starts with better inventory
management. Many companies use inven-
tory optimisation software to determine
the minimum inventory required to protect
customer service commitments. For perish-
able items, this is not enough; you also need
to set maximum inventory levels based on
an acceptable level of overage product.
Solving for both minimum and maximum
stock targets is an important step towards
establishing healthy inventory levels that
ensure service while preventing waste.
New product innovation is ram-
pant – what effect does this have
on companies’ supply chains and
what can be done to reduce any
harm it may cause?
It turns out that growth by innovation drives
far more complexity than sales. Figures
www.foodanddrinktechnology.com

from the Forecasting Benchmark Study
reveal that the number of active food and
beverage items have increased by 29 per
cent over the past five years. Over the same
period, sales have increased only eight per
cent. Furthermore, roughly one third of
products turn over each year. This combina-
tion of rapid SKU proliferation and turnover
drives the long tail and makes forecasting
increasingly challenging.
The benchmark study confirms that using
current information to sense demand allows
companies to cut weekly forecasting error
for new products by 36 per cent and by 41
per cent for items in the tail.
Automation is being increasingly
adopted by the food industry –
where does this sit with supply
chain management?
While automation gets lots of attention in
manufacturing in terms of robotics, it is qui-
etly changing what is possible in planning.
Supply chains are awash in data that can be
systematically used to drive better planning
decisions. The challenge is that there is
simply too much data to process manually
or semi manually. This is where automation
comes in: computers aren’t smarter than
people but are able to process staggering
amounts of data very quickly. This frees
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planners from mundane number crunching
tasks to focus on more strategic activities.
What do you consider to be the
supply chain of the future?
In the next five to 10 years, we will see
increased complexity, shorter lead times and
financial pressures to improve productiv-
ity continuing to rise. The need to profit-
ably serve customers will lead to a wider
realisation that ERP’s traditional inside out
approach has become a bottleneck.
Leaders will increasingly rethink net-
works from the outside in, and encompass
all trading partners in the extended supply
chain; from retailers to suppliers. Supply
chain networks will evolve from being
one-to-one to many-to-many and provide
complete end to end synchronisation.
Automation in planning will augment
human efforts, operationalising the masses
of data required to accurately predict
demand and succeed in a world of rising
complexity.
Real time information will become the
currency going forward and enable a new
level of efficiency. History can be helpful,
but is no way to run a business. Demand
driven forecasts will feed directly into rapid
response systems for immediate execution
and profitably capture growth opportunities.
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SUPPLY CHAIN MANAGEMENT
Collaboration will also become auto-
mated, enabling cooperative inventory
target setting across the value chain to serve
more consumers with less capital invested
in stock.
What does the merger between
E2open and Terra mean for the
industry?
The merger between E2open and Terra cre-
ates the first opportunity for true end to end
synchronisation across the extended supply
chain. E2open has the world’s largest supply
chain operating network, with over 40,000
trading partners and is a leader in supply
planning and execution.
Terra is the industry leader in demand
solutions, including demand sensing, inven-
tory optimisation and transportation fore-
casting. Combined, E2open is uniquely
positioned to power a new generation of
multi enterprise supply chains that dynami-
cally sense consumer demand, understand
supply constraints and quickly react to
profitably serve customers. The benefits of
an automated and connected value chain
network are staggering. ■
Turn to page 42 to read what Robert had
to say when we spent 60 seconds getting to
know him.
May 2016 Food & Drink Technology 21
COLD STORAGE – CASE STUDY
Environmentally
friendly brewery
Austrian brewery
Schwechat has lowered
the annual energy cost
for its refrigeration
system by €30,000
A
ustrian beer producer Schwechat is
one of eight breweries belonging
to Brau Union Österreich and part
of the Heineken Group. As such,
it supports the sustainability programme of
Heineken, together with the aim of becom-
ing the world’s most environmentally
friendly brewing company. Accordingly,
Schwechat brewery has implemented a
number of energy saving projects.
Johnson Controls has extended the life
cycle of Schwechat brewery’s 25 year old
ammonia operated refrigeration system
by implementing solutions in the inter-
ests of energy management and optimised
energy efficiency. Thanks to this upgrade,
Schwechat was able to reduce its carbon
dioxide emissions by 22 per cent, as well as
cut energy costs by €30,000. The costs for
the highly efficient system were recouped
within two and a half years, letting the
brewery control its own efficiency profile
and thus reduce the costs per can.
Sustainability targets
In a preliminary study, Johnson Controls
discovered several challenges applying
to the beer industry in general and to
Schwechat in particular. The brewery spent
€135,000 every year on the energy for its
refrigeration system and at the same time
22 Food & Drink Technology May 2016
was expected to comply with the require-
ments stipulated in Heineken’s sustainabil-
ity programme. In checking the brewery
plant, Johnson Controls detected possibil-
ities for saving energy and drew up the
correct energy profile for the system. This
enabled the company to calculate a payback
period that offered an alternative.
Given the crucial importance of precise
temperature and pressure control throughout
the whole process involved in making beer,
Schwechat didn’t want to take any risks
with the upgrade, which therefore had to be
implemented without interruptions.
Saving energy
The project began in November 2013 and
was concluded in February 2014. Johnson
Controls proposed replacing the electric
motor of the STAL-57 screw compres-
sor with a permanent magnet synchronous
motor and a frequency converter with the
following advantages:
• Higher pressure stability
• Exact temperature control
• Less starting up/shutting down
• Increase in capacity
• Up to 30 per cent energy savings each year
• No motor slip as rotor and rotary field
have the same drive.
A motor that is three times smaller than
an asynchronous motor but still produces
the same torque helps to save transport and
machine costs.
Reduced cost per can
With a total refrigeration capacity of 1.2
MW, the new plant for Schwechat brewery
‘ By cutting its CO2
emissions by 230,000kg,
the brewery has achieved a
new milestone on the way
to a green image
‘
reduced the annual energy costs by approx-
imately €30,000, thus warranting a payback
period of just 29 months. And by cutting
its CO2 emissions by 230,000kg, the brew-
ery has achieved a new milestone on the
way to a green image. Furthermore, the
modernisation measures significantly
reduced maintenance costs.
Johnson Controls has made it possible for
the customer to observe its own efficiency
profile. Calculation of the energy savings
and the payback period has allowed the
brewery to reduce the sales costs per can.
Extended lifecycle
Now that the payback period has been con-
firmed, the brewery also plans to upgrade
the other compressors. The short payback
period and reduced energy costs have turned
Schwechat into a showcase brewery, with
the successful upgrade acting as a role
model for other breweries belonging to Brau
Union Österreich.
Engineer Andreas Schmutz, head of
plant technology at Schwechat brewery,
says, “We have entrusted our long standing
partner with this project because we knew
that they would propose innovative solu-
tions that comply with our interests and
objectives.
“By extending the lifecycle of the exist-
ing plants, we have sent out a strong signal
to the industry – this too is sustainability.” ■
www.foodanddrinktechnology.com

