Wellness & Nourishment • GMP • Advanced ... - Mælkeritidende

Wellness & Nourishment • GMP • Advanced TechnologyHygiene • Analysis • Processing • Ingredients • Packaging

16SEPTEMBER 2006WELLNESS & NOURISHMENT ● GMP ● ADVANCED TECHNOLOGYDenmark - September 2006Wellness & Nourishment • GMP • Advanced TechnologyHygiene • Analysis • Processing • Ingredients • PackagingThe cover shows a lure. This instrumentdates back from the DanishBronze Age (about 600 B. C.). It hasonly been found in Denmark and theformer Danish territories. Today itforms part of the Danish Quality signknown as the ”Lure-brand”, used ondairy products.Circulation: 12.000 copiesReadership: Leading personnel inthe dairy and food industry in morethan 120 countries together withall the Danish embassies and consulate-generals,Government advisersand representations of marketingcouncils.The editorial staff ofDanish Dairy & FoodIndustry ... worldwide:Chief editor, M.Sc.K. Mark ChristensenSub-editor, M.A.Anna Marie ThøgersenLitographed by:Grafisk Data CenterOdense, DenmarkPrinted by:Helmer Jensen Aps,Odense, DenmarkEditorial officeand distribution:Danish Dairy & FoodIndustry ... worldwide”The old Dairy”Landbrugsvej 655260 Odense SDenmarkTel.: +45 66 12 40 25Fax: +45 66 14 40 26www.maelkeritidende.dkinfo@maelkeritidende.dkISSN 0904-4310Reprint permission to interestpublications providing their creditand tear sheets to the publisher.Wellness and nourishment, good manufacturingpractise, advanced technology in order to manufacturehigh quality dairy and food products is themajor theme of Danish Dairy & Food Industry ...worldwide this year.Modern consumers demand safe and high qualityfood products. Moreover, the consumers oftenwant light products with full-fat taste, but yet naturalproducts that contribute to the wellness andK. MarkChristensennourishment of the human body. These different and sometimes conflictingdemands are great challenges for the food industry. But, Danishcompanies within the fields of food products and food machinery, processingand analyzing equipment, advanced hygiene concepts, ingredientsand packaging have a leading international position in the fieldof food production. Therefore, it is only natural to promote Danishdairy and food industry as being at the forefront of new developments.Consequently, Danish Dairy & Food Industry ... worldwide focuses on;processing, ingredients, packaging, hygiene and analysis in relation toproduce healthy dairy and food products, which provide consumerswith wellness and nourishment.Besides studying this magazine our readers also have the opportunityto meet representatives from the Danish dairy and food industryat large international exhibitions held in 2006 as for example: Worldof Food China/International FoodTec China in Shanghai September4 th - 6 th , InterMopro/InterCool/InterMeat in Düsseldorf September24 th - 27 th , SIAL in Paris October 22 nd - 26 th , and the Russian Food Summitin Moscow, November 22 nd - 25 th .Furthermore, a larger number of this issue of the magazine willbe available at the IDF World Dairy Congress to be held in ShanghaiOctober 20 th - 23 rd 2006.The Danish Dairy Managers Association and the Danish Dairy EngineersAssociation own and publish Danish Dairy & Food Industry ...worldwide. It has been published since 1976 and this issue is the 16 th insuccession informing you about Danish dairy and food industry.Danish Dairy & Food Industry ... worldwide is distributed in morethan 120 countries in 12.000 copies. Our experience tells us that about100.000 dairy, food and marketing specialist worldwide study this journalevery year.You are always welcome to contact us for further information.K. Mark Christensen Anna Marie ThøgersenChief EditorSub-EditorDanish Dairy & Food Industry... worldwide 2006 1

Superfos – part of your dayYou probably know our customers betterthan you know us! But our products areeverywhere, and their content is beingused everyday at home and at work…Whether it is hot or cold food, paint,cosmetic or pharmaceutical products– Superfos deliver high quality, easy-to-usepackaging for the products that matterto you most.We strive to add value for our customersand to create preference for their products.www.superfos.com

By Hans Chr.Schmidt,DanishMinister ofFood,Agricultureand FisheriesDenmark - AnInnovativePlayer in theGlobal MarketThe Danish food sector faces increasingchallenges: The globalisation,the enlargement of the EU, therapid development of technology,consumer awareness and increasinginternational competition. Thesechallenges increase the need to beinnovative. This will be a key factorto success for the Danish food sectorin order to continue to produce qualityproducts at competitive prices.The Danish food sector has along tradition for being global andstill today the Danish food sectorhas a strong position on the globalmarket. In this way, the sector contributesconsiderably to the developmentand progress of the Danishsociety. The sector including supply,processing and service is a cornerstone of the Danish economy. Thesector contributes with 20-25 pct. ofthe collected export approximately100 billion Dkr.Bio- and nanotechnologyBio- and nanotechnology are areaswhere knowledge and technologyfrom developing research can contributesignificantly to improve thefood processing industries and foodquality. It is believed that bio- and nanotechnologykeep possibilities thatwill improve the food productionand be of substantial benefit to consumers,industry and the society.Nanotechnology is an area withknowledge and technology from upcomingresearch area, which can contributesignificantly to improve thefood processing industries. It will enhancethe health aspect in food productionin regards to the productionof raw materials and control. For theentire food process technology thecoupling between nanotechnologyand IKT will revolutionise the accesto data and surveillance. Therefore,it is belived that nanotechnologykeeps possibilities that will improvethe food production and be of benefitfor consumers, industry and thesociety.The Danish Advisory Committeefor Food Research has developedstrategies on how to realize the potentialof biotechnology. The suggestionsare described in two reportson research for food, non-food andfeed. The strategies show that biotechnologycan secure a strong ruraland food sector in Denmark and thatthe focus of biotechnology researchis decisive for the future competitivenessof the sector.The connection between food,health and genes are an importantarea of research and development.There is a need to integrate researchon food science and industrial biotechnologyto obtain solid scientificevidence for relationships betweenthe genome in the food process,food, and health, which will supportthe development of products with ahigh nutritional quality.Future strategiesMy general approach for the futureis a vision of a “knowledge-basedbio-economy”. We shall maximisethe potential of biotechnology forthe benefit of economy, consumersand the environment.Denmark has to deal with globalisationby competing on knowledge.We have the possibility to createunique knowledge and transfer theknowledge to new production andproductivity improvements. Theclusters of knowledge and expertisein the food production and processingindustry that Denmark posses isa priority.However when using biotechnologyit is important that ethical aspectsare considered. It is importantto have a holistic approach to theproduction of food, feed and nonfoodproducts. Social, economic andenvironmental considerations shouldall be accommodated. This gives thebest basis for a sustainable developmentdriven by biotech research.My conclusion is clear: Research,innovation and technology are thekey tools for Denmark in the futureif we shall continue to be a key playerin the globalised economy. ■4 Danish Dairy & Food Industry... worldwide 2006 NR. 16

Knowledge makes the differenceDSS is Europe’s leading specialist inmembrane filtration technology for theultimate in high quality dairy processing.Our experience in membrane filtrationand dairy processes is unrivalled.Working closely with you, we integrateour systems seamlessly in yourprocessing lines. More than 250 dairycompanies have already optimised theirplant with our technology.Choose DSS for the best in membranefiltration technology. Innovative, flexibleand reliable - we make the differenceyou need.DSS Silkeborg ASBergsøesvej 17DK-8600 SilkeborgDenmarkTel +45 87 200 840Fax +45 87 200 890info@dss-silkeborg.comwww.dss-silkeborg.com

New Research Results Pave theHealthier ProductsBy Ulla Kjer,Journalist,Arla FoodsCorporateCommunicationsDepartment“With milk, Mother Nature has createda very healthy product with awealth of valuable proteins, mineralsand vitamins. Our job is to continueto develop milk as the basisfor new, inspiring and healthy dairyproducts that meet consumers’ requirements,which are increasinglyaimed at health and convenience.”With these words, Group ExecutiveDirector Michael Stevns, whohas overall responsibility for R&D atArla Foods, sums up the key objectiveof the Group’s research and developmentactivities. The scope of suchactivities is illustrated by the factthat, at any given time, Arla Foodshas 300 projects ongoing within research,technology and product andpackaging development.“To take an example, our researchwithin the fields of nanotechnologyand nutrigenomics is opening upnew perspectives both for improvingproducts and for focusing evenmore strongly on healthy products.Probiotica impacts on fatconversionIn the spring of 2006, Arla Foodsachieved the first concrete resultsfrom the analysis technology knownas nutrigenomics. These results revealthat the probiotic lactic acidbacteria, Lactobacillus casei F19, canimpact on the body’s fat conversion,the sense of satiety, and reduces faton the stomach - so-called belly fat.Lactobacillus casei F19 is Arla’s ownpatented bacteria and is used in allCultura products.Nutrigenomics enables us to assessthe impact of a variety of foodson our genes. One example is that wecan now see that probiotica has animpact on genes, which subsequentlyaffects fat conversion. The resultsof the analyses have been so convincingthat Arla Foods has appliedfor a patent relating to Lactobacilluscasei F19’s ability to reduce belly fatand counteract weight gain.“With enhanced knowledge ofthe relationship between genes anddiet, it will be more interesting to createhealth-optimised food productsbecause they will hit specific targetgroups with greater accuracy,” MichaelStevns explains. “It does, however, requirea considerable amount of basicresearch within the area.”Within the field of nanotechnology,Arla Foods has, since June 2005,partnered other large Danish foodcompanies and research institutionsin a new research centre known asThe Nanofood Consortium. Thecentre aims at strengthening relationsbetween the food industry andpublic-sector research, thus contributingto the development of healthy,safer and nutritional food products.A minor revolutionOver many years, day-to-day developmentwork has centred on reducingthe fat content in dairy products.When Arla Foods, therefore,launched the calorie reduced drinkingmilk, Mini 30, in the Danish marketin 2006, it was nothing less thana minor revolution. For the first timeever, Arla had succeeded in maintainingthe fat percentage in a productwhile reducing the calorie contentby removing half of the lactose.In fact, Mini 30 is a by-productIn principle, membrane filtration is thesame as pouring milk through an ordinarykitchen strainer - a simple process withoutany chemical intervention. In reality,things aren’t quite as simple.from the development of a lactosefreemilk for the Swedish market.Normally, milk for people sufferingfrom lactose intolerance is producedby adding an enzyme which splitsdisaccharide lactose into monosaccharideglucose and galactose, thusenabling those with a lactose intoleranceto digest milk. The problemwith this method is that the milkacquires a very sweet taste. Consequently,there was a need to developlactose-free milk with the greatestpossible similarities to normal milkin terms of both taste as well as vitamin,protein and calcium content.The challenge was handed to ArlaFoods’ development centre for powderproducts, where Arla’s expertisewithin membrane technology is concentrated.Hans Henrik Holst, Headof Department, explains: “We chosea method where we first remove halfthe natural lactose content by filtrationand subsequently hydrolyse therest. This results in lactose-free milkwhich tastes like normal milk, butwhere the vitamin, protein and calciumcontent have been preserved.”Named Lactose-Free Milk Drink,the lactose-free milk is produced asa UHT product.6 Danish Dairy & Food Industry... worldwide 2006NR. 16

Way forMilk without the milky tasteHans Henrik Holst, however, can seeother opportunities in the product:“We thought that the milk tastedrather good even before it was hydrolysed.At the time, there was alsoa great deal of focus on eliminatingcarbohydrates from food products asa result of the “Atkins’ diet”.The lactose-reduced milk was lesssweet than normal milk or Lactose-Free Milk Drink. Moreover, the milkyafter-taste had disappeared. Mini30is made from minimilk with 0.5% fatand, therefore, is energy-reduced interms of both fat and carbohydratecontent.“This milk offers a low-caloriemilk type for, in particular, younggirls and women who regard milk asfattening and do not like the taste ofmilk,” says Hans Henrik Holst.Powder can show the wayHans Henrik Holst believes that thefuture will bring more specially designedmilk products: “In the ingredientssector, we’re used to separatingthe milk so that the componentscan be used for a range of purposessuch as specific nutritional productsfor the elderly, sportsmen and women,infant food etc. Therefore, wehave considerable expertise in termsof what can be used for which purposes.This knowledge can be transferredto fresh milk products.”Even so, Hans Henrik Holst recognisesthat consumers - at least Danishconsumers - may not yet be readyfor such changes.Arla Foods 2004/05Milk volume: 8.4 billion kg (ofwhich Danmark 4.1 billion kg, Sweden2.1 billion kg other, (primarilythe UK) 2.2 billion kg).Head of Department Hans Henrik Holstused membrane technology when hedeveloped a method to filter milk sugar toremove calcium, proteins and minerals.Turnover: DKK 46.4 billion (ofwhich 60% outside Denmark/Sweden).Co-operative members: 10,557(5,197 in Denmark, 5,360 in Sweden).Number of employees: 20,076.Outside Denmark and Sweden,Arla Foods operates production inthe UK, Poland, Canada, USA, Brazil,Argentina and Saudi Arabia. TheGroup has sales subsidiaries in 24countries. ■Discover the benefitsof process optimizationThe performance of your processplant is essential to your business.Plant reliability, bacteriologicalsafety, product safety, minimumproduct waste and maximumexibility: all parameters thatinuence the protability of yourprocess.GEA Liquid Processing Scandinaviasupplies expert process solutions.Let us optimize your process.GEA Liquid ProcessingScandinavia A/SGEA Liquid Processing Scandinavia A/S • Nørskovvej 1B • DK-8660 Skanderborg • DenmarkTel: +45 70 15 22 00 • Fax: +45 70 15 22 44 • post@gea-liquid.dk • www.gea-liquid.dkNR. 16Danish Dairy & Food Industry... worldwide 2006 7

