food Marketing & Technology 2/2021

2/21 

Vol. 35 • 31377 

ISSN 0932-2744 

Cover: Combined Dairy 

and Juice Filling on the 

Same Bottling Line 

Clean Label in Bakery, 

Confectionery and Drinks 

A Food Processing 

Approach to Plant-Based 

Products 

New Labelling 

Solutions for Pizza

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Key No. 100167

Editorial 

Feeling Refreshed in the Springtime 

We started putting this issue of Food 

Marketing & Technology together just 

before Easter in Germany, where there 

are several holidays, making for a long 

weekend. This year I found it more 

special than usual. 

We are all learning from 2020 and the 

challenges Covid-19 has thrown at us. I 

found the days of reflection helpful from 

a personal but also a food perspective. 

In many countries Easter Eggs are a sign 

of a new life and bring hope to all who 

give and receive them. The tradition in 

Germany of painting boiled eggs and 

then concealing a nest, brings fun to the 

hiders and the seekers. It made a new 

start more real for me this year. 

New life and energy are a particular 

focus of food, vegetables, vitamins and 

also warmth and good weather. This 

reflects on health and wellness, as well 

as other topics around sustainability and 

the climate. Springtime is often about 

preparing the ground, planting seeds, 

caring for the crops and harvesting 

food later in the year. I was conscious 

of this too as I walked around the local 

countryside. 

Moving swiftly on from chocolate eggs, 

this time of year is also about shedding 

some of the thick winter coat we may 

have put on and a wish to get into 

(better) shape for the summer months. 

Hope is a healthy emotion. It grows 

in each of us as we take steps to do 

something positive, whether this means 

fresh air and exercise or taking enough 

time for inner reflection. This in turn 

gives a new impetus and focus on life. 

Whatever we plant now, we will harvest 

later. I feel motivated and refreshed, 

so whatever working methods I select 

today, they will surely bear fruit 

tomorrow. 

Definitely a positive result of lockdown, 

slowdown, home office and little travel 

in the last months, has been a reduction 

Ian Healey 

Editor-in-Chief 

in pollution and an increase in time to 

reflect. Both are beneficial to me as a 

person and a member of society. I don’t 

think that any of us will be the same 

again. 

Look after your new self. In body, mind 

and spirit. I certainly intend to. 

Sincerely, 

If you like it – subscribe! 

food Marketing & Technology • April 2021 

3 

food Marketing & Technology • April 2021

XIX International Trade Fair 

for Savoury Snacks & Nuts 

16-17 June 2021 

Hamburg, Germany 

Contents 

food Marketing & Technology April 2021 

1 Editorial 

42 Impressum 

Move your 

business 

forward 

at the worldwide fair 

for savoury snacks 

The only trade fair 100% focused 

on savoury snacks and nuts 

+ Experience the hottest trends, 

tastes and technologies 

+ Develop your business with the 

industry’s leading suppliers 

+ Connect with the decisionmakers 

of the industry and 

find international trade 

partners, distributors 

+ Meet existing customers and 

new prospects from around 

the world 

+ Sell your products to an 

audience that is ready to buy 

The industry-defining fair for 

the savoury snacks sector 

Ingredients 

9 Chocolate Trends in 2021 

11 A New Versatile Clean Label Ingredient for Bakery, 


12 Making Clean-Label Convenience a Reality 

13 Aloe Vera: Valuable Functional Food with Great 

Nutritional Benefits that Reduce Disease Risk 

16 Steady Increase in Plant-Based Fish Alternative Choices 

17 Vegan Barbecue Products 

Processing 

6 RJ Corp in India Implements New Aseptic PET Technology to 

Combine Dairy and Juice Filling on the Same Bottling Line 

18 The Right Approach can Lead to Meaty Profits From Plant-Based 

Products 

20 Making Food Processing Quality More Reliable with Vision AI 

24 New Automated Grading System for Fresh Green Beans 

26 X-Ray Ensures High Quality for Sausage Exports 

28 Cooking up a Storm with its Luxury Frozen Meals 

30 A Sustainable Competitive Advantage for Food Manufacturers 

Packaging 

36 Unconventional Labelling Solution for Pizzas 

38 Robotics: 25 Years of Reliable Palletizing Technology 

Departments 

41 Calendar of Events 

Key No. 99601 

snackex.com

Vol. 35 • 31377 

ISSN 0932-2744 








Products 

2/21 

New Labelling 

Solutions for Pizza 

Cover: RJ Corp. / Varun Beverages 

Ltd. / Sidel 

RJ Corp has installed a new aseptic combi 

machine in its new plant in Punjab, India. 