Freeze out
refrigerant gas leaks
R
efrigerants gases are crucial to
keeping cold storage and refriger-
ation systems running throughout
the food and drink industry, but if
a leak occurs the impact can be extremely
dangerous and expensive.
Given the fact that many cold stores in
operation across the food and drink sector
were designed and built over 20 years ago,
it is perhaps little surprise that gas leaks
remain a problem area for the industry. In
fact, the Carbon Trust has recorded an aver-
age annual leak rate of up to 20 per cent in
UK refrigeration systems – a leak percent-
age that can lead to an 11 per cent reduction
in efficiency in a typical cold store.
This inefficiency not only leads to higher
energy bills, but can also have a detrimen-
tal effect on the amount of food wasted in
the food and drink sector. Manufacturing
accounts for 3.9 million tonnes of the 15
million tonnes of food wasted in the UK
each year, according to figures from WRAP,
with inefficient cold storage systems play-
ing a large part in this dissipation.
Gas leaks occur for a number of reasons.
Equipment failure, improper maintenance
work, mechanical damage and accidental
release during refrigerant replenishment
can all cause a potentially dangerous leak.
Reducing the amount of gas leaks, or
www.foodanddrinktechnology.com
Shaun Evers explains how the implementation
of sophisticated gas detection equipment can
cut down on leaks and the associated costs
spotting and stopping them as early as
possible, not only improves energy effic-
iency and helps to protect the environment,
but it can also ensure employee safety.
Exposure to refrigerant gases can cause
a serious threat to workers, with prolonged
exposure likely to lead to symptoms such as
irritation of the throat, eyes and skin, frost-
bite and chemical burns, as well as more
severe ailments like lung and brain damage.
Due to the fact that 60 per cent of refriger-
ant gas escapes before an employee notices,
it cannot be left to staff to spot potentially
dangerous leaks.
Faced with these figures, and against a
backdrop of increasingly stringent F-Gas
Regulations placed on companies which
use refrigerants, businesses across the food
and drink industry remain on the lookout
for ways to reduce leaks. One such solution
is the use of a sophisticated gas detection
system.
Gas leak detection
A gas detection system can help ensure that
leaks are quickly identified and repaired
at the earliest opportunity. This not only
minimises the risk to the
health and safety
of employees,
but is also a legal
requirement as part
of the EU F-Gas
Regulations.
EU legislation
states that any
refrigeration appli-
ance with 300kg or
more of refrigerants
must be fitted
with a leak
d e t e c t o r.
Cold stores
that have a
charge of three
to 30kg have to
be tested for gas
leaks once annually
and those with a
COLD STORAGE
charge of 30kg or more need to be tested
twice a year.
Fitted gas detectors must have a sensi-
tivity of 5g/year and should be checked
after 25 hours of continuous use. They
should also be calibrated with a 1,000ppm
gas to air mix. This is particularly
prevalent in the food and drink industry
where cold stores are required to operate on
a 24/7 basis to keep foods safe and prevent
spoiled produce.
Gas detectors can be programmed to
detect a wide range of both toxic and non
toxic gases, including hydrofluorocarbons
(HFCs). Staff members are alerted to any
sensed gas leak with an audio and visual
alarm, while LED colours indicate the pres-
ence and status of each sensor. This ensures
that any problem can be quickly rectified.
The sensor that has identified the leak
will be highlighted on the main monitor of
the system so that the leak can be quickly
found and immediately repaired, while
some gas detectors also have a battery back-
up so they will still work in a power cut – a
time that could be more risky than normal
for gas leaks.
Business sense
The demand for gas detection equipment is
growing in the food and drink industry, with
companies keen to improve the efficiency
of their cold store systems and ensure the
safety of their staff. The benefits of install-
ing effective gas detectors are evident, with
reduced carbon emissions and energy costs,
legislative compliance, limiting unnecessary
food waste and safeguarding the safety of
employees amongst the advances.
In addition, with a payback period of
less than two years, installing technologies
to monitor gas leaks and energy waste in
cold storage offers a simple solution for
businesses across the entire food and drink
sector. ■
Author
Shaun Evers, managing director of
Stonegate Instruments.
May 2016 Food & Drink Technology 23
FISH & SEAFOOD
Production
in numbers
Adrian Sunter looks at what can be measured
in fish and seafood production and how data
can be used to build customer confidence in an
industry where negative statistics often prevail
Q
uality control in some form is
now widespread in the fish indus-
try and its use is increasing stead-
ily as demand for uniformly high
quality products grows. This is particularly
true of fish because it is more variable than
most other foods. Product specification
will dictate how the process is set up and
what quality control measures need to be
in place.
Data – whether flagging issues in real
time or measuring performance over days,
weeks and months – can reveal a great deal
of important business information and, ulti-
mately, it can save money and increase pro-
ductivity, as well as driving up both quality
standards and operational performance. It
can also be instrumental in driving behav-
ioural change by encouraging a more results-
driven culture, improving consistency and
integration across shifts and teams and
keeping everyone focused on profitability.
24 Food & Drink Technology May 2016
Data collection can be built into various minimise waste and giveaway and improve
quality control applications across the pro- profitability.
duction line, from checkweighing through Accurate data will also allow you to find
to x-ray inspection and seal testing, and out quickly whether you can adjust produc-
has to be tailored to the specific needs of tion and speed up lines to meet new orders,
the business. As quality control systems for instance, without increasing giveaway.
are compatible with typical work based From a technical, operational and man-
platforms and devices, data can be easily agement perspective, it also enables busi-
accessed and shared, nesses to analyse and com-
as well as aligned to pare the performance of two
local standards, such as machines or lines, or even of
weights and measures two different shifts, giving
regulations. them the vital information
Whether it’s an aver- they need to take action and
age weight versus a improve productivity.
target weight or the From a compliance point
frequency of rejects, of view, records of product
data capture allows that has been x-rayed can
for the rapid remedia- help to exonerate a company,
tion to in-line settings, for example, that needs to
or enhanced training demonstrate that no foreign
for staff to quickly body contaminants were
present when the product
left the factory.
Knowledge is power
Raw fish, particularly that destined for the
European and US markets, is typically high
quality in appearance, texture and taste and
therefore can be expensive. Commercially,
quality expectations are bound by what the
customer is prepared to pay for and, in the
case of fish, they are often happy to pay
more for a high quality product. Indeed,
they will often stay loyal as long as that
quality remains consistent.
Consumers are influenced by the type of
fish, how easy it is to prepare, its appear-
ance, odour, flavour, freshness, size, the
presence of bones, blood and dirt, as well
as condition, packaging and composition.
www.foodanddrinktechnology.com