Close Customer Relationsprovide MarketBy TorbenJensen, MarketManager, ITWNOVADANApSNew cleaning solutionsThe development of new solutionswithin CIP and surface cleaningcontinues to focus on well-knownparameters: expenses, efficiency,user and environment friendliness,safety and documentation. Newagents and application techniquesare usually developed in close cooperationwith the customer, thusensuring that agents and techniquesfunction in a sustainable manner.An example hereof are CIP lines inthe food industry engaged in theproduction of mixed products (vegetableand animal fat). This is an areawhere NOVADAN’s expertise has resultedin the development of uniquesolutions, providing large profits toindividual food producers.Customers are partnersHaving the customer as a partner indevelopment projects has for manySynergiesyears been a natural part of developmentwork performed at NOVA-DAN, resulting in close and longtermrelations between the chemicalcompany and customers in the foodindustry. The company’s applicationmanagers and technical consultantstherefore feel very much at home inthe customers’ production facilities,control rooms and staff areas.NOVADAN’s experts also cooperateclosely with the company’s ownsuppliers on developing new measuringand documentation tools tobe used in connection with hygienesolutions for the food industry. ■Please help us to keep upa complete mailing list!We continuously update our mailing list. In order to receive the journal on aregular basis, we kindly ask you to inform us if you have changed your addressor it is incomplete.Identification No.Title and NameCompanyStreetPostal codeCityCountryDanish Dairy & Food Industry ... worldwideThe old Dairy • Landbrugsvej 65 • 5260 Odense S • DenmarkFax: +45 66 14 40 26 • E-mail: info@maelkeritidende.dk8 Danish Dairy & Food Industry... worldwide 2006NR. 16

The Hygiene SolutionsPreferred by Food IndustriesWhether CIP or open plant cleaning is the issue- immaculate standards of hygiene are of vitalimportance to your production capability. Ourcomprehensive range of highly effective cleaningagents and disinfectants are developed at our ownlaboratory and designed to offer you the rightsolutions to improve your business.We continuously monitor your cleaning processand guarantee the highestlevels of hygiene – that is ourcontribution to food safety.we create reliable solutions for food safety!Platinvej 21 · DK-6000 Kolding · Tel. +45 7634 8400 · post@novadan.dk · www.novadan.dk

Whey Concentrate onthe MoveBy Jan Sprogø,MarketingManager, DSSSilkeborg ASkg/hour. This means whey concentrationprior to transportation hasonly been cost effective for somecheese dairies.Up to 40% reduced costWith the WheyCon, the fixedcosts involved in establishing smallerRO and NF plants are 25-40%lower than for a similar customisedplant. A standard unit for RO orNF concentration of sweet or acidwhey, the WheyCon is compact,skid-mounted and pre-engineeredand includes MCC, a frequency converterand a semi-automatic controlsystem.In addition to enabling cost-effectivelogistics, the unit creates opportunitiesto decentralise RO concentration.High quality whey proteinconcentrate (WPC) can then be pro-The DSS WheyCon has createda new opportunity todeliver better and cheaperraw materials for the productionof high quality wheyprotein concentrate.DSS WheyCon unitNew innovative filtration technologyfrom DSS now makes it possiblefor smaller cheese dairies to enjoy thesame advantages as their larger counterparts.Using the new DSS Whey-Con unit, long-distance whey concentratetransportation and reverse osmosis(RO) concentration of relativelysmall whey quantities has become acommercially viable proposition.The WheyCon responds to therise of large whey processing centresand their growing need for highquality whey and whey concentrate.In many cases, the whey is transportedto the centres over long distances- often in concentrated form to keeptransportation costs to a minimum.For smaller cheese plants, the costof establishing an RO or nanofiltration(NF) plant for the purpose ofwhey concentration has, until now,been disproportionately high. A standardRO plant with a capacity of20,000 kg/hour, for example, costsonly around 20% more than a similarplant with a capacity of 10,000A successful DSS WheyCon installation at a Polish cheese dairy.Costs / kg TSProduct valueFeasibility point,local RO concentrationUnconcentratedwhey, 6% TSWhey conc. 18% TS(traditional RO)Whey conc. 18% TS(WheyCon RO)Feasibility point,transport distanceTransport distanceFigure 1: The DSS WheyCon turns local whey concentration and transportationinto a feasible opportunity.10 Danish Dairy & Food Industry... worldwide 2006 NR. 16

duced using whey that previouslywas either used locally for low-valueapplications or disposed of as waste -with environmental consequences.The development of the Whey-Con coincides with the growinginterest in new technology for theproduction of value-added, dairybasedingredients. DSS is also involvedin projects that include microparticulationof whey proteinsand the use of microfiltration forprotein fractionation.DSS supplies all types of membranefiltration processes for wheyprocessing. Large processing linesfor the production of diverse WPCproducts are a speciality. A typicalsystem solution from DSS coversUF concentration on one or severalplants, RO or NF processing of UFpermeate and an RO polisher forwater recovery. ■A DSS WPC processing line showing an RO and RO polisher with UF in the background.Feed, kg/h Feed TS Retentate TSRO sweet whey 4,500 6.0% 18.0%NF sweet whey 10,000 6.0% 18.0%Table 1: The DSS WheyCon unitcomes in one standard size. Capacityvaries depending on the membrane (ROor NF) and feed type.NR. 16Danish Dairy & Food Industry... worldwide 2006 11

Gerstenberg Schröder PromoteTechnological Transfer -By PernilleGerstenbergKirkeby, M.Sc.in Food Scienceand Technologyand Managerof Technologyand Marketing,GerstenbergSchröder A/S,DenmarkIntroductionGerstenberg Schröder A/S (GS) develop,manufacture and install modern,high efficient and reliable processinglines for the food industry, especiallyfor the production of crystallisedfat products like margarine, butter,spreads and shortenings. GS also deliverprocess lines for emulsified foodproducts such as mayonnaise, saucesand dressings. The main focus of GSis to be the preferred partner whenthe food industry demands scrapedsurface heat exchanger (SSHE) forthe manufacturing of food products.Examples of this could be foodproducts that require gentle thermaltreatment (heating and/or cooling).GS have installations in more than110 countries around the world andhave been in business for more than100 years.ServicesFood companies today are like othermanufacturing businesses not onlyfocusing on the reliability and qualityof the manufacturing equipmentbut also on various services that theequipment manufacturing companycan deliver. This means that ourcustomers and potential customersare also interested in other aspectsof our business than the high qualityequipment we supply. We have developedpackages of services meaningthat we are able to supply ourcustomers and potential customerswith efficient processing lines andthe best possible service from theinitial idea or project stage to thefinal commissioning phase, not toforget the important after-sales service.This palette of services will bedescribed in the following.Project managementEvery project is tailor made andgets special attention from a projectmanager who handles the projectfrom the initial quotation stage. Ifa project involves process development,we typically divide it into:definition of the process, descriptionof the process and requiredequipment, and finally design ofthe actual processing line for themanufacturing of the specific foodproduct. When the processing line isinstalled, our commissioning engineersare taking over the project. Oftenthe commissioning involves notonly close contact to the managersof the customer but also training ofkey operational personnel and technologicaltransfer on the productionsite. Thus, our commissioning teamneeds to be and is highly flexible andknowledgeable.Partnership and value for ourcustomersHowever, our portfolio of servicesis not ending at the commissioningstage since for decades we have investedin expert man power to meetthe possible demand of other servicesthan an equipment manufacturernormally supplies. We differ fromother equipment suppliers since wePerfector and Kombinator for high pressure crystallised products.14 Danish Dairy & Food Industry... worldwide 2006 NR. 16

Value for our CustomersConsistatorfor thermaltreatment.try to have a holistic view on themarket we are in. We focus on howwe can create extra value for our customers,thus the equipment is only apart of this value chain. Apart fromthe project management alreadydescribed where process knowledgeand expertise is highly needed andavailable, the process knowledgeand expertise also exist in all otherdepartments in GS, even in the topmanagement. By spreading expertiseconcerning our customers’ businessthroughout GS we believe we herebycan add extra value to our customerssince every entrance to GS willbe met with an understanding of thecustomers’ business, needs and challenges.Service departmentWe build long-term relationshipwith our customers since our equipmentand processing lines are madeto last for decades. After-sales serviceis of great importance in this respect,as the equipment needs to be wellmaintained in order to continue toprocess efficiently. With preventivemaintenance downtime is reducedto a minimum. In addition, we areable to deliver spare parts for almostevery piece of equipment, which wehave supplied over the years, and ifthe parts have been discontinued, anup-graded version of the spare partwill be available. Our team of serviceengineers has long experience inhow to keep our customers’ processinglines and equipment in the bestpossible condition. If a breakdownoccurs, we will be able, also on a holiday,to send a service engineer andparts promptly in order to minimisethe downtime.ProductdevelopmentTestfacilitiesProjectmanagementPriceTechnologicaltransferEngineeringEngineeringExtra value for our customersQualityDesignProductProductReliabilityProcessknowledgeTurn KeyprojectsOther after-sales servicesWhen our customers are in need ofassistance in product developmentor process optimisation we can supplythat either as an in-house serviceat the customers’ site or by thepilot laboratory facility we have inLübeck, Germany or in Brøndby,Denmark. We have promoted thepartnership relation to our customersin many years by offering lowcost product development service.Our pilot plants are well equippedwith not only SSHE or related equipmentbut also analytical apparatusin order to describe and evaluateingredients and products before andafter production, respectively, of thespecific food products. We are capableof making process developmentin terms of choice of ingredients,recipes, process and also equipmentas the technology department isnaturally in close contact to the engineersin the technical and projectengineering departments. In addition,we have partnerships withvarious other equipment manufacturerswho supply equipment in relatedniche markets hereby securingavailability of expert expertise forour customers in processing fieldswhere we normally do not operate.By promoting internally and externallythis holistic view on ourspecific market we hope to be ableto create extra value and hereby successfor our customers. The successand profitability of our customerswill usually result in more businessand we will have a chance of beingpart of this prosperity.For more information on GerstenbergSchröder A/S please visitour homepage www.gs-as.com. ■DeliveryServiceTrainingSparepartsValue Valueformoney forNR. 16Danish Dairy & Food Industry... worldwide 2006 15

Unique ‘Two-in-One’ PackBoosts ConvenienceBy AnnetteGøttsche,CommunicationManager,SuperfosA new insert for Superfos’ Uni-Pak solution enables dairy producersto cater for increasedconsumer demands for delicate‘two-in-one’ brands.Superfos has just upgraded itsunique UniPak solution with a newround insert build into the pack offeringtwo pots in one. The insert isdesigned for manufactures that producehigh quality two-componentdairy products such as müsli withcrunch, desserts with sauces andmuch, much more.The new two-in-one solution enablesdairy producers to cater for thefast growing high-end conveniencemarket and increasing consumer demandsfor healthier ‘two-in-one’ alternativesto drinks and snack-foods.Safe and delicateWith the UniPak solution, two-componentbrands improve both userfriendlinessand convenience oftheir brand. The insert fits perfectlyinto the UniPak pot and there is norisk of content leaking or splashingout, as it is safely stored and separatedinside the pack for end-userconvenience.The strength of the insert is optimizedcompared to other twocomponentsolutions and offers improvedprotection of the content.Furthermore, both components usethe same liquid tight lid increasingreusability compared to i.e. flexiblebags. Other benefits include easyhandling, improved stacking abilityboth at the store and for the enduser.Superfos has just upgraded its UniPaksolution with a new round insert buildinto the pack offering two pots in one.The UniPak range is already extensivelyused for i.e. yoghurt and ice-cream.Outstanding brandingpossibilitiesThe UniPak range is already extensivelyused for i.e. yoghurt, ice-creamand cheese products; not least becauseof high product safety combinedwith outstanding design anda number of unique decorationfeatures offering completely newbranding possibilities.Among other things, the possibilityof colourful IML-print on theskirt increases opportunities to makepromotional offers stand out andprovides for strong in-store brandingavoiding inconvenient stickers.Also, it enables a clear marking ofranges, flavours, seasonal versionsor helps bring allergy advices andhealth messages through. New isalso the placing of the IML-label atthe bottom of the pack for i.e. barcodes.This speeds up counter-serviceand better utilization of visiblebranding space.Finally, coloured text in a food-approvedand scratch free black colouron the tamper evidence tab increasesproduct-safety visibility making iteasier for the consumer to open andre-close the pot correctly.Highest hygiene standardsSuperfos is a substantial supplier ofpackaging to the consumer segmentwithin high quality conveniencefood. The entire UniPak range is coveredby Superfos’ very strict hygienesystem, that takes stand in the quality-and hygiene standard BRC/IOPdeveloped for the British market.Furthermore, the production isalso approved by some of the largestinternational food manufactures andsupermarket chains such as Marks& Spencer, Sainbury’s, UNIQ andNestlé, who have their own specialdemands to hygiene management,that food and packaging producersmust live up to. ■16 Danish Dairy & Food Industry... worldwide 2006NR. 16

Engineers of Food Processing TechnologyWe guarantee that your productionis just running and running and running…PARAMEDIA 1129/04The consumer expectsthe same high quality intaste and consistency.Over and overYou can always relax when you choose a solutionfrom Gerstenberg Schröder (GS). We ensure safe andstable long-term production, due to the original GSspare parts.We guarantee swift delivery anywhere in the worldof any components required for upgrading or regularmaintenance of the GS scraped surface heatexchangers and emulsification equipment.For more peace of mind the GS Logic system controls,records and documents all the important parametersregarding the process.This advanced technology will keep a keen eyeon every stage of the production and monitor theflexibility of the system and the manufacturingeconomy. It’s easy to use and even moreimportantly – easy to learn to use.Always on the lookoutfor improvementand better economywith GS Logicwww.gs-as.com · Tel: +45 4327 7000 or +49 451 37 09 0