This project aims to expand PET bottling 

capacity and provide production flexibility 

for the milk brand Cream Bell as well as 

the Tropicana juice range. The investment 

marks two major achievements for RJ 

Corp: the company’s first step into aseptic 

PET bottling and also its first experience 

with dry preform sterilization. 

Our Cover Story starts on page 6. 

Ingredients: Clean Label Ingredients 

For the food industry, the newly developed Emwaxy clean 

label starchderivative range offers a good start to create new 

innovative appealing products. The unique characteristics of 

Emwaxy serves todays trends e.g. easy handling, non-GMO, 

kosher & halal, gluten and allergen free as well as plant-based 

and clean label. Check out the full story on page 11 

Processing: Plant Based Production 

Meat replacement products are growing in popularity with 

consumers, whether for ethical, environmental or nutritional 

reasons, and retailers are quick to jump on the bandwagon by 

offering an increasing range of plantbased alternatives across 

all their stores. How can food processors best profit from this 

revolution in eating habits? The choice of equipment depends 

on different factors. Find out more on page 18 

Packaging: Unconventional Pizza Packing 

Automatic labelling, high-quality appearance, and large area 

for information but still with an unobstructed view of the 

product - the full wrap labelling solution for pizzas and other 

flat food products fits the bill in every way. This solution is also 

significantly more cost-effective than traditional box packs. 

And it meets the increasing demands of the market as regards 

sustainability!. See page 36 

Key No. 97065 

food Marketing & Technology • February 2016

Cover Story 

RJ Corp in India Implements New 

Aseptic PET Technology to Combine 

Dairy and Juice Filling on the Same 

Bottling Line 

Varun Beverages Ltd, part of RJ Corp group, one of the largest franchises for PepsiCo Inc. globally, has 

installed Sidel’s Aseptic Combi Predis in its newly established plant in Punjab, India. This pivotal project 

aims to expand PET bottling capacity and provide production flexibility for the private label milk brand 

Cream Bell as well as Pepsi’s Tropicana juice range. By choosing the new aseptic dry preform sterilization 

technology, RJ Corp is commercializing its liquid dairy products (LDP) in PET for the first time in India. 

Since the early nineties, the privately 

owned Indian company RJ Corp 

has made itself a multinational 

powerhouse with thriving businesses 

in beverages, fast food restaurants, 

retail, ice cream, dairy products, 

healthcare and education. Through its 

operating company Varun Beverages 

Ltd., the group is one of the largest 

bottling partners for PepsiCo in the 

world, currently holding 36 plants on 

the Indian subcontinent and in Africa, 

and producing carbonated soft drinks, 

water and hot-fill juices as well as LDP. 

When production flexibility 

matters 

With Indian consumers looking more 

and more for nutritional beverages, 

the market keeps shifting towards 

so-called “better-for-you” drinks. To 

remain competitive in light of this 

trend, RJ Corp decided to diversify its 

portfolio and put more emphasis on its 

100% juices with pulp and ultra-high 

temperature (UHT) LDP, thus gaining 

more production flexibility to switch 

product categories easily. “Managing 

both juices and dairy products on 

the same PET packaging line flexibly 

was essential for us, and we could 

make it happen only by producing in 

aseptic,” says Mr. R.J.S. Bagga, Director 

Technical & Operations at RJ Corp. 

“High-level food safety and hygiene 

standards were must-have features 

to answer Pepsi’s demanding quality 

protocol as well as to pass internal and 

external validations.” To face these 

challenges, RJ Corp decided to go with 

Sidel’s Aseptic Combi Predis, including 

dry preform sterilization. They were 

convinced that it is a very safe and 

easy-to-operate solution while visiting 

a French copacker that has used and 

trusted this technology to handle both 

juices and milk for more than 10 years. 