While much investment in quality control
is to meet the high expectations of customers
and ultimately the end user, products may
also have to comply with regional and
national regulations. In either case, data
has a valuable role to play in demonstrat-
ing compliance and proactive management
of quality. It can also play a key role in
informing pricing strategies and helping to
achieve competitive advantage and profit-
ability in a keenly contested marketplace.
Consistency is key
Accurate weighing of fish fillets is vital to
reduce giveaway, but also to ensure packs
adhere to weight requirements, offer the
best possible pack presentation and ensure
speedy throughput of product to maintain
freshness and quality.
Fish is a typically sticky product and
systems that maximise performance and
integrity are critical in ensuring that
consistency and quality can be guaranteed
for the consumer.
Data captured means that real time moni-
toring of systems is available and any errors
captured are dealt with prior to distribution.
Accurate recording and measurement of
product not only gives customers peace of
mind, but it also benefits manufacturers as
the visibility and transparency of processes
will be available for any future scrutiny by
both customers and regulators.
Data is also vital in helping processors
to refine and adjust their lines to optimise
efficiency and minimise waste, and also
track performance and productivity and
thereby manage costs more effectively.
Coatings, too, must be carefully managed in
order to deliver product consistency across
the range.
Eliminating contamination
Many fish products that are packaged in
Europe have already travelled long distances
and in the case of shellfish, for example,
they can be shelled and eviscerated on board
ships or at the quayside across the Atlantic,
prior to going on to Europe for packaging.
In large volumes, these products can be
www.foodanddrinktechnology.com
“Accurate recording and measurement of product not
only gives customers peace of mind, but it also benefits
manufacturers as the visibility and transparency of
processes will be available for any future scrutiny by
both customers and regulators”
vulnerable to contamination at any point in
the supply chain. Systems to monitor bacte-
rial contamination also need to be supported
by inspection for physical contamination. In
this case, advanced x-ray systems introduce
a new level of certainty for consumers. In
addition to grit and shell, the latest equip-
ment is also capable of detecting, at very
low levels, far rarer contaminants such as
steel, aluminium, tin, glass, stones, hard
rubber, plastic and bone.
The key to successful inspection regimes
is that they should have the flexibility to
manage a large throughput of materials,
whilst diverting and recording any anoma-
lies so that these can be dealt with in-line
and with minimal disruption.
For the processor, data gathered by such
systems ensures full accountability for the
product’s integrity when it
leaves the plant – a great reas-
surance to the end user and a
valuable management tool for
the operations team.
Product quality,
pack integrity
Many fresh fish and shellfish
products are packaged on sealed
trays for supermarkets, so con-
sistency in colour, appearance
and weight is vital. Testing the
integrity of seals is another area
where timely management of
FISH & SEAFOOD
rejects and accurate reporting can deliver
commercial benefits.
Ultimately, data capture systems give
companies vital information. In some cases,
they will allow for tailored analysis across
lines and products that can help frame the
future performance of the business. They
act as a vital management tool, but most
importantly, because fish is so perishable,
their increasing sophistication is making
them a key part of delivering the reassur-
ance about quality that customers seek from
their suppliers, adding value to the customer
relationships and helping to deliver long
term loyalty and customer satisfaction.
Investing in data capture makes busi-
ness sense on so many levels, and when it
comes to quality control in particular, this is
where the numbers really stack up. Not only
will the benefit be felt in an improvement
in overall equipment efficiency, quality
and productivity, but a good system will
typically pay for
itself in a short
period of time
– a win-win for
both supplier and
customer. ■
Author
Adrian Sunter is
technical director
at Ishida Europe.
May 2016 Food & Drink Technology 25
 www.prosweets-cologne.com

t o
Parallel

29.01.–01.02.2017
The international supplier fair
for the sweets and snacks industry

Your direkt contact:

Koelnmesse GmbH
Messeplatz 1
50679 Köln, Germany
Tel. +49 1806 383 763
Fax +49 221 821-991360
visitor@prosweets-cologne.de

T
he environmental impact of food
and drink packaging is now firmly
at the front of consumers’ minds.
This interest has progressed from a
focus on the end of life of a package – over
80 per cent of consumers are now actively
recycling waste – to an increasing apprecia-
tion of the beginning of life, with customers
associating ethically sourced products with
good quality. Furthermore, two thirds say
that they have bought environmental prod-
ucts, even when they cost more.
This means that sustainable practice is no
longer a nice to have, but an essential part of
doing business. In response, the industry has
been focusing its attention on innovating
across three key areas – design, materials
and production – which all lead to signifi-
cant reductions in environmental footprint.
Design
Looking first at design, two foremost devel-
opments have been in weight and shape.
Lowering weight reduces a package’s
environmental footprint both directly, in
terms of less materials used; and indirectly,
through emissions saved during manufac-
turing, transport and recycling.
Package shape has become a particular
focus point, as an efficient square or rectan-
gular design can hold more food, facilitate
faster shelf replenishment, reduce waste
handling and optimise use of shelf space to
help lower direct product cost for retailers.
Furthermore, these modern packages allow
a clearer view of high quality printing on all
sides, increasing information visibility for
consumers considering their next purchase.
Materials
Secondly, the materials used in packaging
have become a primary focus of the industry
www.foodanddrinktechnology.com
as consumers become more environmen-
tally aware. According to Tetra Pak’s
Environment Research 2015, consumers are
increasingly expressing a preference for
cartons because they are made of renewable
resources such as paperboard, and nearly 40
per cent of consumers now look for environ-
mental logos when shopping.
Recognising this consumer trend, Tetra
Pak has been investing in creating renew-
able packaging. The company and other
industry players have also increased engage-
ment with objective, third party environ-
mental measurements, including the Forest
Stewardship Council and the Life Cycle
Assessment, which help showcase environ-
mental credentials to consumers who are
increasingly hungry for information on this.
Production
Last but not least is production, and the
ongoing innovation in packaging production
Tetra Pak delivers 200 billion FSC labelled packages
At the end of April, Tetra Pak had deliv-
ered 200 billion packages labelled with
the Forest Stewardship Council (FSC) logo.
Since 2007, the number of Tetra Pak
cartons bearing the FSC logo has increased
each year to reach 54 billion in 2015 – and
the company expects that trend to accel-
erate as consumer awareness grows.
With increasing consumer interest in
environmental issues, companies are
expected to communicate their impact on
the environment and the actions they are
taking in a transparent way. The FSC logo
enables consumers to choose brands that
are committed to sustainable forestry.
Founded in 1994 by a group of non
governmental organisations, timber users
ENVIRONMENTAL PACKAGING
CODE
of
ethics
Tetra Pak looks at the role
of packaging in reducing
environmental impact
lines that allows modern machines to deliver
vastly improved operational efficiencies and
overall environmental performance.
For producers, this means less water and
energy consumption, reduced waste produc-
tion and lower CO2 emissions. Achieving
these reductions allows them to address
increasing consumer demand for environ-
mental efficiency, stay competitive and
operate their business in a sustainable way.
These three key areas of innovation have
resulted in the creation of ground breaking
products and demonstrate the contribution
packaging can make towards the sustain-
ability agendas of producers and consumers.
As the world’s population grows, demand
for packaging and pressure on the envi-
ronment will only increase. Industry lead-
ers have recognised this and are taking
their responsibility seriously, by continuing
to invest in developments that minimise
environmental impact. ■
and traders, FSC is
widely recognised
as the highest
global certification
standard for forest
management. For a
product to carry the
label, there must
be an unbroken
Chain of Custody
certification for all relevant sites. Tetra Pak
has completed the certification for all con-
verting plants and market companies, and
can supply FSC labelled packages from
anywhere in the world.
Part of Tetra Pak’s long term ambition is
to deliver all packages with the FSC label.
May 2016 Food & Drink Technology 27
ACCESS ALL AREAS
A gentle fudge
in the right
direction
In this new monthly feature, Food & Drink
Technology travels to a different manufacturing
facility to get a behind the scenes look at the
business, its people and its processes. This month,
Carly Wood visits Fudge Kitchen to hear more
about its humble beginnings over 30 years ago,
from founding MD Sian Holt
H
aving finished her degree in
business studies and marketing,
Sian Holt had just set up a small
marketing consultancy when, in
1983, American fudge maker Jim Garrahy
approached her with an idea to open a
fudge shop in Blackpool, UK. “Initially, I
thought he would be a client,” Holt recalls,
unbeknown to her that she had just played
her role in founding the company she would
remain at the helm of to the present day. “He
put everything you need to build a fudge
shop in a container and sent it to the UK.
I met the container, I took it to Blackpool,
I built a fudge shop, I went to America, I
learnt how to make fudge, I came back, I
bought staff, I trained staff and we opened
the shop on Blackpool Pleasure Beach.” Jim
Garrahy’s Fudge Kitchen was born.
28 Food & Drink Technology May 2016
she says. “Footfall has changed and shops
have come and gone. What is a good site
today may not be tomorrow.”
There are currently seven thriving shops
around the UK – in Bath, York, Cambridge,
Canterbury, Windsor, Edinburgh and
Oxford, as well as a fudge bar inside the
Selfridges Bullring store in Birmingham –
each hand making fresh, whipping cream
fudge on the premises using authentic 1800s
American recipes and traditional techniques
involving bubbling copper pans, six foot
spatulas and five foot marble counters.
Whole lot of wholesale
In 2009, Holt sought to expand the business
into wholesale: “I realised that there was no
corresponding premium brand as a pack-
aged fudge when I looked at the market,”
she says.
However, having sold loose fudge in
shops where packaging was an after sales
thought, the team had to find a way to pull
across the personality of the brand, which
was normally done by the staff in the shops,
onto the box.
“We already knew who we were and
therefore we wanted to have an extension of
who we already were in the high street into
a standalone brand.
“Brand to us previously wasn’t some-
thing we generally thought about because
the packaging was post sale. So one of the
first things we had to do was to rebrand –
create, even, the brand. We had to come
up with a proper logo and a definition of
the business; previously, we just worked
where we worked and it was all down to
the people.”
Branding, however, was not the only
obstacle. As the fudge sold in the Fudge
Kitchen shops is produced using fresh
whipping cream, and no butter, it has a short
Holt recognised the potential in the brand, shelf life which isn’t suitable for wholesale
but believed it hadn’t been positioned cor- supplying – suddenly, the fudge’s short
rectly: “We had a fantastic product but in the
wrong place; we should have been in
historic cities rather than
on Blackpool Pleasure
Beach,” she notes. And
so, in 1995, Holt bought
the company now known
simply as Fudge Kitchen.
Holt set about realis-
ing her historical cities
vision, and over time
has opened around 30
high street shops. “Our
retail growth has changed
according to the way the
UK leisure shopping
market has changed,”
www.foodanddrinktechnology.com