Food Industry Embraces Health and Wellness- But Pockets of UncertaintyRemainBy Karen S.Frost,Journalist,Communication& PR,Chr. HansenA/SIn May 2006, Chr. Hansen asked selected customers andexperts from all over the world to share their opinion ina web poll. 108 Research Scientists, Sales Managers, FoodTechnologists, Plant Managers, Purchasers, and otherindustry professionals responded.Healthy future foodsHealth is the future of food. Of this,food industry professionals participatingin the survey have no doubt.An overwhelming 96% considerhealth and wellness very important(76%) or above average importance(20%). The clear majority (59%) ofthe respondents have already actedon their conviction and launchedproducts (see figure 1). However, asizeable minority - nearly one infour - are uncertain about how toapproach this quickly evolving foodcategory. For now, this minority remainssidelined without concreteplans for market-entry.“There appears to be some confusionand uncertainty about howto approach the market and whichstrategy to follow. When asked ‘Whatis the most important factor for a successfulhealth and wellness product?’respondents were fairly equally splitbetween authorized health claims,marketing, taste, or scientific documentation.Not surprising, becausein reality the right strategy is likelyto be a mix,” says Ken Gawley, Chr.Hansen’s Industry Manager for Foodand Beverage.Push and pull factorsNearly half the respondents (47%)identify consumers as the most importantdriver behind the health andwellness market (see figure 2). Butalmost as many (44%) acknowledgethe substantial effort from the foodindustry ingredient suppliers (16%)plus food producers (28%) in developingthis high value category.“It is definitely a combination ofpush and pull factors,” says HansChristian Bejder, Global MarketingManager for Probiotics at Chr.Hansen. “There is no doubt that largegroups of consumers are activelylooking for healthy foods, but newconcepts like ‘gut health,’ ‘friendlybacteria,’ or the ‘daily dose’ did notIt is not relevant for my companyWe are interested, but have no concrete plans at the momentWe expect to launch our first products in 2006We have already launched productsbecome widely established withouta significant effort in informationand education from the industry.”The responses to “Who is yourmost important source of inspirationfor health and wellness foodproducts?” show that the food industrywisely obtains its knowledgeand information from a broad base.Ingredient producers (27%), foodindustry media (27%) and marketresearch (24%), are all significantsources of inspiration for the producers.Perhaps a little surprising,the retailers - that link in the chaindirectly connected to consumers -apparently have little (6%) to offerin this respect.The place to beWhen asked, “Which do you considerthe most important health andwellness food trend in 2006,” therewas no clear answer. Probiotics(20%), Low fat (19%), heart health(19%), and organic foods (18%) weretied for first place, and all categoriesgot at least a few responses. Similarly,women were considered the demographicgroup to hold the biggestpotential (37%) for health and wellnessfoods, but aging (24%), children(19%), and men (11%) received afair number of responses. Such evenfields demonstrate that health andwellness is fast becoming an establishedproduct category, rather thana niche market dominated by productsfor small, committed groups.What is ahead?Looking at specific ingredients, fiber18 Danish Dairy & Food Industry... worldwide 2006 NR. 16

RetailersRegulators and Government bodiesConsumersFood producersIngredient suppliersand whole grain (37%) appear to bethe most important ingredients forhealth and wellness, particularlyin the Americas. In 2006, omega-3(25%) and probiotics (22%) are secondand third, but this could beAntioxidantsOmega-3Fibre and whole grainPlant sterolsabout to change. Respondents choseprobiotics (31%) as their favoriteingredient for 2008, with fiber andwhole grain, omega-3, and antioxidantsall in close battle for secondplace (see figure 3).PrebioticsProbioticsA tough jobThe global survey confirms the singlemost important challenge facedby food producers today: developingnew and healthy food products.“This is exactly where a workingpartnership with a major ingredientsupplier like Chr. Hansen can makethe difference. Our application andindustry specialists can provide theknowledge, inspiration, and supportto make our customers successful,”says Mr. Gawley.Presented here are the highlights ofthe survey. On www.chr-hansen.comthe complete results are available. ■APV LeanCreme – better flavour, less fatAPV LeanCreme is a groundbreaking microparticulationprocess that gives you total control over whey proteinparticle size distribution.APV’s new Shear Agglomerator (ASA) is designed to provideoperating parameters for optimum particle quality and control.APV LeanCreme gives you:• High, protein-based nutritional value• Full flavour and mouth feel• Bigger yield – reduced raw material costs• Rapid pay-back and big ROIFind out more at www.apv.com under ”Latest news”.APVPasteursvejDK-8600 Silkeborg T: +45 70 278 278F: +45 70 278 330www.apv.comNR. 16Danish Dairy & Food Industry... worldwide 2006 19

Nutrigenomics- Nutritional Research with a MolecuBy LisbethMunksgaard,Director,Centre forAdvancedFood Studies,Denmark(lm@lmc.dk)Mapping of the human genome hasmade it possible to study the influenceof diet on which genes are upordown-regulated. Genes code forproteins, which again regulate orcatalyze the formation of metabolites,which may change in abundancedepending on gene expressionrates. Studying the effect of dieton the system of genes, proteinsand metabolites is called “nutrigenomics”.Nutrigenomics is a new, promisingtool in nutritional science. Themolecular approach aims to revealprecise, biochemical explanations tonutritional mechanisms. This mayhelp us to change the regime of increasingobesity and related life stylediseases. Research in nutrigenomicsis a priority in the collaboration betweenpublic, Danish food and nutritionresearch and the private foodsector.Applications of nutrigenomicsWhile health is an increasingly importantdeterminant for choice offoods in some consumer segments,unhealthy eating and drinking habitsremain the cause of bad healthand large economic losses for society.The market for well-documented,healthy foods that meet the modernconsumer’s demands for convenienceis increasing world-wide.However, the proper documentationof improved health effects of foodsis currently a major obstacle for innovationworldwide. Nutrigenomicscan serve a systematic approach tothe revealing new biomarkers and atool to improve throughput in foodtesting and health claim documentation.Such a standard will meet thelegal requirement according to a recentlyproposed EU regulation.Functional foods are developedto improve health, well-being andto have other functions such as improveddigestion. The internationalmarket has seen many pre-and probioticproducts, especially related todigestion. Nutrigenomics serves agreat potential for obtaining betterinformation regarding their interactionwith the gut flora and theireffects in the individual. This informationwill strengthen knowledgebaseddevelopment of cultures forhealth improved food and feed andfor targeted choice of ingredients,variety of vegetables or breed of animalsfor production of food with improvedhealthiness.Nutrigenomics may:● lead to tools that can prove healthclaims● give basis for development of functionalfoods or ingredients thatmay improve healthiness of food● lead to more precise nutritional adviceto individuals and to groups ofindividuals (elderly people, top athletes)and food specifically addressedto people with specific needs.The regime of genes, proteins and metabolites creates a huge number of data. Bioinformatics is statistical handling of the data inorder to identify differences between samples.20 Danish Dairy & Food Industry... worldwide 2006NR. 16

lar ApproachCentre for Advanced Food StudiesAll major Danish food science institutionsin Denmark (see box) collaboratewithin the frame of Centrefor Advanced Food Studies (LMC).LMC coordinates the scientific activitiesand higher educations withinthe food area and serves as a uniquepartner for the private and publicfood sector. LMC was establishedin 1992, highly encouraged by theprivate Danish food sector. LMC is acentre of excellence within food science.Groups in the LMC frame areinvolved in more than 40 projectsunder EU Frame Work 6 program andhave the leading role in a number ofprojects.LMCLMC is an interdisciplinary collaboration of research and education withinfood science and technology. The following institutions take part in LMC:The Royal Veterinary and Agricultural University (www.kvl.dk)Technical University of Denmark (www.dtu.dk)Danish Institute of Agricultural Sciences (www.agrsci.dk)MAPP-centre, Aarhus School of Business (www.asb.dk)Danish Institute for Food and Veterinary Research (www.dfvf.dk)Danish Institute for Fisheries Research (www.dfu.min.dk)University of Southern Denmark (www.sdu.dk)Please visit our website at www.lmc.dk for more information on LMC.Nutrigenomics is a priority in theLMC strategy 2006-10. A new, internationalM. Sc. programme willstart in September 2006. A nationalresearch platform is headed by ProfessorLars Ove Dragsted, Danish Veterinaryand Food Research. The institutionscooperating within LMC houseworld leading groups within omicstechniques, bioinformatics (ProfessorSøren Brunak at the TechnicalUniversity of Denmark) and humanintervention studies and obesity (ProfessorArne Astrup, the Royal Veterinaryand Agricultural University).LMC hosted an international nutrigenomicsconference in March2006. After the conference LMC andGenome Canada hosted a workshopfor selected scientists from Denmarkand Canada and invited keynotespeakers from US and Holland. ■opus FIL-D-01GEA MEMBRANE FILTRATIONIndustry Know-How– Process ExpertiseFrom ingredient production tobacterial removal – GEA Filtrationbrings know-how and industryunderstanding to any partnership.GEA Filtration is a world leader incrossflow membrane filtration,with reverse osmosis and nano-,ultra-, and microfiltration ascore technologies.A company of mg technologies groupGEA FiltrationGEA Filtration • Noerskovvej 1b • DK-8660 Skanderborg • DenmarkTel: +45 70 15 22 00 • Fax: +45 70 15 22 44 • info@geafiltration.dk • www.geafiltration.comNR. 16Danish Dairy & Food Industry... worldwide 2006 21

ESL Technology Ensuresand QualityBy FrederikW. Petersen,AccountManager DK,Tetra PakNorth EuropeCommercial product qualityESLOne common ESL definition is theability to extend the shelf life of achilled distributed product beyondthe shelf life of the traditional pasteurisedequivalent in a specific market.The global trend towards dairyindustry deregulation has created acompetitive market situation for localdairies as well as for multinationals.Consolidation and exploitingeconomies of scale has become thekey to growth and even survival formany dairies. It means fewer plantsand wider distribution areas. In thisnew scenario, ESL technology is a keytool to ensure that the milk can travelgreater distances, while remainingfresh and having the required shelflife after arrival at its destination.The ESL technology offers the opportunityfor the dairies to focus onbranded and added value productsThe shelf life assumed in the graph is to a high degree dependent on the quality of theraw milk, hygienic processing and packaging conditions and the temperature level inthe distribution cool chain.with possibilities of higher margincompared to traditional dairy products.ESL technology also offers advantagesin terms of product safetyand quality. The basis is improvedhygiene and reduction of the riskfor recontamination by pathogenicspoilage organisms in productionand distribution. With the currentfocus on food safety issues in thefood industry, these aspects will becomemore prominent drivers forESL technology in many markets.The shelf life of a food productdepends on a number of differentfactors. For pasteurised low acidproducts as milk and other non-fermenteddairy products, the mainfactor is microbiological activitycausing sensory quality defects and,ultimately, product spoilage.The technologies for extending theshelf life of dairy products are basedon improved hygiene, increased microbialkilling and removal effectduring processing, prevention of reinfectionduring filling, and reduceddistribution temperatures.A higher microbial killing effect in the process and a reduced risk of recontaminationdownstream of the processing result in a lower bacterial load in the product and thusimproved quality and a longer shelf life.Processing solutionsMilk pasteurisation and UHT treatmentare well defined, but specificstandards or legislation for alternativeESL processes are rare. The possibilityto use alternative or additionalprocessing beyond normal pasteurisationisn’t available in all markets.In these cases, control of the operationaland environmental factors becomeseven more important.Even with advanced hygienic features,the processing equipment is22 Danish Dairy & Food Industry... worldwide 2006NR. 16

Safetystill sensitive to the surrounding environmentand the operator’s handling.For optimal performance, environmentalfactors must therefore becarefully monitored and controlled.Operational procedures should bedocumented and implemented byproperly trained operators. There arethree main process technologies forESL treatment. Which technologiesare chosen, and sometimes combined,depends on the type of productand the desired outcome:● Pasteurisation combined with bactofugation.● Pasteurisation combined with microfiltration.● High Heat Treatment.Good ESL results require good control of the whole production chain.SummaryThere are many factors influencingthe quality and shelf life of chilledliquid products. Quality can be affectedat every stage of the productionchain - from raw milk qualityto processing and filling operationsand finally distribution. That is whythere is no standard ESL solution. Optimalline solutions have to be tailormade according to individual needsand the strengths and weaknesses ofthe whole production and distributionchain. Tetra Pak is the only supplierin the world with the necessaryskills, know-how and experience inprocessing, packaging and distributionto treat the product chain asan entity. This enables the companyto provide customized knowledgebased solutions that meet customersESL technology needs, whether thereare improved product quality, greaterproduct safety or longer shelf life. ■Using Tetra Alcross Bactocatch bacteria and sporesare removed from the feed at an efficiency of at least 99,9%.Tetra Pak Processing North EuropeSøren Nymarks vej 13, DK-8270 HøjbjergTelefon:+45 89393939 Fax:+45 86295311NR. 16Danish Dairy & Food Industry... worldwide 2006 23

Natural Cheese Flavoursbased on EMCBy Jesper Friis,Vice President,Sales &Marketing,A/S EINARWILLUMSENEINAR WILLUMSEN’s spray-driedEMCs are pure cheese flavours withno addition of powdered carriers ofany kind. The powders are 10-15times stronger than cheese.The manufacturing processThe main steps of the manufacturingprocess are shown in fig. 1.notes) are added and the flavour isthen filled while it is still liquid. Underthe subsequent cooling to 5 °Cthe flavour sets to a firm paste and isready for use.The cheese flavour plant is integratedin EINAR WILLUMSEN’smain GMP, and the web based qualitymanagement system, which isIntroductionNatural Cheese Flavours are a specialitywith EINAR WILLUMSEN, otherwiseprimarily known as a leadingNordic flavour house within thearea of sweet- and fruit flavours andbeverage compounds. The range ofcheese flavours has been developedover the past 20 years and it is continuouslygrowing.The core of EINAR WILLUMSEN’snatural cheese flavour range is a seriesof enzyme modified cheeses.All flavours are produced with realcheese as the main raw material.Enzyme modified cheeses (EMC) areproduced from a variety of industriallyavailable cheeses with water andsalt and then hydrolyzed with foodgrade, non GMO, enzymes. The resultingenzyme modified cheeseshave a strength typically 4-8 timesthe corresponding cheese.The EMCs also constitute thebase of an extensive range of naturalcheese flavours called IN CREASE®cheese flavours. In this range EINARWILLUMSEN have increased the intensityand influenced the flavourprofile by the addition of variousnatural flavour components e.g. fattyacids. The IN CREASE® flavourshave an intensity compared to thecorresponding cheese of 8-12 times.Finally a small range of spraydriedEMCs are offered for applicationswhere flavours in a paste form,like all the above, is not suitable.▼▼Blend of cheese„emulsified„ with H 2 OPasteurisation andHomogenizationAddition of enzymesFigure 1: EW Natural Cheese Flavours - Process flow.The cheese raw material is cutand dispersed to a slurry with water.The chemical analysis may beadjusted with butter, milk powderor salt and the slurry is pumped toa reactor tank where enzymes (variousproteases and lipases) are added.The reaction in principle resemblesan accelerated version of the naturalmaturation which cheese is undergoingwhen it is aged. The reactiontime is calculated in hours or daysand when the correct level of enzymatichydrolysis has been achieved,the finished flavour is pasteurized toinactivate the enzymes. If required(the IN CREASE® range) naturalflavour components (so called top▼Addition of Top Note(optional)Processing, Pasteurisation andHomogenizationNatural Cheese Flavour - PasteSpray dryingNatural Cheese Flavour - Powdergoverned by the principles of ISO9001:2000 and ISO 22000.This “simple” process is actuallyquite complex, the secrets is lying inthe composition of the enzymes, inthe processing parameters and in theselection of raw materials. In Europeonly a small handful of flavour companiesmasters this technology.Products and characteristicsThe cheese flavour range in fig. 2gives an overview of the types ofstandard cheese flavours offered byEINAR WILLUMSEN.It is important to note that the describingname of the cheese flavouris only a guideline. The describing24 Danish Dairy & Food Industry... worldwide 2006 NR. 16

Traditional EMC Flavours Type IN CREASE® Cheese Flavour▼▼Paste Spray dried Taste profile Paste099486 099500 Cheddar 099810099450 099566 Emmenthaler 099819- - Feta 099828- - Gouda 099837099404 099512 Mature Cheddar -099465 099523 Parmesan -099411 099555 Blue 099891099467 - Strong Blue -099425 - Goat -099430 - Manchego -- - Swiss 099840- - Mature Gouda 099860Approx. flavours strength in comparison with real cheese:4-8 times 10-15 times 8-12 timesFigure 2: EW Natural Cheese Flavours - Standard Range.Facts (typical for pastes): Dosages: 0.5-2.0 % (InCrease), 1.0-3.0 % (StandardEMC). Dry Matter: 36-38 %. Fat: 13-15 %. Protein: 14-16 %. Salt: Approx. 4 %. pH:4-5. TPC < 1000/g. Shelf life: 9-12 months at 5 °C.names e.g. “Mature Cheddar” or“Parmesan” are not an indicationthat these flavours necessarily havebeen manufactured from the namedcheese. EINAR WILLUMSEN usehigh quality industrial cheeses as rawmaterials, typically young cheesewith a good ratio between dry matterand price and with a dry matter composition,which is suitable for enzymemodification. In some cases specificcheese raw materials correspondingto the type of flavour is used. Examplesare blue- or goat cheese.This is an important point, assome users of cheese flavours thinkthat the products are simply modificationof the named cheeses, andthat therefore only “cheese” has tobe declared on the label. This is notthe case. EMCs and enhanced naturalcheese flavours based on EMCsuch as IN CREASE® all come underthe European Flavours Directive88/388. This means that they areconsidered as flavours concerninguse and labelling. The correct labelon the ingredients statement of thefinished food product reads “aroma”,“flavour”, “cheese flavour” or“natural cheese flavour”.The Flavour SpecialistsReady-to-use flavour andcompound solutions for:❋ Beverages❋ Spirits❋ Confectionery❋ Bakery Products❋ Dairy Products❋ Convenience Foods❋ Processed Fish ProductsEINAR WILLUMSEN-partner with the food and beverage industryA/S Einar Willumsen Abildager 23-25, DK-2605 Broendby, Denmark Phone: +45 4345 2244, Fax: +45 4345 9400AB Einar Willumsen Betselgatan 3, Box 9213, S-20039 Malmoe, Sweden Phone: +46 40670 1900, Fax: +46 4022 0401Einar Willumsen«s sales office, Norway Murgarden, Postboks 34, N-2688 Lom, Norway Phone: +47 6121 9110, Fax: +47 6121 9109Einar Willumsen«s sales office, Finland Aurakatu 1C, 3 Kerros, Fl-20100,Turku, Finland Phone: +358 2251 6599, Fax: +358 2251 6598 E-mail: mail@einarwillumsen.comwww.einarwillumsen.comNR. 16Danish Dairy & Food Industry... worldwide 2006 25

As mentioned the type descriptionsin the product overview areonly indicative to the user. EINARWILLUMSEN very often customizesflavours to the specific applicationfor our most important customers.If the volume potential is sufficient,we have the opportunity to tailormakeflavours using either a combinationof the standard flavours orsimply designing new flavours withtheir own process and characteristicsspecific to the individual customer.This is commercially very importantas many food manufacturers wishto have unique flavour profiles fortheir branded products. The standardrange of flavours can be madeavailable to the product developmentdepartments of our customersor EINAR WILLUMSEN’s own laboratorycan use them to create applicationsuggestions.ApplicationsThe typical and most common applicationsfor EINAR WILLUMSEN’snatural cheese flavours are given infig. 3.● Processed cheese (incl. recombined)● Cream cheese / fresh cheese● Cheese analogues● Yellow spreads● Sauces (incl. UHT-processed)● Dressing and dips● Soups● Pasta dishes● Ready Meals● Bakery products● Processed meat and fish● Breading and batter● Mashed potatoes (dry)Figure 3: Typical Applications for NaturalCheese Flavours.The most important applicationis processed cheese and fresh- orcream cheese products where thenatural cheese flavours provide thebasic flavour. In processed cheeseproduction, it is often costly and logisticallytroublesome to work withmature cheese raw materials. Mostoften young industrial cheese rawmaterials in combination with EI-NAR WILLUMSEN’s natural cheeseflavours provide a much more costefficient and uniform alternative.The new recombined processedcheese technologies offer a verylarge potential for cheese flavours.In this technology the processedcheese manufacturer avoid traditionalcheese as a raw material andin stead use the combination of butter,dry milk solids and water withstabilizers to produce the correctprocessed cheese texture. This typeof processed cheese needs cheeseflavours to achieve the right flavour,“dairy body” and mouth feel.In cream cheese, especially in fatreduced versions, the natural cheeseflavours provide the “dairy body”,mouth feel and the specific, oftenbuttery and cheesy flavour notes,that makes the product attractive.This is also the case when the creamcheese is flavoured with herbs orother foods such as bacon or salmon,because the best result is achievedwhen the cream cheese base is fullbodied.In many other applications likesauces, dressings and dips the flavoursbring the characterizing flavourprofile to the product. Bluecheese, Emmentaler and goat flavouredvarieties are good examplesof this.Depending on the source andthe composition of the fats, yellowspreads are most often flavouredwith butter flavours where diacetylis a primary component; however,the rich, full “dairy body” of realbutter is missing. Low dosages of EI-NAR WILLUMSEN’s natural cheeseflavours e.g. Gouda type can providethe solution. This is a very good exampleof an important application,where the desired flavour profile isnot recognized as cheesy at all.Fig. 3 gives several other applicationswhere the cheese flavours playdifferent interesting roles. Amongmany can be mentioned varioussavoury systems, like tomato saucefor pizza or pasta, where the cheeseflavour added directly to the tomatosauce have a marked flavour enhancingeffect. Furthermore, grill-sausageswith cheese fillings - if made onlywith cheese, the dosage of cheese becometoo high, which gives a technicalproblem of managing the hotliquid cheese when the sausages areconsumed. Lower dosages of cheesein combination with cheese flavourswill solve this problem.AdvantagesSome of the main advantages of usingnatural cheese flavours based onEMC are summarized in fig. 4.● Uniform flavour profile andintensity● Provide ”dairy body” andmouth feel● Reduce dependency of maturecheese raw materials● Easy to adjust taste● Heat (UHT) resistant● Cost saving potential● No enzymatic activity● Better ”light” products● Friendly label● No GMO enzymesFigure 4: EW Natural Cheese Flavours- Advantages.The main advantages are obviouslyrelated to flavour as the cheeseflavour contributes to the uniformityand characteristics of the finishedfood product, features thatare impossible or difficult to controlotherwise.A series of advantages are connectedto practical and economicalbenefits: The flavours reduce dependencyon costly mature cheeseraw materials that can be difficultto source and handle, and in manyapplications, the flavours provide acost saving potential. Further, theflavours give uniformity to the finishedproduct, which eliminates frequentrecipe adjustments and “repair”projects in order to maintain aconsistent flavour profile of the foodproduct.The flavours are robust - also toheat and importantly, the flavourshave no enzymatic activity as theyare UHT treated prior to filling. Thereare no GMO involved in the productand they provide a friendly label. ■26 Danish Dairy & Food Industry... worldwide 2006 NR. 16

opus D-Gen 1NIRO POWDER TECHNOLOGYCompleteMilk PowderFactoriesWhy risk working withseveral suppliers, whenyou can entrust yourdairy factory to just one?Niro unites innovationwith proven industryexperience in dairyprocessing, including milk, whey, andformulated products. We bring superiorand reliable quality to every part of asuccessful processing line, from receptionand storage over pasteurisation,evaporation, and spray drying, topowder handling, storage, and bag fillingsystems. So stay away from unnecessaryrisks – choose one process supplier.Choose Niro.Niro is a world leader in industrial drying,with spray drying, freeze drying, and fluid bedprocessing as core technologies. The NiroNiro A/Scompanies are part of the Process EngineeringDivision of the GEA Group.A company of GEA GroupNiro A/S • Gladsaxevej 305 • PO Box 45 • DK-2860 Soeborg • DenmarkTel: +45 39 54 54 54 • Fax: +45 39 54 58 00 • food.dairy@niro.dk • www.niro.com

Dryer IFDPhoto 2: The IFD dryer installedat Colun Factory.Photo 3:Air dispenser and nozzle unit.in the opposite direction of the processair stream. Powder particles accumulatedinside the filter materialare pushed out/dissolved to reach athorough cleanliness of the bags.The start-upThe rest of the dryer, including theclean air plenum below the perforatedplates in the fluid beds and in theclean air plenum on top of the filterbags, is cleaned by means of retractableNiro CIP nozzles. There are nocyclones or powder conveying ductsto clean, and that means less surfaceand reduced effluent discharge.During the commissioning ofthis new type of drying plant it wasproved that it is possible to passmore drying air through the system.The result is that less volume forthe drying chamber is needed. Thefootprint of the building is thereforereduced.For traditional spray dryers thepowder is normally discharged fromthe integrated back-mix fluid bedinto a vibrating plug-flow fluid bed,the VIBRO-FLUIDIZER ® . This requiresbuilding height. In the IFDdryer the final drying and coolingis done in a ring-formed plug-flowfluidbed surrounding the back-mixsection, and one moving part iseliminated. Further, no extra heightis required. The height of the buildingis therefore reduced.In total, that means a smallerbuilding and a reduction in investment.Extended applicationsThe start-up of this new spray dryingplant concept in an industrialscale with integrated filters andfluid beds has proved its superiorityto traditional drying plants. In themeantime, tests on other productsare conducted on the pilot plant,in order to extend its application toother industries. ■Photo 4: Clean air plenum with reversejet nozzles (after 1 week production).NR. 16Danish Dairy & Food Industry... worldwide 2006 29

Health and WellnessBy TorbenB. Lund,Sales andMarketingManager,Dairy FruitThe ratio of lifestyle related diseasesis exploding. Many of our times’ diseasescan be related to our lifestyleand eating habits. As such, obesityhas never been more widespread inthe western countries than it is rightnow. And unfortunately, this developmentseems to continue. In thewake of this development, we arealso seeing a number of diseases thatcan be directly related to obesity. Itis a well-known fact that the risk ofcardiovascular diseases increases significantlyas the weight goes up.Number of productsAs a natural part of this development,the food industry has displayeda huge interest and creativityin an attempt to meet the risingdemand for healthy and nutritiousproducts. This development is wellsupported by health and lifestyleexperts, who constantly underlinethe importance of living and eatinghealthier.The dairies have managed to followup on this development andhave for several years now offereda number of products that accommodatethe request from consumersfor dairy products that support ahealthy lifestyle. First and foremost,the result has been a number offat-reduced products. As such, yoghurtproducts with a fat content of0.5% or less is the accepted choicetoday in most European countries.Lately, there has been an interest inlaunching products with reduced orno sugar. This interest is mainly theresult of diet and nutrition opinionsof experts like the American scientistAtkins. Sugar has become the centreof focus, as the elimination of sugarwill reduce the number of calories.ChallengeFor Dairy Fruit, who is a manufacturerof fruit additives, the reduction ofsugar has a great impact on the overalltaste experience. Sugar enhancesthe taste of the fruit and for severalyears now, the consumers have becomeused to the sweetness of thesugar. To compensate for the lackingsweetness, artificial sweeteners suchas aspartame, acesulfame K and mostrecently sucralose have been addedAloe Vera is known for its positive effecton the general well-being. Here usedin ecological yoghurt marketed in theNetherlands. Ecological products arecurrently experiencing very successfulprogress in several European countries.A natural development in the wake ofincreased focus on health and wellness.to the dairy products as well as otherfoods. However, not everyone prefersthe artificial sweeteners, whichis why alternatives like concentratedfruit juice are often used instead. Inthis way, the natural fruit sugar of theraw material is exploited to sweetenthe product. Based on experience,Dairy Fruit finds that the use of fruitsugar in drinking products is a goodchoice. However, the problem oftoo many calories is not solved withthis solution, but by using naturalfruit sugar, the doors are opened formarketing the products as productswithout granulated sugar.The texture of the products willchange, when the sugar content isreduced. So in addition to tryingto preserve the taste, we also needto focus on preserving the texture,mouth sensation and stability of theproducts. For fruit mixes this oftenmeans the use of other ingredientsthan the regular ones (e.g. stabilizers).Extensive work in the field ofresearch and development is thereforeoften required before a productcan be launched as a sugar reducedproduct.The market is largeIn addition to developing fruitmixes with low calorie content, themarket also offers a number of otherdairy products with a positive effecton the general well-being. Creativityand supply are large. The range ofproducts is wide, from omega 3 andplant sterol products with a positiveeffect on the blood circulation to vitamins,minerals, fibres and muchmore. The common denominatorfor all the products is that they aremeant to compensate for a poor lifestyle.For consumers it may be difficultto tell apart the many differentproducts. In many countries, legislationmakes it illegal to praise thebeneficial effect of the products un-30 Danish Dairy & Food Industry... worldwide 2006 NR. 16

on Everybody’s Lipsless the praise comes with scientificdocumentation.Future trendsAmong scientists, there is a widespreadinterest in developing newproducts to accommodate the largedemand for functional products.The most recent initiative in thefield of new foods is nutrigenomics,where the interaction between humangenes and nutrition is emphasized.However, the general opinionis that it will last several years beforethe first custom-made foods can bemarketed on the background of researchresults in nutrigenomics. Forthis reason, Dairy Fruit will continueto focus on the use of fruit and berrieswith functional characteristics.Acerola and Sea Buckthorn serve astwo good examples in this connection.The content of vitamin C ishigh in the two fruits, while otherfruits such as cranberries are usedwhen a product with a high contentof anti-oxidants is the desiredresult.Through the years, Dairy Fruit hasacquired an extensive knowledge inthis field and we continue to cooperateclosely with our suppliers to explorenew options and ingredients.Who is Dairy Fruit?Dairy Fruit is a state-of-the-art facilitywith 80 employees, who for morethan 30 years have produced asepticfruit mixes for the North Europeanmarket. More than 50% is exported.Our most recent initiative is a productionof liquid spice mixes as additivesfor dairy products.Dairy Fruit would like to be thenatural choice of the customers,who look for a supplier of fruit mixesfor the dairy, ice-cream, confectionaryand dessert industries. At DairyFruit, the development of new ideasand products has our full attention.Hence, in 2005 Dairy Fruit launchedmore than 100 new products in cooperationwith our customers for thebenefit of the consumers. ■NR. 16Danish Dairy & Food Industry... worldwide 2006 31