shelf life, considered a USP for freshness in
the shops, was a weakness as far as whole-
sale was concerned, and so begun a period
of reformulation spanning several years.
“We already had a demand for that prod-
uct and had quite a core of Fudge Kitchen
fudge lovers, so we really wanted to keep
that same product and just make it last
longer,” explains Holt.
Some reformulation of sugar saw the
shelf life extend from five to seven days to
three weeks, but it still wasn’t long enough
for a wholesale market. The answer was
eventually found in butter; the addition of
fat means the moisture is retained within
the fudge, so it prevents the product from
drying out. With that, a shelf life of between
four and nine months was achieved and
Fudge Kitchen’s Gourmet Butter Fudge
was launched at the 2011 Speciality & Fine
Food Fair in London, opening up a new set
of retailer and wholesale opportunities.
The butter fudge range, which uses only
natural, gluten free ingredients with the
same smooth, melting texture as the original
whipping cream recipe, is now stocked by
more than 200 retailers across 20 countries.
Production and export
Along with new products which have joined
the Fudge Kitchen line up over the years –
including drinking fudge, fudge sauces and
home kits – the butter range (like its original
whipping cream cousin) is still handmade in
small batches and hand decorated by highly
skilled staff in Fudge Kitchen’s dedicated
production facility in Aylesham, Kent.
Due to the seasonal nature of the busi-
ness, output at the facility greatly varies,
with production running between a single
shift four days per week during Q1, to a
double shift (6am to 8pm) seven days per
week during Q4 when business peaks. One
fudge maker can manage the three industrial
cookers, depending on the
complexity of the
www.foodanddrinktechnology.com
ACCESS ALL AREAS
product being produced, with assistance on customer favourite: “Flavour is a funny
batch preparation and pouring. It’s the cut- thing. Whether it is in our shops or whole-
ting, decorating and packaging that are both sale, you need flavours to attract attention
most labour intensive and complex, yet so and you need to be innovative so there is
critical to the brand values – if the fudge is always something new; but at the end of
not packed quickly after cutting, it begins the day, you sell sea salted caramel! It is the
to dry out. best seller by a long shot.” ■
To counter the seasonal nature, Holt has
been pursuing the brand’s export potential.
She explains, “In the UK our business is
very seasonal, so if it roughly splits into
supplying speciality retailers on the one
hand and supplying gift food retailers on
the other, speciality is year round but still
peaks in Q4, whereas gift foods is entirely
Q4. For us, the role of exporting is to try
and even that out a bit.” Holt notes that
Fudge Kitchen currently exports “a little bit
to quite a few countries”, but with attend-
ance at trade shows a priority, the company
knows where it needs to focus its export
business and intends to spend the next
12 months building up a network of key
distributors.
To the future
2016 is set to be another big year of growth
for the company with more new product
development; following further expansion
‘
into sugar confectionery early this year with
the launch of two new brittles and caramels
in its Delectables range, the business is set
to unveil its dairy free fudge – which uses
We already had a
a variety of milk alternatives – after taking
enquiries from vegan retailers and societies. demand for that product
New flavours will no doubt be joining and had quite a core
the Gourmet Butter Fudge range, as Holt
says, “We’re quite lucky being retailers as of Fudge Kitchen fudge
well as wholesalers, as we can trial new
flavours in our own shops before we do a
full launch.” However, she has no doubt
that the salted caramel variety will remain a
lovers, so we really
wanted to keep that
same product and just
‘
make it last longer
Sian Holt
May 2016 Food & Drink Technology 29
FATS & OILS

Innovative enzyme technology

increases oil yield and protein
value, explains Wouter Smits

V
egetable oils, such as soybean,
canola, sunflower and corn
oils, are an important source of
nutrition across the globe, and
demand for such oil has never been higher.
Their consumption has shown a rapid
increase over the last decade, with per
capita consumption rising from 17.4kg per
year in 2005 to 24kg per year in 2015 [1].
The soybean crush, in particular, is
a market segment on the rise, growing

Well oiled
from 177 million metric tons (MMT) in
2004/2005 to 259 MMT in 2014/2015, and
is expected to grow further to 305 MMT
in 2020 [1]. As a result, oil producers need
innovative oil refining technology to address
the increasing global demand for vegetable
oil in a wide variety of applications, in the

machine
most effective and efficient manner.
Compared to other refining techniques,
enzymatic degumming allows for more
effective seed oil refining, increases food
producers’ yield and boosts their profits.