A Strong Partner in VibrationTechnologyBy Anna Marie Thøgersen, M.A.,Sub-Editor, Danish Dairy & FoodIndustryScan-Vibro is an expert andglobal partner within vibrationtechnology. Customerdesigned sifters, conveyors,feeders and elevators arebuild and in operation atmany dairies, milk powderplants and other food industriesall over the world.Hygienic vibration technologyScan-Vibro is an expert within vibrationtechnology for a broad range ofindustries and products, and the companymanufactures different typesof spiral elevators, sifters, conveyorsand feeders. Each machine can alsoexecute a range of other processes,such as spreading, cooling, heating,draining, distributing, aligning, dusting,sorting and drying.Before designing a solution, theexperts at Scan-Vibro perform athorough test on the new product,i.e. milk powder, instant coffee, cereals,potato chips etc. The skilledtechnicians perform the test eitherat Scan-Vibros testing facility or onthe customer’s premises to makesure that the vibration solution isoperational and as required.Within the food and dairy industries,sanitary demands are very high.To meet these customer demandsScan-Vibro is approved according tothe strict sanitary standards of theUSDA-3A and the NZCP6. In general,the company construct the vibrationequipment in stainless steel, AISI 304or AISI 316. On request, the equipmentis suplied with different typesof cleaning systems such as CIP.Optimized food production- In these years, dairies and otherfood companies all over the worldoptimise their production facilitiesin order to meet their costumers’demands for cheaper, yet highquality food products. That is thereason why we during recent timehas gained several orders of new vibrationequipment as replacementof outdated, says Steen BrogaardLarsen, owner and Managing Directorof Scan-Vibro.The orders are placed either byindividual food company customersor by international engineeringcompanies. - No matter who, we examinethe existing production plantrespectively plant drawings beforeconstructing the desired equipment,tells Sales Manager Poul Vadstrup.He adds, that for the time being thecustomers have great interest in especiallytwo types of the company’svibration equipment; Reversible VibratingConveyors Type TRS-R andLow Profile Vibrating Sifters TypeSRS 10.Figure 1: Scan-Vibro Reversible Vibrating Conveyor Type TRS-R.Reversible vibrating conveyorsThe TRS-R is a 2-way vibrating conveyor- either one way or the other- for conveying of products in thedairy, milk powder and similar foodindustries where a gentle, closed andsanitary conveying is required.The conveyor can be constructedwithin the following dimensions:Tube diameter from 200-600 mm,length from 500 to 10.000 mm. Theconveyor is constructed with 3 dustand waterproof (IP 66) vibration motors,of which only 2 are in operationat one time.Moreover, this conveyor type is32 Danish Dairy & Food Industry... worldwide 2006 NR. 16

Figure 2: This horizontal type ofVibrating Sifter SRS 10 has highcapacity and requires less space.designed to be placed directly underthe powder drying chamber, andthus the conventional insert of a deviceis unnecessary. (See Figure 1).Low profile vibrating siftersWhen designing the SRS sifter typeScan-Vibro placed great emphasis ona long list of parameters that wouldmake the sifter applicable to siftingprocesses such as fractionation, controlscreening, and dust removal. SRSis constructed with 2 dust and waterproof(IP 66) vibration motors.The low profile type of sifter SRSis designed for companies who wanthigher vibrating capacity in a compactsifter, which requires less space,both in width and height. Thus, thegradient from inlet to outlet in a SRSis typically 300 mm, versus up to1.300 mm in a traditional sifter. (SeeFigure 2).Both the TRS-R and SRS are freeswingingvibrating conveyor andSteen BrogaardLarsen,ManagingDirector andowner of Scan-Vibro A/S.Poul Vadstrup,Sales Managerand VibrationTechnician.sifter types with linear oscillationequipped with removable covers foreasy access at cleaning and inspectionand posses high sanitary designsmanufactured in S.S. AISI 304or AISI 316. Furthermore, TRS-R andSRS are constructed for continuousoperation, which means that no lubricationor regular inspections arenecessary.Long lasting relationshipsThe technological superiority ofScan-Vibro’s solutions rest on knowledgeand several years of high technicalexperience among the employees.The staff counts highly skilledengineers, smiths, CAD draughtsmenand other technicians.Scan-Vibro is also engaged inlong lasting relationships with largeinternational plant and engineeringcompanies. When it comes to collaborationwith these companies,Scan-Vibro contributes as a subcontractorwithin the field of vibrationtechnology expertise.However, Scan-Vibro also worksalone, when customers worldwidelearn about the company’s expertiseand want to either replace or expandtheir plants with new types of vibrationequipment.Scan-Vibro was founded in 1949under the name Vester Åby Vibratorshortened into VÅV - or in EnglishVAV. The founder designed VÅV/VAV as a sinus curve, characteristicfor vibration frequency. Today, VAVis still part of the company logo andregarded as a worldwide synonymoustrademark for Vibration Technology.Scan-Vibro has been thename of the company since 1992.Scan-Vibro has 2 production facilities,55 employees, and customers allover the world. ■Processing and HandlingVibration EquipmentFor Dairies all over the WorldBased on our experienceand broad range of productswe develop tailor-madesolutions together withour customers.Pictured below areexamples of our equipment– for a general viewplease visit our website.SiftersConveyorsFeedersWe view new projectsas a welcome challengeSCAN-VIBRO A/SSørup Kirkevej 745700 SvendborgDenmarkTlf.: +45 62 21 16 20Fax: +45 62 22 37 30vav@scan-vibro.comwww.scan-vibro.comNR. 16Danish Dairy & Food Industry... worldwide 2006 33

Mixing of Low-FatBy ErikPetersen,SalesManager,Scanima A/SConsumers’ demands for food products are shifting towardsproducts with a low fat content. This is especially evidentin the supermarkets where the range of” light” and/orlow-fat products is growing constantly. This trend is achallenge to the manufactures because the compositionof ingredients are getting more complex.Mixing technologyCompetition to day requires an efficientR&D department with an openmind to close co-operation with suppliersof ingredients and equipmentmanufactures as well. Especially themixing technology has become increasinglyimportant. The complexityof ingredients with functionalqualities, emulsifiers, stabilisers andpartly substitution of e.g. vegetableoils, makes high demands on themixing equipment for the future.In some products, the butterfat caneven be reduced without change intaste.Stable products with DynamicStatorSome products are sensitive to shearforces, but at the same time, they requirea pre-homogenized base mix.Scanima has developed a patentedsystem for handling these products.This new option we call a DynamicStator.The Dynamic Stator allows a bettercontrol of the shear forces in themixing process. The shear forces areused to disperse powders and especiallyto create a stable emulsion.The function of the Dynamic Statoris to produce a very efficient homogenisation/emulsificationwhen thestator is down. When the stator islifted the product passes under thestator thus avoiding homogenisation/emulsification.This is especi-ally important in connection withproducts that are easily overworkedor products containing ingredients,which are not meant to be homogenised/emulsified.Scanima Turbo Mixer with stator down,high shear.Scanima Turbo Mixer with stator lifted,no shear.All-in-one technologyThe all-in-one technology providesgreat flexibility and allows the productionof many different types ofproducts in the same unit. This technologyalso provides the producersof foodstuffs with the option ofproducing new low-fat/low-calorieproducts, which taste and feel justlike the traditional products thathave a higher content of butterfat.The mixer is also suitable for productswhere sugar is replaced by newtypes of sweeteners.This system allows the productionof e.g. soups containing wholepieces of vegetables or processedcheese/cream cheese containingshrimps, pieces of ham or similar.When the stator is lifted away fromthe rotor the shear forces are reducedto a minimum thus avoidingthe crushing of the vegetable/meatpieces. Scanima has sold several TurboMixers with Dynamic Stator to anumber of international producersof convenience foods.Reduced costFurthermore, the Scanima MixingTechnology increases productioncapacity, reduces processing timeand the amount of each individualingredient and reduces the CIP timeas well as the time needed for maintenance.This reduces the cost price ofproducts produced in Scanima mixersand thus makes them more competitive.The Scanima mixing technology34 Danish Dairy & Food Industry... worldwide 2006NR. 16

Products with“Full-Fat” Tasteprovides optimal powder/liquid orliquid/liquid mixing with or withoutshear force. Products/ingredientscan be homogenised, emulsifiedand dispersed in a matter ofseconds - even products with a highcontent of dry matter or a high viscosity.Furthermore, particles can bemixed into the product gently.Recombined productsThe Dynamic Stator has also madelife much easier for producers of recombinedproducts, which have atendency to create foam. With a specialview to mixing caseinates, soyaprotein and similar powders, Scanimahas succeeded in developing vacuummixers for continuous productionwithout any noticeable creation offoam - even with a high content ofdry matter and high viscosity.Custom-made plantsFor Scanima it is not just importantto follow the trends of the market.Scanima continuously seeks to bea step ahead of the development inthe mixing industry, by producingthe most flexible production unitsand - in close co-operation with ourcustomers - tailoring the plant/mixerto the specific needs and economicfunds of the customer.Pilot plantsBy word-of-mouth, Scanima’s saleof mixers worldwide has grown constantly.Naturally, the company realiseshow important a good reputationis within the group of potentialcustomers, and thus Scanima hasa constant number of pilot plantsplaced with both national and internationalcustomers, such as producersof ingredients for the foodindustry. Often the customers willvisit Scanima to see what the plantis capable of, and often this visitwill result in a new order for a TurboMixer. ■Scanima A/S · Gugvej 152 · DK-9210 Aalborg SØTlf.: +45 96 33 10 00 · Fax +45 96 33 10 11scanima@scanima.com · www.scanima.comNR. 16Danish Dairy & Food Industry... worldwide 2006 35

CS, GMP, EHEDG,By SteenSørensen,Sales Manager,Keofitt a/sDevelopment of technologies for industrial productionkeeps accelerating. In earlier days, it was the inheritedcraftsmanship and traditions that guaranteed a highlevel of product quality and healthy hygiene allthrough the production process. But, as the insight andinfluence of the craftsman is gradually replaced by, say,automation and closed industrial processes, measuringand measurements remain the sole means of securingeffective quality control.Development of more sensitive analysisequipment puts greater demandson product quality. Greaterdemand to product quality has inturn meant that the equipment hasto be developed to an even higherstandard of hygiene. The level oftraditional craftsmanship used tomark the difference between goodand average products. However, intoday’s world, when all aspects ofindustrial food production have tobe automated, controlled and validated,human efforts may now suddenlyput quality at risk. Because althoughpeople have the same industrialbackground they do not alwayssolve tasks in the same way, preciselybecause they are human beings andnot machines.CS, GMP, EHEDG, HACCP …Most of the abbreviations above areterms well known to professionals inthe food industries. CS is actually anabbreviation of them all: CommonSense, GMP (Good ManufacturingPractice), HACCP and EHEDG designguidelines are in reality basedon professional common sense.They are tools created to ensuremaximum food quality while minimizingthe risk of errors. In otherwords, you can now get a certificateof Common Sense. One example isEHEDG, which stipulates that eachcomponent must pass a standardizedtest before being certified.Uniform control is commonsenseIt is also common sense to checkthat the process is the best possible.A sample is extracted from the highlytechnological process to be analysedin a laboratory using the ultimatein modern, advanced analysisequipment. It is also common sensethat an analysis is no better that theOKTOBER 2001Keofitt sampling valve does not onlycomply to the EHEDG guidelines, but itssampling valve has also been EHEDGcertified.sample with which it is taken. If theresult of the analysis is not OK – is itthen due to the process, the sampleor the analysis? The sampling andthe handling of the sample fromprocess to laboratory can easily becomethe weakest link – particular ifthe sampling is done manually andthe equipment is not up to par. It isdifficult to contaminate with GMP,HACCP … and common sense. Thetradition for upholding quality andthe professional discipline amongmanagers and staff are, however,also important factors.Sterile sampling is commonsenseKeofitt has been involved in providingsterile microbiological samplesfor 30 years. The first valve was speciallydesigned for the very sensitivefermentation tanks in breweries. Itwas the very first valve that couldbe sterilised before it was opened,safeguarding both the process (fermentation)and the sample (analysis)against contamination. Keofitt’svalve was the first sampling valveto be approved by the American 3Astandard and today, Keofitt is theonly company that has a samplingvalve that does not only comply tothe EHEDG guidelines, but its samplingvalve has also been EHEDGcertified.36 Danish Dairy & Food Industry... worldwide 2006NR. 16

HACCP…Complete control of asepticprocessesA strong, standardised product rangehas been developed based on theEHEDG certified sampling valve:the MicroPort, with the sample beingextracted with a needle throughseptum, in semi and fully automatedsystems. Particularly for use in asepticprocesses, there is a completelyclosed sterile system, which canguarantee a completely valid way oftransporting a sample from processto laboratory without risking contamination.And it does not matterwhether the substance is water,thick liquid, fruit pulp or yoghurtwith berries.To stimulate common senseIrrespective of which future advancedtechnology will be usedfor the processing of products thatcome into contact with the humanorganism it will be necessary to securecomplete biological transparencyand hygiene control at everystep of the process.Sterile samples in conjunctionwith common sense and consistentprocess discipline make it possiblefor those responsible for the foodproduction processes to carry outstrict quality control.Keofitt Aseptic Bottle.The Keofitt standardKeofitt, the Danish expert in processhygiene has over the last 30 yearsgained recognition by developingthe world’s best valves for all typesof sampling. Keofitt’s valves are theestablished standard for the brewingindustry. Breweries all over theworld use Keofitt valves to track thefermentation process, just as do leadingFood/Dairy and Pharma/Biotechcompanies in order to secure sterilesamples. To learn more about samplinggo to www.keofitt.dk. ■w w w . k e o f i t t . d kNEEDMOREPROOF?When it comes to sterile samplingprocessors need to be absolutely sure.Keofitt ® never compromise on approvals and validation.More than 50.000 valves in operation.Keofitt a/s . Hans Egedes Vej 19 . DK-5210 Odense . Tel. +45 6316 7080 . Fax +45 6316 7081 · keofitt@keofitt.dkDistributører: DK: Gustaf Fagerberg A/S · +45 4329 0200 · www.fagerberg.dk SE: EGTE-Teknik AB · +46 155 26 85 20 · www.egte.seNR. 16Danish Dairy & Food Industry... worldwide 2006 37

The Best of HygieneDrainageBy JesperLarsen, AreaSales Manager,BLÜCHER,DenmarkSeveral advantagesCompared to the materials traditionallyused for drainage systems, stainlesssteel offers the advantages ofease and speed of installation, excellenthygienic properties, easy cleaningand maintenance, durability andfavourable whole-life costs. Stainlesssteel has an extremely smooth surfaceproviding fast flow, preventingdeposits and minimising bacterialgrowth. Inherent advantages, whichin BLÜCHER ® drainage products areenhanced by careful product design,making them particularly suitablefor the dairy, beverage and food industry- and other applications requiringhigh levels of hygiene.EU hygiene requirements state,among other things, that floor surfacesin food processing plants mustbe easy to clean and allow adequatesurface drainage. Legislation on safetystates that floors should be slipresistantunder normal conditionsof service.WorldwideBLÜCHER ® drainage products havebeen installed in dairies and foodprocessingfactories worldwide overthe past 40 years. Among the dairies,breweries and food processing factoriesfitted with a BLÜCHER ® drainagesystem are:● Almarai Dairy, Saudi Arabia● Heineken, Sevilla (Spain)● Danone, Valencia (Spain)● Unilever (Helados Holanda), MexicoCity (Mexico)● Valio Ice-Cream Factory, Turenki(Finland)● United Dairies, Westbury (England)● Several Arla dairies in Denmark andSweden, among these Taulov dairy,Arinco and Rødkjærsbro dairies.Hygienic drainageFood processing plants require equipmentof the highest quality in termsof operational, hygienic and environmentalstandards. To minimisethe risk of bacteriological contaminationof the products, the equipmentused must be easy to clean and keepclean.All BLÜCHER ® drainage productsare made entirely from high-performanceaustenitic stainless steelgrade 304 or, for the most demandingcorrosive environments, grade316L. All products are chemicallydescaled and passivated to enhancetheir natural corrosion resistanceand to provide a uniform matt silversurface finish.BLÜCHER ® drainage products have beeninstalled in dairies and food-processingfactories worldwide over the past 40years.38 Danish Dairy & Food Industry... worldwide 2006 NR. 16

in theSystemModular and hygenicBeing a modular system comprisingfloor drains, drainage channels anda pipe work system - all combinable,the BLÜCHER ® stainless steel drainagesystem offers numerous possiblecombinations and a solution to anydrainage project.For industrial applications, BLÜ-CHER offers heavy-duty floor drains,channels point, and linear drainage.The hygienic design of drains andchannels without corners or cavitiesinside the drain body prevents bacterialgrowth, and reinforcement of theunderside of the frame edge with syntheticresin infill provides a hygienicstructure also without any cavities.One of the most important featuresis the removable water trap withits excellent self-cleansing propertiesand small water surface that minimisesbacterial growth. In addition, thewater trap unit is easily removed forcleaning. Experience shows that thiswater trap facilitates cleaning becauselarger solids trapped in the water trapand grease deposits in the water trapcan be removed by washing down.Being easily removed and refitted inthe drain or channel, it also providesaccess to the drain bowl and the pipeunderneath.Floor drains and channels are fittedwith a grating, the load capacityand slip resistance of which is suitablefor the application in question.For the drains and channels BLÜCH-ER offers a range of gratings withone, or two-way non-slip surface, alldesigned with a view to obtainingexcellent hygienic properties andfacilitating cleaning.The smooth surface of stainlesssteel also makes it the perfect materialfor drainage pipework systemsin hygienically demanding applications.BLÜCHER EuroPipe ® is alight-weight and versatile drainagepipework system featuring simplepush-fit jointing, thus ensuring easyhandling and rapid installation.A further and important safety advantageis that BLÜCHER ® productsare non-combustible. In the event offire, the high temperatures will notcause any toxic gases to be releasedfrom the drain and pipe material.BLÜCHER®BLÜCHER ® is certified in accordancewith ISO 9001 and all products aremanufactured under this globallyrecognised quality assurance systemusing the most modern productiontechnology. BLÜCHER is an internationalgroup of companies with headoffices and production facilities inDenmark, subsidiaries in Norway,Sweden, the UK, Germany, Franceand a world-wide network of salesrepresentations and distributors. ■CPS - CHEESEMAKING SYSTEMSCheese VatsProcess DesignWhey Draining SystemsProject ManagementCurd HandlingBlockforming / MouldingSystemIntegrationAutomation and ControlConstruction Design and ManagementPressing SystemsAfter Sales ServiceCPS Damrow Frichsvej 15 8600 Silkeborg DenmarkTel. +45 7550 5499 Fax. +45 7550 5489 info@damrow.dk www.damrow.dkNR. 16Danish Dairy & Food Industry... worldwide 2006 39

The APV LeanCremeBetter FlavourBy BentØstergaard,Product GroupManager,MembraneFiltration,APV A/SSilkeborgThe healthy and advantageous properties of whey meanthat today, a large proportion is processed and sold asa high-value ingredient for food and wellness products.With the APV LeanCreme process for Microparticulationof whey protein concentrate (WPC), dairies now have anopportunity for adding additional value to whey.What is microparticulation?Microparticulation is a combinedthermal and mechanical processthat denatures and processes WPCin order to create ideal protein particlesof a similar size to fat globules inmilk. In the case of the APV LeanCremeprocess, this means the additionaladvantage of a neutral flavourand a mouth feel virtually identicalwith that of milk fat.Types of LeanCremeMicroparticulation of protein fromsweet whey results in a productcalled LeanCreme Neutral - aWPC60whitish and creamy product withthe consistency of coffee cream, andwhich in contrast to whey has a neutralodour and taste (Fig.1).When used in a low-fat cheesewith 20 per cent fat/dry matter thisresults in a consistency and flavourprofile very much like full-fat cheese.As whey protein is a relatively cheapraw material, it can also be used toadvantage in full-fat cheeses.Microparticulation of WPC from,for example cottage cheese, whichis acidified using a lactic acid culture,results in LeanCreme Lactic,a white and creamy product with apure, acidic taste like buttermilk. Asimilar product can be made by acidifyingsweet whey using mesophilicLeanCreme TM 60 NeutralFigure 1:WPC 60andLeanCremeNeutral.and/or thermophilic cultures prior toor after the LeanCreme process.So what’s new? We have knownfor many years that thermal treatment,for example using a plate heatexchanger, in order to denature wheyprotein with subsequent mechanicalprocessing in a homogeniser orshear mixer results in the propertiesdescribed above.True enough. But the reason whythis was never very successful is thatit was difficult to achieve optimumquality of the particulate.The APV Shear AgglomeratorThe APV LeanCreme process isbased on a technology developedby the Weihenstephan Institute atthe Technical University of Munich(TUM). In contrast to previous practice,the process is a one-step processin which the thermal and mechanicalstages are combined into a singleprocess using a combination of aplate and scraped surface heat exchanger.This enables particulationbefore the proteins can aggregate,thus producing a significantly higherquality. The raw material (WPC)composition and process parameterssuch as temperature, holding timesand shear rate etc. are critical to optimumparticle formation and functionalquality.APV has carefully investigatedand tested the new method togetherwith customers. This resulted ina decision by APV to design a new40 Danish Dairy & Food Industry... worldwide 2006NR. 16

Process- Less Fat - Higher EarningsFigure 2:Particle curves:Flexible achievementof optimum particlesize distribution.scraped surface heat exchanger(SSHE). The specific purpose was tofulfil operational parameters foroptimum particle formation andfunctional quality as well as an acceptableindustrial cycle time, whichis a well-known problem of conventionaltypes of SSHE.The new SSHE, called the APVShear Agglomerator (ASA), ensures ahighly uniform and optimum particlesize distribution, for example 5microns, which is perfect for cheese(Fig. 2). In addition, the particle sizedistribution can be shifted along thespectrum to 1-2 microns for otherproducts such as ice cream or yoghurt.Figure 3: MP2000l/h plant forLeanCreme 60 Neutral for cheese.NR. 16Danish Dairy & Food Industry... worldwide 2006 41

Figure 4: Different types of LeanCreme.Figure 5: LeanCreme TM applications.• LeanCreme Neutral made from sweet whey• LeanCreme Lactic made from lactic acid whey• LeanCreme Acid made from HCI or acid whey• LeanCreme Ideal made from ’ideal’ whey• LeanCreme Plus with cream• LeanCreme Mix with protein powder• LeanCreme ’grades’ from 28 to 80 (TOP/TS)• Pressed, soft and fresh cheeses• Acidified milk products and desserts• Protein enriched milk drinks and yoghurt• Dressings, sauces and mayonnaise• Ice cream, chocolate and confectionery• Bakery products• Nutraceuticals and powdered ingredientsThe ASA has already demonstratedits unique abilities. Four Lean-Creme pilot plants have been inoperation over a longer period, andseven commercial plants have beensold during the last year. Many arealready in operation, including anMP2000 plant (Fig. 3), which hasbeen successfully producing Lean-Creme Neutral from WPC 60 forcheese products since August, 2005.Figure 6: Payback time in months as a function of whey price and volume.WheyWhey volume m 3 /day PriceEuro cent/liter 150 300 6000.67 6 4 31.35 10 5 42.02 21 10 62.69 - 90 32Products and applicationsThe enormous flexibility that theASA brings to the LeanCremeprocess enables the production of along line of different LeanCremeproducts designed for a variety ofapplications in the dairy, food andneutraceutical industries, includinghigh-quality “wellness” productswith reduced fat content.Figure 4 provides an overview overLeanCreme product types producedon the basis of various whey types/rawmaterials. Figure 5 shows examples ofthe wide choice of applications. While“in-house” applications will use Lean-Creme as a fresh-made concentrate,it can also be spray-dried to make aLeanCreme powder ingredient.But does it pay?There are two aspects to this question.One is objective capitalisationbased on the cost of whey raw materialcosts compared to skim milk andthe cost of producing LeanCremeproducts. The other is the opportu-nity to make high-quality cheesesand other dairy and food products.This aspect is a subjective one anddifficult to capitalize. However, itdoes represent a potential for premiumprice products by meetingincreasing consumer demand forhigh-quality wellness products.The economics of using Lean-Creme can be directly assessed onthe basis of the protein compositionor the added amount of protein. Ittakes about 5.5 kg of whey to makeone litre of WPC 35 - or a skim milkequivalent corresponding in compositionto one litre of skim milk.Assuming a skim milk price of Eurocent 16.00 per litre and a whey priceof 1.35 per litre, the skim milk equivalentwhey price is Euro cent 7.40,representing a reduced raw materialcost of Euro cent 8.70 per litre.Figure 6 illustrates ROI for variousvolumes of whey and at whey pricescorresponding to a skim milk priceof Euro cent 16.00 per litre. Assumption:360 production days a year,three shifts per day, and return oncapital of 5 per cent p.a. over threeyears excluding scrap value. Theplant comprises UF for the productionof WPC and the LeanCremeplant configuration delivered andrunning.The conclusion is that the Lean-Creme process represents a “CashCow” for dairies with additionalearnings potential by exploiting theexcellent opportunities for productionof the high-quality wellnessproducts that consumers are waitingfor. ■42 Danish Dairy & Food Industry... worldwide 2006 NR. 16

Joy of eatingNR. 16Danish Dairy & Food Industry... worldwide 2006 43

High QualityProductionFacilitiesBy Jesper Pauli,ManagingDirector,MA Project A/SModern consumers demandhealthy, high quality - yetlow-cost - food products.Thus, the food industry isforced to optimize production,either by renovating orbuilding new effective andflexible production plants.Whatever, MA Project hasthe expertise to help.From concept to ready plantMA Project offers comprehensiveconsulting within the dairy andfood industry in the two main areas:Building & Construction and Technology& Environment.When MA Project takes on a project,it is often in the very earlyphase. We cover the entire processfrom concept and planning to theclient has an operational facility:● Site search process and environmentalconsent● Programming and master plan● Pre-project, main project and tenders● Supervision, construction management,project follow-up● Coordination of the client liabilityin terms of safety and health at thebuilding site● Handing-over and guarantee inspection.Furthermore, MA Project is capableof accomplishing overall analysesof minimizing the consumption andwaste of energy, e.g. water, electricity,heat - and of creating the best workingconditions for the employees.Useful databaseThe modern food industry is meetinghuge demands from consumers,retailers, and food authoritiesto produce healthy, high qualityproducts within safe, hygienic, andwell-documented production facilities.Last, but not least the foodindustry’s insurance companies arevery strict when it comes to whateverfailure may occur within theproduction.It can be very difficult for the industryto keep track and documentationof all details within a modern,large and often complicated foodproduction plant.During the last decade, MA Projecthas gained expertise within handlingand up-dating vital production data.Our database service offers continuousfollow-up and updating of: Construction,management, lending andmaintenance of digital drawing filesfor factory buildings, updating of mechanicallayout and flow diagrams,performance of fire and emergencydrawings, site calculations/statementsof factories, administration and othertenancies for insurance purposes.Of course, our customers have independentand secure access to theirpart of the database. They can logon, check and change data as muchas they want. MA Project’s databasewill always have copies of the originaland last changed documents.Food industry worldwideYears back, our first clients were severalhundred Danish dairies. We stillperform projecting tasks for Danishas well as international dairies, butduring recent decades we have proudlygained customers from several otherfood industries, such as margarine,egg, fish, poultry, meat, conveniencefood, fruit, ingredients and feed.During the years, MA Project hasprojected quite many large dairies,e.g. GlaxoSmithKline's recombinationdairy plant, Maya Haryana in India,and the largest dairy plant in theMiddle East, Almarai Dairy in SaudiArabia. Furthermore, MA Project hascarried out many tasks for the largestEuropean dairy company Arla Foods,e.g. Taulov, the largest cheese factoryin Northern Europe, Arla Foods Plc'snew dairy in Leeds, England, and anew milk condensation plant in Vimmerby,Sweden.Among other projects abroad, itis worth mentioning the BulawayoDairy Plant in Zimbabwe, DaniscoSpecialities in England, two Fan Milkdairies in Ghana and Nigeria, LactosanGley in Uruguay, a Multi-ProductPlant in Panama, besides the ChineseAnda Dairy and two dairy trainingschools in Harbin and Shanghai.44 Danish Dairy & Food Industry... worldwide 2006NR. 16