Refined seed oil

In order for crude oil extracted from seeds
to be suitable for commercial sale, it must
first be processed.
After cultivation, crops for oil seed
refining, such as soy bean, are collected and
transported to a nearby refining plant. After
the seed’s skin is removed, the seed is then
crushed and separated into two parts: the
meal (containing proteins) and the oil. The
oil obtained from crushing contains a high
level of impurities (eg pesticides), which
adversely impacts the oil’s stability, colour
and flavour – vital elements that are needed
to meet the final product specification.
Oil refining involves the progressive
removal of these impurities in order to
achieve a more stable, high quality product.
Oil refining challenges
To maintain a competitive edge in the
market, oil producers strive to manufacture
products of optimal quality. As with any
complex process, oil producers are also
faced with the continued challenge of
improving output while reducing costs, and
must optimise each step to ensure there is
minimal loss or waste.
In the case of oil refining, each step to
separate the oil composed of triacylglycerol
and diacylglycerols, from impurities such
as phospholipids, results in a loss of oil
yield.
Naturally occurring, phospholipids
are emulsifiers and their properties vary
from one type to another. Hydratable
phospholipids are easy to remove, while
non hydratable phospholipids are more
challenging to take away.
In traditional oil refining, phospholipid
removal is achieved by the addition of water
to the crude oil, hydrating the phospholipids
and causing an emulsion to form, trapping oil
in ‘gum’. This viscous gum is then separated
from the bulk oil by centrifugation, in a
process termed ‘water degumming’. The
gum may be further processed to lecithin, or
can be returned to the meal, which can have
an adverse effect on the meal value due to
the dilution of the protein content.
Following the centrifugation process to
separate the gum fraction from the oil,
neutral oil (triacylglycerol) is entrained
within the intact phospholipids in the gum.
The entrained neutral oil represents a yield
loss, and therefore water degumming can
be costly to oil producers. This method also
uses high amounts of water, energy and raw
materials, increasing production costs.
A growing number of manufacturers are
therefore turning towards a more efficient
and cost effective solution: enzymatic
degumming.
A golden opportunity
Enzymes act naturally on specific molecules
belonging to impurities, thereby increasing
the precision with which oil can be refined,
without affecting its quality. Enzymatic
degumming takes oil refining to another
level, harnessing the catalytic power of
phospholipases to break the phospholipids
into water and oil soluble fragments,
disrupting emulsion formation and releasing
entrained oil to make degumming easier.
This process is an economical alternative
to water degumming as it makes the
gums easier to separate and allows for
the production of more oil. Enzymes also
reduce the volume of gum and so decrease
the dilution of protein which can be put back
into meal. This is particularly significant for
the growing feed industry where feedstock
is scarce and concerns around the protein
content of meal is increasing.
Due to the reaction it creates, enzymatic
degumming offers a reduction in fatty
content in meals, and is therefore higher

30 Food & Drink Technology May 2016 www.foodanddrinktechnology.com


protein in meals, increasing its value to
producers as well the return on investment
for its users.
The commercially available
Phospholipase C (PLC) enzymes are
the preferred molecules for enzymatic
degumming because of unrivalled oil yields.
Compared to Phospholipase A (PLA),
PLC enzymes remove the water soluble
phosphate ester from the phospholipid,
leaving intact diacylglycerol oil. On the
contrary, PLA based degumming solutions
generate lysophospholipid and a fatty acid,
which has a significant negative impact on
the oil quality.
Proven results
Developed by DSM, the latest version of
PLC, called Purifine 3G, has proven to
increase oil yield by up to 2.5 per cent
compared to traditional water degumming
and results in a significant performance
enhancement, as well as a more sustainable
process. A historic leader of Argentina’s
agricultural industry, Molinos Río De
La Plata, has used these PLC enzymes
since 2010 and has become one of the
country’s main soybean and sunflower seed
processors (6,000,000 and 500,000 tons
per year respectively) [2]. Molinos recently
upgraded to the latest generation of the PLC
FATS & OILS
Purifine 3G. This resulted in a 50 per cent
performance improvement in oil yield, a net
oil yield gain of 2.4 per cent. In addition,
the use of these enzymes also resulted in
reduced fatty content in the meal of 1.10
per cent relative to results prior to using
enzyme. This has led to 0.55 per cent higher
protein in the meal, increasing its value and,
therefore, Molinos’ return on investment.
Environmentally friendly
Adding to the challenge of increasing
oil yield whilst improving oil quality,
worldwide manufacturers need to produce
in a sustainable manner, meaning they need
to produce more with their raw materials.
As a result of its composition, enzymatic
degumming is an environmentally friendly
process for oil producers. It makes oil
conversion more efficient, for a longer
period and producers need less resources
– such as raw materials, water and energy
– compared to traditional water degumming
for optimal results. ■

References
[1] Oil World, ISTA Mielke
[2] www4.molinos.com.ar/en/molinos-
agro.aspx

Author
Wouter Smits is DSM business
development manager, oils and fats.

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Visit www.palsgaard.com to learn more about how we can help you in your product development.

www.foodanddrinktechnology.com May 2016 Food & Drink Technology 31

FATS & OILS

Health slick

R
ewind back to the 1970s and
1980s, a time when people were
Emma Woods discusses the rise of and demand
told to limit their fat consumption for ‘healthier’ cooking oils and the challenges that
in order to cut the risk of heart dis-
ease and death. National dietary guidelines manufacturers could face if the trend continues
were released that recommended reducing
dietary fat consumption to 30 per cent of more traditional cooking oils. The rapeseed
total energy intake and saturated fat to 10 variety, for example, is considered healthier “Coconut oil does
per cent of total energy intake; but in 2015 because it contains the lowest saturated fat present its own problems
that advice was thrown out, with researchers content of any oil and 50 per cent less than
saying that it lacked any solid trial evidence olive oil. The cold pressed rapeseed market though; getting it to the
to back it up and that it ‘should not have is now worth £9.6 million – up 47.3 per cent point where it’s ready to
been introduced’. One expert even warned be dispatched to the
that ‘an overreliance in public health on
saturated fat as the main dietary villain for
supermarket and put on
cardiovascular disease has distracted from the shelves is challenging”
the risks posed by other nutrients, such as
carbohydrates’.
Today, nutritionists are much more in
favour of the balanced diet approach, and
people are becoming ever more conscious
about the things they consume. The fact that
consumers are always on the lookout for the
next best thing gives food manufacturers
a lot of scope to develop new, innovative
products which are nutritious yet tasty at
the same time.

A new generation of
cooking oils
Particular attention has been paid to ‘health-
ier’ oils, which can offer a lower saturated
fat content, or ‘healthier’ fat content, over

32 Food & Drink Technology May 2016 www.foodanddrinktechnology.com

 FATS & OILS

year on year. And it’s only going to continue

to grow; perhaps by as much as 10 times
its current size over the next five years. If
that comes to pass then it could account for
almost 10 per cent of the UK’s rapeseed
harvest by 2020.
But one oil has been garnering more
attention than the rest recently, and that’s
coconut oil; a product which is often talked
about as the new superfood. The oil was
once demonised for its high saturated fat
content, but here’s where it gets tricky: there
are different types of saturated fats, and
some are worse than others.
Coconut oil is made up of a blend of
medium chain saturated fatty acids, which
are believed to offer certain health benefits.
According to Kantar Worldpanel data from
September 2015, sales of coconut oil more
than tripled last year, so it’s well and truly
flying off the shelves.
Celebrities are no doubt playing a part in a liquid into jars, labelled and packed for gest challenge now is ensuring growers can
its rising demand – not only are they using it dispatch. supply enough to keep up with demand. ■
to cook with, but they’re also shouting about It joins other coconut products on the
the beauty benefits it can offer too. Want supermarket shelves – with coconut water Author
to deep condition your hair and add more and sugar also currently ‘on trend’. A recent Emma Woods is technical manager at
shine? Coconut oil can do that. It’s also article by the Wall Street Journal found that Phoenix Group, a UK supplier of contract
said to strengthen your nails, whiten your the appetite for these products is actually packing and speciality enhanced care
teeth and ward off tooth decay. Vita Coco, pushing the price of coconut oil up. The big- manufacturing to the food industry.
which we pack cold pressed coconut oil for,
even shares ways for people to make a body
cream, hair mask and make up remover Case study
using coconut oil on its website. Product: Vita Coco Organic Coconut Oil
Processes: Delicate heating, hot filling, packing, dispatch
Manufacturing challenges Volume: Almost one million units of coconut oil in 2015, packaged
With the largest cold pressing facility in the into volumes of 250ml, 500ml and 750ml jars.
UK, we’ve seen first hand how the market
The idea behind Vita Coco
for healthier oils has grown over the last was born during a casual
few years and we think that trend is only outing to a Manhattan bar,
going to continue: the speciality oil sector where childhood friends
is now worth £41 million, up 55.4 per cent Mike Kirban and Ira Liran
on last year. met two young women
Last year we invested in a new bottling from Brazil. They asked the
women what they missed
line at our factory to cope with increased
the most about Brazil, to
demand, and future planned investments which they answered ‘agua
include upgrading our filtration systems to de coco’ (coconut water).
allow up to six million litres of oil per year Two months later, Liran travelled Phoenix Group has been working
to be processed by the end of 2016. to Brazil and started researching the with the global brand since 2014,
Coconut oil does present its own prospect of branding coconut water producing almost one million units
problems though; getting it to the point for the American market. Soon after, of coconut oil for Vita Coco in 2015.
Vita Coco was born. The company is on track to hit five
where it’s ready to be dispatched to the
The company is now the market million units a year by 2017. While
supermarket and put on shelves is challeng- leader for coconut water, sold in Phoenix is the contract filler for the
ing. The oil melts at 24°C, which means over 30 countries including the US, oil, labelling is designed by the brand
Vita Coco’s product, for example, leaves Canada, most of Europe, Japan, China in association with New York creative
the Philippines as a liquid, but arrives in the and New Zealand. agency Madwell.
UK as a solid. As the coconut craze continued, Its organic coconut range includes
To preserve the product’s integrity, we its founder realised that the com- three sizes. Made using cold pressed
pany could capitalise on consumers’ coconut oil from the Philippines, the
gently heat the oil for between 12 and 36
growing appreciation for the wellness 250ml and 500ml sizes are available
hours up to 30°C in order to melt the oil for properties of the fruit, and so it devel- in a glass jar and the 750ml size is
filling without causing damage or risking oped an organic coconut oil range. available in a plastic jar.
its cold pressed status. It is then bottled as

www.foodanddrinktechnology.com May 2016 Food & Drink Technology 33

FATS & OILS
No margarine
for errors
A
‘category five’ frying margarine
isn’t something you want in your
kitchen. Crackling and spitting
like a fire in a pine forest, it can
clear a radius of five metres in under one
minute and demands hours of cleaning once
the heat has died down.
Of course, no manufacturer would ever
want their product to act so aggressively
– yet at Palsgaard, over the past year or so
we’ve seen more than one customer’s for-
merly peaceful margarine turn into a kitchen
tyrant. The cause? Most often, it is the result
of relatively minor changes in salt, lecithin
type and/or milk solids content.
One small step for frying margarines, it
seems, can be a giant leap for their frying
performance.
Spitting image
Frying margarines – either in stick or liquid
form – contain combinations of mono-
diglycerides, lecithin, citric acid esters and
salt in order to reduce ‘spattering’ – the spit-
ting of hot fat that occurs when the marga-
rine, or other frying aid such as oil or frying
fats, melts in the pan. As vapour pressure
increases, spattering occurs when coalesced
34 Food & Drink Technology May 2016
droplets sink to the pan’s hot surface, rap-
idly converting to steam and causing small
explosions that send fat globules flying.
In the vast majority of frying marga-
rines, lecithin or alternatively citric acid
esters are used both as emulsifiers and for
their anti spattering properties, along with a
number of other functionalities. Both prod-
ucts emulsify water droplets, reducing their
tendency to coalesce and facilitating fast
evaporation before gravity can bring them
into contact with the pan.
Is spattering a problem solved, therefore?
Not for European manufacturers, especially
– and even less so as time goes on.
Down with salt
To begin with, an increasing proportion of
lecithin production is based on genetically
modified (GMO) crops. That’s hardly a
problem in North America, for example,
where GMO based products are commonly
accepted. As such, manufacturers in that
part of the world continue to reap the advan-
tages of highly functional soy lecithin.
For European and American manufac-
turers, however, allergens such as lecithin
won from soybean oil must be declared in
Anders Mølbak Jensen
discusses how best to
maintain or improve
frying performance
foods. And in Europe, GMO products are
widely viewed with suspicion by consum-
ers, activists and politicians alike – so using
high quality North American lecithin isn’t
an option. In its place are products sourced
from South America or India. Typically
inferior across a broad spectrum of attrib-
utes, these products rarely have the same
power to reduce spattering.
The simple reaction for the majority
of European manufacturers, has been to
increase salt levels. Anti spattering proper-
ties are positively influenced by salt content
in the margarine because of its effect on
partial steam pressure in the water droplets.
Maintaining high salt content in markets
that are increasingly demanding salt reduc-
tion is, however, hardly a strategy for long
term success. Instead, manufacturers have
started down the path to creating frying
margarines with ‘normal’ salt levels – while
still using lower grade lecithin – and many
are finding the going tough, with increased
spattering as a result.
But salt reduction isn’t the only demand
from the marketing departments of manu-
facturers. With buyers beginning to
also favour lecithin free, non allergenic
www.foodanddrinktechnology.com
 FATS & OILS