Functional food processing plants and architecture in harmony with nature is one of MA Project's trademarks - to the benefit ofthe clients who achieve comprehensive, architecturally harmonious, quality- and future-proofed plants. (Photo by Arla Foods,Vimmerby).MA Project A/SMA Project, founded in 1946, is aconsulting company of architectsand engineers offering our expertiseto the dairy and food industry.We are specialised within the followingmain fields: Building andconstruction, service and mechanicalengineering, energy and envi-ronment. We offer our expertise tothe entire food and dairy industryand provide assistance in all stages ofthe project - from basic idea to operatingplant.For each project, a responsible projectleader is appointed. This projectleader is the client’s contact personthrough all phases of the project. Furthermore,we operate by strict guidelinesof how to work and operate ona daily basis, meaning that each employeeregisters time spent on eachdifferent project. In that way we, andour customers, can always keep trackof expenses.Our company key words are: TRUST- EXPERTISE - FUTURE PROOFING. ■ NR. 16Danish Dairy & Food Industry... worldwide 2006 45

The easy way toGood ManufacturingBy JørnPedersen,M.Sc. inDairyTechnologyandManagingDirector,JP ConsultDemands on dairy producersDuring recent years, demands fromauthorities, customers and consumerstowards the dairy and foodindustry regarding documentationof production flow, and quality etchave raised with huge intensity.The dairy industry, primarily thelarger companies have complied thedemands by working out Quality,HACCP, Laboratory Manuals etc.,often followed by an official ISO certification.So far, the medium sized… in the dairy industryand minor dairies have not shownthe same interest or used resourceson the matter. Probably they havenot felt it was important or theydo not have the work force, time orfinancial resources to meet this demandingchallenge. However, in thefuture, authorities, customers, andconsumers will forward the samedemands on the minor and mediumsized companies. They will ask forbetter and clearer documentationregarding their daily production. Inthe end, these companies will needto work out their own manual.Quality & Working ManualBearing this in mind some Danishdairies and JP Consult in 2000 starteda project developing a ”StandardQuality & Working Manual”, whichis easily converted to a factory specificmanual. The idea has shown tobe viable and during the last 6 years,it has been further developed. Today, the following six titles are foundunder the umbrella name “X-townDairy Management Tools”:● Quality & Working Manual● Dairy Laboratory Manual● Hygiene Training Manual● Dairy Training Manual● Milk Balance Control● Dairy & Food LIMS (Laboratory InformationManagement System)The basic philosophy for all X-Town Dairy Management tools are,that they can easily be converted intoa factory specific manual by anyone,who has the necessary knowledgewithin dairy production and MicrosoftWord and Excel. All manuals arein English and can be of great helpand inspiration to all dairies, whowant to improve their quality controland/or documentation system to preparespecific factory manuals.Do you want to learn more aboutthe single title please visit - www.dairyconsult.dk.Figure 1: Menu D&F LIMS program.Dairy & Food LIMSThe latest development within theX-Town Dairy Management toolsis a Dairy & Food LIMS program.D&F LIMS is inspired from the goodexperience by using Excel in registrationof laboratory results andthe strengthening in EU statutoryregulations within the food industry,which require improvement infactory specific documentation forthe daily quality control. The mainfeatures within D&F LIMS are:● D&F LIMS covers the needs of mostdairy and food factories, and is aunique, small, easy operated program,which only cost a fraction ofexisting LIMS system (Laboratory InformationManagement System).46 Danish Dairy & Food Industry... worldwide 2006 NR. 16

Practice● D&F LIMS is based on MicrosoftExcel and programmed in Visual basic.Basic language is English, but it iseasy to convert and operate in otherlanguages.● D&F LIMS can easily be designedand changed according to individualneeds of different dairy and foodindustries.● D&F LIMS includes a total pictureof the quality control from raw materialarrives at the dairy or foodplant to the final product leaves thefactory.● D&F LIMS is a comprehensive documentationand graphic/statisticalanalysing tool.ImplementationIntroduction and implementationof D&F LIMS in a dairy/food factoryincludes no changes in the daily operationaccording to the actual analysislaboratory work, as the systemis just a new and easy way to organiseregistration and documentationof the laboratory analysis.D&F LIMS is a simple system,which can be introduced and implementedby all persons, who possesgeneral knowledge of laboratorywork and Microsoft Excel. The systemis easily installed and only requiresthat the existing data and informationis organised and adjustedfor practical use in D&F LIMS.Two versionsDairy & Food LIMS comes in twoversions:● D&F LIMS Basic model: Customerhas to organise content and key inthe required basic data.● D&F LIMS Factory Specific model:Similar feature as D&F LIMS BasicModel, but ready for use and designedaccording to communicationand questionnaire filled out by customer.However, D&F LIMS has flexibleset up and can be tailor made accordingto customer desire, if the standardversion does not cover the needs.Examples of further developmentsare i.e. a module for organolepticevaluation of final products, or amodule for analysis carried out in alaboratory outside the factory.Dairy & Food LIMS is based onmany years of experience, and thusit is chosen to break down the qualitycontrol documentation into threegroups, in order to ease the generaloverview:● Quality Control of raw material(i.e. raw milk).«JP Consult - Industrial Dairy ConsultancyDanish Dairy Technology and Know How - when it’s BestX-Town Dairy ManagementTools:A series of standardised managementtools, developed byJP Consult, make it easyfor minor and medium sizeddairies to work out their ownfactory specific manuals.Business idea:To give a personal, individual, customer adjusted advisory andconsulting assistance.Field of activity:After 50 years in the dairy industry and more than 40 years ofexperience within management, JP Consult has solved and isready to solve a broad spectrum of assignments. Our key fieldsof activity are:● Dairy technology● Milk plant management● Quality control● Project management● Product development ● Project developmentBusiness Activity:Since 1997, JP Consult has carried out many different assignmentsfor customers, both in Denmark and abroad within ourentire key field.JP Consult has a broad network and good contact to colleagueswithin all fields of work in the dairy industry and will as such beable to take on assignments of all kinds - from a specific taskto a total Dairy project.JP Consult - Industrial Dairy Consultancy, Vester Boulevard 5, DK 8900 Randers, DenmarkTel.: +45 8642 0277 - email: info@dairyconsult.dk - www.dairyconsult.dkNR. 16Danish Dairy & Food Industry... worldwide 2006 47

Figure 2: Example Graphic analysis.● Quality Control processing (manufacturefrom raw material to finalproduct).● Quality Control of final product.D&F LIMS systemThe Dairy & Food LIMS consist ofthree file parts: 1: D&F LIMS Program,which is the operating part,2: D&F LIMS Period Archive and 3:D&F LIMS Total Archive, where thelater two is for data storage and analysing.During daily use, there is only oneentry to D&F LIMS - the “Analysisreport” in D&F LIMS Program (Seefig. 1). When all data from a laboratoryanalysis is available, they has tobe keyed into the “Analysis Report”,after keying is finalised, a single ploton “Transfer” will execute the following:● All analysis data is send to the preprogrammedData sheet (i.e. Rawmaterial).● Data in analysis report sheet iserased automatic and a new analysisreport is ready to use.All other operation transfer ofdata and analysing is done with a few“mouse click”, which means that afterone hour or two all employees areable to use the D&F LIMS.D&F LIMS graphic analysis consistof analysis norm figure, upperlimit, lower limit and a tendencyline, which clearly indicates, whena quality control point needs corrective,and action has to be carried out.In Fig. 2 you can see an example of agraphic analysis and Fig. 3 shows thestatistic analysis for the same figure.It is very simple to operate D&FLIMS, which makes it a useful tool toimprove your laboratory documentationand save time. Furthermore,the system gives you a general viewof all quality matters for any productand control points in your productionwith a few “mouse click”. Fig. 4shows a flow chart of the schematicoperation of D&F LIMS.Do you want to know more aboutsystem, please visit our website, orrequire our demo D&F LIMS. ■Figure 3: Example Statistic analysis.Figure 4: D&F LIMS Program operational set-up.48 Danish Dairy & Food Industry... worldwide 2006 NR. 16

Hygienic PrecisionBourdon-Haenni suppliesa wide range of hygienic,stainless steel instrumentsfor pressure, temperature,level and conductivitymeasurements.• CombiTemp, temperaturetransmitter with displayLevelTemperature• LSM, electromagneticlevel switch• FlexBar HRT,pressure transmitter,4...20 mA or Profibus PAConductivity• ISL, conductivitytransmitterPressureBourdon-Haenni A/S • Jacob Knudsens Vej 148230 Aabyhøj • DenmarkTel: 89 31 76 11 • Fax: 86 25 65 77info@bourdon-haenni.dk • www.bourdon-haenni.comNR. 16 Danish Dairy & Food Industry... worldwide 2006 49

Customer OrientedSolutionsBy Ole Olsson,ProductManager,OlssonsMachineryBroad product lineOlssons Machinery, founded in1955, strives to establish itself asone of the worlds leading suppliersof machinery to the dairy and foodindustry, with focus on the latesttechnology.Our major products are: cheesecuttingmachines, cheese waxingmachines, and aseptic “bag in box”filling ma chines. Furthermore, wealso con struct and manufacture; customfit ted pneumatic seat valvesin stain less steel AISI 316, non-returnvalves to build in unions DIN, DS,SMS and build in valve for tanks.Olssons’ products and solutionsare based upon three characteristics:Qual ity, Flexibility and Efficiency.With more than fifty yearsof ex perience as supplier to a widerange of food industries, Olssons iswell aware of, what fine craftsmanshipsupple mented with the latesttechnology and high level of qualitymean to the modern and efficientcompany.InnovationThrough constant awareness of newemerging technologies, Olssons Machinerythereby provides innovativeideas to its products and solutions.One example is the latest experimentconducted at Olssons test facilities,where the process of cuttingcheese was tested using various instruments:knives, wire, rotatingblades, water, laser and ultrasoniccutting. The experiment was doneSimi-automatic cheese cutter with fivecutting programs can easily be made toa fully automatic cutter.in collaboration with field leadingpartners using Olssons Machinery.Cheese waxing machinesOur fully automatic wax coating machinesfor cheese employ the brandnew technology that includes spraying,bottom waxing rollers, andbrushes. The cheese is transportedthrough the system on a speciallydesigned wire mesh belt, which allowsspraying from below. The systemfacilitates the use of differentwax colours by having interchangeablewax tanks. These wax tanks aredesigned to prevent overheatingand scorching of the wax and product.The system is available in morewidths and the machine inlet andoutlet can be tailor-made to meetthe dairy’s requirements.Cheese cutting equipmentOlssons Ma chinery provides the widestrange of cut ting and portioningequipment for any type of cheese.For hard cheese, our product ran geincludes fully automatic cutting andsemi automatic machines with up tothree cutting stations. The ma chinesare also offered in several differentwidths. Fantastic flexibility is achieved by including interchangeablecut ting frames and cutting blocks.Changing the cutting equipment toa different size can be done in lessthan 60 seconds. Cutting can bedone using the latest technology forany application, or just using wiresor knives. The inlet and outlet canbe adapt ed to suit your factory andfull au tomation can be supplied toensure that our machine will workwith your existing equipment.Aseptic Bag-in-Box fillingOur Aseptic Bag-in-Box Machine isdesigned for sterile filling into bags.50 Danish Dairy & Food Industry... worldwide 2006 NR. 16

Our machine is equipped with aDanfoss mass flow meter, whichgives a system accuracy (tolerance)less than 0,1% of the current flow.The filling amount and choice ofprogram is performed on the frontof the machine by a finger touchscreen. As sterilization during thefilling cycle, a barrier of sterile airand 4% hydrogen peroxide (H202)is spray ed over the filling headthrough stainless steel nozzles. A filteris in stalled to make the air sterile.This filter can be sterilized by usingsatu rated steam. The aseptic Bag-in-Box filling machine from Olssonshas an ad justable roller table, and iscon structed with a connection unitfor CIP-cleaning and water separatorfor steam sterilization. The machineis working semi au tomatic thus, theoperator manually place the bag inthe machine and pres the start bottom.The rest of the operation runsautomatically; Cork of, Filling, andCork on. The filling can be done eitherthrough a sterile pressure tankor through a mono pump and eventuallya by-pass valve.The capacity depends on the bagsize and product viscosity - from 1000-5000 l/h. When filling juice and milkproducts the capacity is ap proximately:3 bags of 20 kg/min, 5 bags of 10 kg/min, and 7 bags of 5 kg/min.For delivery of aseptic bags, wecooperate with several leading companiesin Europe.Non-aseptic Bag-in-Box fillingOlssons Machinery recently expandedits program through a non-asepticBag-in-Box filling machine line. Thisline offers the smallest manually fillingstation to the full automatic linewith high capacity.Pneumatic seat valvesOlssons Machinery has laun cheda new generation of custom fit tedstainless steel pneumatic seat valves.Our high quality seat valves are designedin stainless steel AISI 316. Thevalve head is supplied with a heat resistantseal ring and close against astainless steel seat. The valve stem issealed by viton rubber seals for usingin many applications.AS800 is a semiautomaticBagin-Boxfillingmachine withhigh capacityand economicworkspace.By Olssons you can get the tailormadedesign, in the exact configurationyou want.Quality and efficiencyOlssons fully customised tailormadesolutions to the food industryare created as a result of very closecooperation with the food processingcompanies and customers allover the world. ■Customized on Demands - Stainless Steel Machinery- Stainless Steel Heat Exchangers- Stainless Steel Tanksto the Food IndustryAseptic Bag-in-Box.Size of bags: 1-1000 l.Capapcity: 1000-5000 l/h.Filling: Mass flow or by weight.Filling via 30 or 50 mm nozzle.Automatic Cheese WaxingEquipment.Manual or semi-automatic vessels.We meet your requirements.Advanced multifunction or smallmanual solutions.Fully automatic lines.We meet your requirements.Stationsvej 10 · DK-5464 Brenderup · Denmark · www.omy.dk · info@omy.dk · Phone +45 64 44 13 12 · Fax: +45 64 44 13 92NR. 16Danish Dairy & Food Industry... worldwide 2006 51