solutions, requiring the removal of milk
solids or the replacement of soy lecithin
with less efficient rapeseed or sunflower
lecithin, developing low spatter frying mar-
garines is becoming increasingly difficult.
R&D teams are finding themselves
caught between a rock and a hard place.
And many are surprised when they make
a comparatively simple change with, quite
frankly, horrible results. Who would have
thought it would make such a difference?
New solution ‘engine’
To assist manufacturers with these chal-
lenges, Palsgaard has invested almost two
years in compiling more than 1,000 multi
parameter trials into a comprehensive ‘solu-
tion engine’ that can determine how best
to maintain or improve frying performance
when swapping out ingredients, altering
their proportions or changing process equip-
ment and parameters.
While similar testing has been carried
out in the past, this is the first time the task
has been approached with such diligence.
Palsgaard used, for example, an extremely
sensitive ‘worst case’ test methodology that
put recipes through their paces using elec-
tric, induction and gas stoves, different fry-
ing pan types (steel pans on gas turned out
to be the toughest challenge) and different
quantities of margarine.
The company’s application special-
ists have systematically documented, for
instance, the effects of:
• Reducing or increasing salt content from
0.2 per cent up to 1.5 per cent
• Altering production parameters
• Optimising emulsifier systems.
The results of the many tests are now
being used to support real life trials at
Palsgaard’s application labs or on site at
customers’ manufacturing plants, speed-
ing up the time it takes to identify the best
recipe for the lowest possible spattering.
Additionally, as part of the research
effort, five distinct categories were created
defining different levels of spattering. These
range from mild mannered category one
frying margarines to category five recipes
with fat spitting qualities so aggressive they
could only be used with special protection.
Manufacturers trying to reduce salt con-
tent while using the same emulsifier system
as for their regular recipe are almost without
exception certain to go a category or two
in the wrong direction – most likely at the
expense of market share.
Complex interdependencies
As any margarine application specialist
worth his or her salt knows, the effect of
salt in a frying margarine also depends on
the emulsifier system and the milk solids
present in the margarine. The processing
setup, however, also has an influence as
pressure, capacity, cooling and the actual
setup of pin machines, crystalliser and tube
chillers will affect the spattering perfor-
mance of the frying margarine.
It is such interdependencies that make the
job of maintaining spattering performance
so tough – and the list is long.
Consider the role of milk solids, for
example. Their inclusion in frying mar-
garine has a number of beneficial effects,
ranging from the desirable browning effect
of the Maillard reaction, to improved taste
and smell. Milk solids also destabilise
the margarine, causing water droplets to
become less regular, which reduces the
tendency to spatter. And deposits of tiny
particles on the base of the pan attract heat
to enable the creation of small ‘chimneys’
that channel steam from the base of the pan
safely up to the surface.
So, removing milk solids as part of creat-
ing a non allergen product has a profound
effect on margarine performance.
Control strategies
To control spattering, you need to enable
gradual rather than rapid evaporation of the
water droplets released as the margarine
heats up. Additionally, foam formed as the
frying margarine heats up, and generated
by citric acid ester or lecithin, also helps to
keep a lid on the flying fat droplets resulting
from the small explosions of heated water.
A good emulsifier system is essential
to distribute the inevitable explosions in
a delayed pattern. For example, mono-
diglycerides can be used to achieve a good
emulsion, then hydrolysed or native lecithin
can be added to make the emulsifier blend
more hydrophilic. Lecithin, in particular,
supports the creation of an emulsion that
isn’t strong enough to form uniform water
droplets that can simultaneously evaporate
– and helps to avoid the extreme situation
where larger droplets agglomerate to trig-
ger massive explosions. See figures 1 and
2 for tests of emulsifier systems with IP soy
lecithin and rapeseed lecithin respectively.
From the two figures it is evident that the
type of lecithin plays a huge role in anti
spattering behaviour, especially when the
salt content is reduced.
Used in isolation, however, lecithin is
likely to cause problems, so it is usually
necessary to combine it with mono-
glycerides and a little citric acid ester.
Removing lecithin altogether calls for

Figure 1: results of frying tests of a brick margarine made with an
emulsifier made from a mixture of mono- and diglycerides of edible
fatty acids, rapeseed lecithin and citric acid esters. With this emulsi-
fier system the best results are achieved without milk solids, either
skim milk powder or whey, and with a high salt content
Figure 2: results of frying tests of a brick margarine made with an
emulsifier made from a mixture of mono- and diglycerides, IP soy
lecithin and citric acid esters. Compared to figure 1 it is evident to
see that this emulsifier system with and without milk solids and with
low or high salt content offers much better frying results

www.foodanddrinktechnology.com May 2016 Food & Drink Technology 35

FATS & OILS
careful selection of a new emulsifier
system as a key aspect of the recipe, but
also requires the balancing of multiple other
elements in the ingredients and production
mix.
For manufacturers making frying mar-
garine recipe changes, our solution engine
tells a clear story: the copy/paste product
development model, where R&D takes an
existing recipe and ‘tweaks’ it by removing
or replacing an unpopular substance (salt,
milk solids or soy lecithin), then adjusts
the content of the remaining ingredients
to combat the inevitable increases in spat-
tering, simply isn’t good enough. A few
hundred hours later, at least, the product is
still likely to be one, two or more categories
higher up the spattering ladder – and prob-
ably failing to live up to other functional
requirements, too.
In fact, selecting the right emulsifier
Figure 3: results of frying tests of a liquid margarine made with an
emulsifier made from pure citric acid esters. Compared to figure 1
it is evident to see that this emulsifier system with and without milk
solids and with low or high salt content offers much better frying
results. As opposed to the emulsifier system tested in figure 1, this
system does not contain any lecithin, which makes it a good choice
for an allergen free margarine
36 Food & Drink Technology May 2016
system is the one thing every R&D team should be focused upon to
effectively control spattering.
What works best?
The many screenings have, for the first time, revealed exactly why
manufacturers have been encountering such difficulties every time
they want to make a change. Of course, it’s not possible to summarise
the results of so many trials with so many different parameters and
values. However, key insights from Palsgaard’s work include:
• Soy lecithin, used together with specific emulsifier systems, gives
the best spattering performance of the different lecithin types (see
figure 2)
• Combining mono-/diglycerides and lecithin reduces some spattering
in margarines with low salt content
• Pressure, capacity, cooling and the actual set up of pin machines,
crystalliser and tube chillers also have an influence
• Adding citric acid esters of mono- and diglycerides (citrem) is
perhaps the most effective solution (see figure 3).
Naturally, this focused effort around frying margarine trials has
enabled Palsgaard to build a huge base of analytical data and spatter-
ing knowhow. Having uncovered the key role emulsifier systems can
play in countering spattering, along with greater clarity around the
mix of other ingredients, the solution engine has become an effective
new tool for adjusting frying margarine recipes to meet a wide variety
of demands.
In our application labs, the focus is to move manufacturers back
down the categories to a safe place – or to help them keep their prod-
uct’s performance within the same category. The weapon of choice
is typically a combination of emulsifier systems based on citric acid
esters with or without lecithin (based on soy, sunflower or rapeseed,
hydrolysed and non hydrolysed) – guided by the solution engine’s
vast library of test results. In this way, frying margarine manufacturers
have a new opportunity to use their emulsifier partner as a sounding
board, sending samples to assess and repair spattering performance,
and speeding up the new product development process. ■
Author
Anders Mølbak Jensen is product and application manager, lipid and
fine foods at Palsgaard. Before joining the company 16 years ago, he
held various roles as a laboratory, quality control and R&D manager
at a large margarine producer for 10 years.
www.foodanddrinktechnology.com
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Bowl Cutters
New Fatosa 35 litre Bowl Cutter S/S Bowl
New Fatosa 120 litre Bowl cutter all S/S
Used Fatosa 125 litre Bowl Cutter all S/S
Used Laska 130 litre stainless steel Bowl Cutter
Used Laska 65 litre Bowl Cutter, S/S Bowl
Used Rex 45 litre Bowl Cutter black bowl
Mincers & Mixer Grinders
Used Butcher Boy AA66 Mincer 50 HP motor
Used Weiler Model 878 grinder, 50 HP Motor
Used Weiler 1107 all stainless steel grinder
Used Hobart 56 Flat pan Mincer
Used Biro 56 flat pan Mincer
Used Wolfking 400/160 Mixer Grinder
Used Wolfking 140 Mixer Grinder
Vacuum Packers & Shrink / dip mc’s
New ATM Table Top Vacuum Packer, single phase
New ATM Packman single chamber Vacuum Packer
New ATM large single chamber Vacuum Packer
New ATM double chamber Vacuum Packer
Used Cryovac CJ 51 heat shrink Tunnel
Used GSP 55E Flowrapper, year 2007
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Used Ilpra Inline Tray sealer, Model Speedy year 2002
Mixers & Tumblers
New Uniball 220 litre concrete style Mixer tumbler
New table top 20 litre vacuum tumbler
New Fatosa 150 litre single paddle Mixer
Used Asgo 450 litre Z arm Mixer in stainless steel
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Used Possenti 300 litre twin paddle Mixer
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Used Ruhle 56 Needle Injector
Dicers, Flakers, Graters
Used Treif Dicer 84 x 84 chamber
Used Torrey ST 290 Bandsaw sliding table
Used Cheese Cutter Model C23 2 stage cutter
Used single stage cheese cutters
Miscellaneous
Ishida Multihead weigher and Ilapak bagger
Year 2009 Saimo weigher and bagger system
Used Koppens VM 600 HS Former
Used Meat Pro 170 Burger maker with papers
Used Handtmann VF 200 sausage filler linker
Used Vemag Robot 500 Vacuum Filler
Used double clipper to suit vac filler
Used Vemag LPG 202 high speed sausage linker
Used Nilma auto Pasta Cooker gas heated
Used Boldt incline screw feed 400 mm dia
Used Ende incline screw feed 320 mm dia

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Aeration & Boilers Colours & Ingredients Depositors

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 DIARY

MAY Gluten-free: staying

ahead of the game
IFFA Date: 14 June
Date: 7-12 May Location: British Motor Museum, Warwickshire, UK
Location: Messe Frankfurt, Website: www.coeliac.org.uk
Germany
Website: www.iffa.messefrankfurt.com Legal Labels – FIC
Essentials
Vitafoods Europe Date: 15 June
Date: 10-12 May Location: Great Burgh, Epsom, UK
Location: Palexpo, Geneva, Website: www.leatherheadfood.com
Switzerland
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How to do it better
Food & Drink Trends & Date: 29 June
Innovations Conference Location: Campden BRI, Chipping Campden, UK
Date: 24 May Website: www.campdenbri.co.uk
Location: Cavendish Conference
Centre, London, UK JULY
Website: www.foodanddrinkconference.com
Food and Drink Federation
Crisis Management Convention 2016
Training Experience Date: 5 July
Date: 24-25 May Location: Willis Towers Watson, London, UK
Location: FoodChain ID EU, Four Oaks House, Website: www.fdf.org.uk/events
Lichfield Road, Sutton Coldfield, UK
Website: www.foodchainid.eu/training-courses
UK AD & Biogas
Date: 6-7 July
JUNE
Location: NEC, Birmingham, UK
Chocovision 2016 Website: www.adbioresources.org/uk-ad-
biogas-2016
Date: 7-9 June
Location: Morosani
Schweizerhof Hotel, Davos, Switzerland
Fruit Focus 2016
Date: 20 July
Website: www.chocovision.ch
Location: East Malling
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Free From Food Expo
Website: www.fruitfocus.co.uk
Date: 9-10 June
Location: Amsterdam RAI, the
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www.foodanddrinktechnology.com May 2016 Food & Drink Technology 41

60-SECOND INTERVIEW

“I vacation in
a very rural
location with
no indoor
plumbing”
Robert F Byrne, VP and GM, forecasting solutions at E2open, predicts
that more new and exciting tastes will become available over the
next 12 months as flavours and cuisines spread globally
Describe yourself in three words: Who do you most admire? Any vices?
Father, nerd, driven. Barack Obama. Bordeaux.
What’s your biggest professional What do you consider to be the most Tell us something about yourself that
achievement? important attributes for a leader? few people know.
Co-founding Terra Technology. Ability to attract good people, a vision and a I vacation in a very rural location with no
focus on results. indoor plumbing.
How did you get to where you are
today? Which people/organisations or compa- What single thing would most improve
Bad luck. I was happily leading pro- nies are the ones to watch right now? the quality of your life?
fessional services at Numetrix when it Other than E2open, Amazon and Google. A cure for jet lag.
was bought by JD Edwards. Rather than
Which words do you most overuse? How do you relax?
finding another job I started Terra with
Multi-enterprise, optimise. Hanging out with the family. Rock concerts.
three Numetrix colleagues.
If you weren’t in your current position, How would you like to be
What does a typical day look like for what else might you be doing? remembered?
you? Teaching at a university. As a loving father and good boss.
I fly about 1,000 miles/day on average, so
pretty much one to two meetings and off to
a new city.
What have been the highlights of
your company’s history, in your
opinion?
Inventing Demand Sensing, signing our
first global license (with P&G) when
we had 10 employees and joining
E2open to build the multi-enterprise
supply chain.
Flying, on average, 1,000 miles per day, Robert longs for a jet lag cure
What is your pet hate?
People who don’t prepare for airport
security.
Give us a positive prediction for the
food industry over the next 12 months.
Flavours and cuisines are spreading glob-
ally, so more new and exciting tastes are
becoming available.

42 Food & Drink Technology May 2016 www.foodanddrinktechnology.com

DAIRY CanTech

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