By Jesper Bjørn Hansen,Managing Director, Trepko A/STrepko is probably the biggestproducer of filling andclosing machines for preformedcups in the world.Trepko has factories in Denmark,Poland and India, andmore than 300 highly specializedemployees.New customer requirementsDuring the past few years the foodproducers focusing on production ofonly very big batch sizes have beenforced to produce small batch sizesas well, due to the customers’ - andhereby also the retailers’ demandsfor bigger and broader variations inthe product supply. This applies toall types of milk products.Flexibility and HighPackingCombining the production ofsmall, sometimes even very small,batch sizes with the daily productionof big ones can be a very difficult -almost insoluble - task, since eachproduct requires its own package.Several change-overs are thus essentialwhen switching from one productto another. Therefore, the flexibilityof the filling and packing machines isa central and critical factor.Trepko’s flexibilityTrepko’s machines manage the wholeprocess from the separation ofTrepko´s fully integrated Pick & Place unit can handle several cup formats with simpleadjustments from the touch-screen panel.- Can a broad productrange fit into amodern high capacityproduction?cups, filling, closing, to end-packingin trays or multi-layered cardboardboxes. These are highly specializedtasks, and many machine types donot allow a quick change-over fromone cup type to another. This processcould be both complicated andtime-consuming.In the case of Trepko, the demandfor more flexible machines has led tothe development of fully flexible machines.Despite the capacities of upto 50,000 units/hour the machinesallow either a manual change-overto new packing formats in 30 minutes,or a fully automatic changeoverin less than 10 minutes - by theoperators pressing a button on thetouch screen display.These short change-over timeshave been obtained by careful analysisof every single machine function.For example, stack feeding magazinesfor cups and lids are changedwithout the use of tools, but by turningfour handles (in the manual version),or by synchronous motors,activated from the touch screendisplay of the machine (in the automaticversion).Furthermore, the change of cassettesis made without the use oftools but simply by lifting the cassettesof the machine and place thenew cassettes on it. Alternatively,this operation can be made by automatic(servo-driven) lifting of the52 Danish Dairy & Food Industry... worldwide 2006NR. 16

Capacity in Filling andProcessescassettes for accumulation in a verticalcassette tower, while the cassettesof the new cup type is taken downautomatically from another cassettetower and placed on the chains ofthe machines.So far, one of the biggest obstaclesto quick format change has been thereplacement of sealing heads, as theold sealing heads require cooling beforereplacement. With Trepko’s newtechnology within the sealing technique,it is possible electronically tocontrol the sealing pressure, sealingtime and sealing temperature fromthe touch screen display of the machine.This technology provides the opportunityfor a 100% controlled sealing,allowing a combination of moresealing profiles (and hereby formats)with the same sealing head, due to theminimized movement of the sealinghead under production. Therefore,the change-over of the sealing headshas become unnecessary.Discharge of leftover product atthe product change and cleaningbetween different productions iscontrolled by the fully automaticCIP-system of the machines.As standard, Trepko’s machinesallow “recipe handling”, whichmeans that all the automatic adjustablefunctions are adjusted at once,when the operator presses a buttonon the touch screen display of themachine (choice of new recipe).Without exaggeration one could saythat the operation is more simpleand user friendly than the remotecontrol for a new TV.Trepko’s technologicaldevelopmentThe food production seems to havetaken a new leap towards an optimizedmarket adjustment, andTrepko is proud to be able to offerthe needed tools. With customersin more than 90 countries and in 6continents, we watch the new trendscontinuously and develop our productsoptimized for the demand. ■NR. 16Danish Dairy & Food Industry... worldwide 2006 53

NanotechnologyCould have a Huge Impact on FoodsBy GrithMortensen,Head ofSecretariat,NanoFOODand FlemmingBesenbacher,Director ofNanoFOODand the InterdisciplinaryNanoscienceCenter(iNANO),University ofAarhusFood safety is one of the key issuesof the food industry as e.g.contamination of foods withpathogen bacteria has consequencesnot only for the consumerwho becomes ill, but alsofor the food producer who losescreditability and often suffersfinancial losses. Another importantaspect is the impact offoods on health and diseaseprevention. These areas are ofmajor public interest and requireincreased insight intomaterial science with respect tothe production facilities, analyticalmethods for detection andquantification of both food safetyconcerns and impact onfood quality, and finally a morethorough understanding of chemical,molecular, and physicalcomposition of foods and theireffect on our well-being. Thesechallenges call for the use ofnew interdisciplinary nano-technologicalapproaches, methodologiesand tools.Nanoscience, nanotechnologyand nanofoodThe prefix “nano” originates fromthe Greek word for dwarf implyingsomething small. In more technicalterms, the word “nano” means onebillionth of something, e.g. 1 nm =0.000.000.001 m = 10 -9 m.Nanotechnology is the ability tooperate at atomic, molecular, andsupramolecular levels, on a scalefrom 0.1-500 nanometers, with theobjective of designing and applyingmaterials, devices, and systemswith novel physical, chemical andbiological properties and functionsdue to their minute dimensions.Most nanotechnological efforts arestill exploratory, but the potentialapplications have motivated hugeinvestments in nanoscience, withsubsequent technological developments.It has been maintained that nanotechnologymay lead to the nextThe entire Encyclopaedia Britannica will easily fit on a pinhead. Allthe books in the world will fit on a piece of paper if nano-sized letterswere used. Drawing by Ebbe Sloth Andersen.54 Danish Dairy & Food Industry... worldwide 2006 NR. 16

industrial revolution. However, whenit comes to food science, the impactof nano should rather be consideredas an evolution, since food researchon a nanoscale has taken place formany years. For instance, food proteinsare globular particles between10 to 100 nm in size; hence they arenature’s own nanoparticles! Furthermore,many polysaccharides and lipidsare linear polymers, all less thanone nm in thickness.Understanding the nature of nanostructuresin foods allows a betterselection of raw materials andcontrol of processing and packagingin order to optimize product qualityand shelf life. A large numberof nanoscience tools have been developedover the last 10-20 yearssuch as the atomic force microscope(AFM), which has enabled researchersto gain atomic and molecularscale insight. Additionally, a varietyof synthesis techniques have resultedin design of new functional nanoparticlese.g. for targeted delivery ofcomponents.Nanofood refers to the use ofnanobiotechnology and nanotools,applied during the cultivation, production,processing, or packaging offoods. Nanotechnology can be usedto create tiny sensors and diagnosticmachines, which prevent spoiledand contaminated foods from leavingthe processing facilities and endingup at the consumers. Furthermore,nanotechnology may bringabout food products, which aredesigned from scratch starting withsimple molecular structures. The resultantproducts may have tailoredfunctionality and be produced atlower cost using sustainable productionmethods.The NanoFOOD ConsortiumThe Danish food industry has a longtrack record when it comes to producingsafe and healthy foods. TheNanoFOOD Consortium associatedwith the iNANO center was establishedin 2005 with the objective ofensuring that the food industry remainscompetitive through furthercollaboration with research institutionsactive within the areas of foodscience, nanotechnology, nutrition,and information and communicationtechnology. The mission is toprovide nanotechnology-based solutionsto the food industry, in orderto ensure safe and healthy foodproducts in the future.Participants in the NanoFOODConsortium include: Aarhus KarlshamnA/S, Arla Foods amba, DaniscoA/S, Systematic Software EngineeringA/S, NanoNord A/S, DanishInstitute of Agricultural Science,Danish Institute for Food and VeterinaryResearch, InterdisciplinaryNanoscience Center (iNANO) atthe University of Aarhus, EngineeringCollege of Aarhus, Danish MeatResearch Institute, and the DanishTechnological Institute. The boardof directors includes members fromacademia and the private food industry.Other (inter)national partnersare invited to join the ConsortiumThe NanoFOOD Consortium hasidentified a number of focus areasfor the required research:● Diagnostics, traceability, andbiosensing: The ability to monitorand trace product quality fromfield to end-consumer would have atremendous impact on food safety.Examples include biosensors for thedetection of virus or pathogenic bacteriaand sensors able to detect fooddecay during storage.● Nanostructured surfaces: Developmentof materials with newnanostructured surfaces, where forexample bacteria do not adhere, maybe used to prevent biofilm formation,thereby reducing down-timesdue to cleaning. These materials willtruly revolutionize the processingequipment industry.● Nanoemulsions: Producing nanoemulsionsmay e.g. lead to developmentof low-fat products, whichtexture- and aroma-wise resemblefull-fat products.● Designed release using nanoparticlesas delivery vehicles: Examplesinclude encapsulation anddelivery of probiotic bacteria, whichare not released until they reachthe intestines, and release of aromacompounds in the mouth.● Packaging: Applications includepackaging materials with e.g. nanoclay,which may change the permeabilityor mechanical stability of thematerials. Improved nanoelectronicsmay monitor product qualityinside the package throughout theshelf life period.Since the establishment of the NanoFoodConsortium in 2005, an internationalconference on nanofoodhas been held, and a project on nanostructuredsurfaces for the dairy andmeat industry has been established(sponsored by The Danish Dairy ResearchFoundation and “Svineafgiftsfonden”/theDanish meat industry).Furthermore, brainstorming sessionshave been arranged in order to matureresearch and development ideas.This will hopefully make an importantcontribution to the future competitivenessof the food industry. Forfurther information, refer to: www.nanofood.org. ■The interdisciplinaryNanoscience Centre (iNANO)iNANO was established in January2002 with the aim for fosteringinterdisciplinary researchwithin the areas of nanoscienceand nanotechnology. The centercombines cutting-edge expertisein physics, chemistry,molecular biology, biology, andmedicine to create science at thehighest international level andto enhance industrial innovation.Focus areas of iNANO includebio-nanotechnology, nanomedicine,nanophotonicsand electronics, functional nanomaterials,nanocatalysis, energystorage, and nanofood. Agraduate school, the iNANOschool,has been establishedwith the aim of playing a keyrole in the education of the nextgeneration of scientists withinnano-technology at the Bachelor,Master, PhD, and postdoctorallevels. Close to 100 scientistsand 80 PhD students areassociated with iNANO.Further information on iNA-NO may be obtained from FlemmingBesenbacher, e-mail: fbe@inano.dk, or at www.inano.dk.NR. 16Danish Dairy & Food Industry... worldwide 2006 55

is distributed in the following countries:Africa:Asia:Australasia:Europe:North America:South America:The MiddleEast:Algeria, Belize, Benin, Botswana, Burkina Faso, Cameroon, Congo, Ethiopia, Gabon, Gambia,Ghana, Guinea, Kenya, Lesotho, Liberia, Libya, Madagascar, Malawi, Mali, Morocco, Mauritius,Mozambique, Niger, Nigeria, Senegal, Sierra Leone, Somalia, Sudan, Swaziland, South Africa, Togo,Tunisia, Tanzania, Uganda, Zambia and Zanzibar.Bangladesh, Bhutan, Burma, China, Fiji, Hong Kong, India, Indonesia, Japan, Laos, Malaysia, Mongolia,Nepal, North Korea, Philippines, Singapore, South Korea, Sri Lanka, Taiwan, Thailand andVietnam.Australia, Fiji and New Zealand.Austria, Belarus, Belgium, Bosnia, Bulgaria, Croatia, Cyprus, Denmark, Eire, Estonia, Faeroe Islands,Finland, France, Germany, Greece, Greenland, Holland, Hungary, Iceland, Italy, Latvia, Lithuania,Luxembourg, Malta, Macedonia, Norway, Poland, Portugal, Rumania, Russia, Serbia, Slovakia,Slovenia, Spain, States of CIS, Sweden, Switzerland, The Czech Republic, Ukraine and United Kingdom.Bermuda, Canada, Mexico, Panama and USA.Argentina, Barbados, Bermuda, Bolivia, Brazil, Chile, Columbia, Costa Rica, Cuba, Ecuador, El Salvador,Guatemala, Guyana, Haiti, Honduras, Jamaica, Montserrat, Nicaragua, Paraguay, Peru, PuertoRico, Tobago, Trinidad, Uruguay and Venezuela.Afghanistan, Bahrain, Cyprus, Egypt, Iran, Iraq, Israel, Jordan, Kuwait, Lebanon, Oman, Pakistan,Qatar, Saudi Arabia, Syria, Turkey and Yemen.Are you looking for new Marketsfor your Products?- or Highly Skilled Dairy Employees?Contact:Mælkeri tidende- the onlyprofessionaljournalabout theDanish dairyindustry!New markets or employees?Are you looking for new markets to introduce yourproducts, such as new dairy plants, ingredients,packaging, analysis or sanitary equipment? Or areyou looking for highly skilled dairy employees withinternational experience such as dairymen, dairytechnicians or M.Sc. in Dairy Technology? No matterwhat, you can always advertise in Mælkeritidende!Mælkeritidende"Mælkeritidende" as well as "Danish Dairy & FoodIndustry ... worldwide" is published by the DanishDairy Managers Association and the Danish DairyEngineers Association.The scope of Mælkeritidende is scientific and technicalissues within the dairy and related areas. Furthermore,subjects of dairy Research & Develop-ment,dairy product information’s, company profiles andexhibition information’s are accepted for the journal.Subscribers of MælkeritidendeThe subscribers of Mælkeritidende are managersat Danish dairies and several Nordic dairies, employeesat the Danish dairies, members of the twoAssociations in Denmark and other countries, dairyresearchers, dairy advisers, personnel at dairy organisationsand managers at other food companies.Contact MælkeritidendeIf you want further information about the Danishdairy industry, please contact the editorial staff: ChiefEditor, M.Sc. in Dairy Technology, K. Mark Christensen,sub-editor M.A., Anna Marie Thøgersen.Mælkeritidende · The old Dairy · Landbrugsvej 655260 Odense S . Denmark · Tel.: +45 66 12 40 25Fax: +45 66 14 40 26 · www.maelkeritidende.dkinfo@maelkeritidende.dk56 Danish Dairy & Food Industry... worldwide 2006NR. 16

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