This technology, approved by the FDA 

for low-acid production since 2017, 

allows the beverage producer to switch 

easily and safely between four UHT 

milk flavors (white UHT milk, coffee, 

chocolate and mango) and various 

kinds of juice recipes (i.e. orange delight 

& 100% orange juice with pulp, mixed 

fruit delight and 100% mixed fruit juice, 

guava, apple delight and 100% apple 

juice, and lychee delight) on the same 

line. This represents a major turning 

point for the companies in India, which 

were previously producing juices in PET 

bottles with the hot-fill process and 

milk in cartons. 

Up to 200 hours of continuous 

production 

The investment in Sidel’s Aseptic Combi 

Predis marks two major achievements 

for RJ Corp in India: not only is this the 

Sidel’s Aseptic Combi Predis TM with dry preform sterilization technology requires no water consumption and can reduce the use of chemicals significantly 

6 


Cover Story 

RJ Corp has expanded the packaging options of LDP products for PET bottles 

company’s first step into aseptic PET 

bottling, but also its first experience 

with dry preform sterilization. 

Employing the injection of hydrogen 

peroxide (H 2 

O 2 

) before the oven, Sidel’s 

patented Predis technology requires 

no water consumption and can reduce 

the use of chemicals significantly. This 

is a lighthouse project for PepsiCo Inc. 

worldwide regarding the processing 

and bottling of its high-acid products 

– the Tropicana juices. The Aseptic 

Combi Predis also features a similar dry 

sterilization for caps, Capdis, as it was 

very important to optimize the cleaning 

process and the handling of the caps 

themselves to avoid deformation and 

ensure tightness between the cap and 

the bottle. 

“RJ Corp chose Sidel because of our 

long-standing expertise in PET and 

aseptic technologies. Their new 

line allows for up to 200 hours of 

continuous production without any 

stoppages for cleaning, keeping the 

production running steadily without 

any compromise on product quality. 

Moreover, the equipment is easy to 

manage, and the operators find its 

functions intuitive and easily accessible,” 

says Rohit Sawhney, Sales Director for 

Sidel India. 

Optimized and efficient aseptic 

PET packaging line 

In addition to the Aseptic Combi Predis, 

the complete line at RJ Corp in Punjab 

is equipped with a very competitive 

and flexible End of Line. It features 

the seamless shrink-wrapper VersaFilm 

Access, offering the best combination 

of production quality, performance and 

price at medium speed. It also includes 

the automatic and safe PalKombi layerby-layer 

palletizer working with a steady 

low-level pallet infeed and allowing 

easy access and control. To understand 

its line operations and maximize 

Overall Equipment Effectiveness, RJ 

Corp also invested in Sidel’s Efficiency 

Improvement Tool (EIT®). This modular 

and scalable software provides the most 

significant performance indicators, 

reports and analyses, based on live and 

historical data, to better understand 

line flow, uncover sources of efficiency 

loss and achieve in-depth performance 

evaluation. It monitors quality, losses, 

consumption, accumulation and traceability, 

and interfaces with inspection 

devices and business systems. 

To make the most of this line, specific 

training was delivered to enable 

all RJ Corp technicians to get the 

right understanding of aseptic PET 

packaging, including the Hazard 

Analysis Critical Control Point system 

(HACCP), and thus avoid any risk of 

contamination or detect root causes 

efficiently in case it happens. Since its 


7

Cover Story 

Complete aseptic packaging solution owns high flexibility to help RJ Corp manage both juices and dairy products 

implementation and validation, the 

line has been working successfully with 

an output up to 36,000 bottles per 

hour. Overall, it expands production 

capabilities in terms of volume as well 

as a higher number of SKUs. 

Ensuring packaging performance 

across the supply chain 

Traditionally, in India, milk is packaged 

in pouches, glass bottles or cartons. By 

choosing Sidel’s aseptic PET packaging 

technology, RJ Corp has widened 

packaging options for its LDP products. 

The brand-new PET bottle assures 

high food quality standards and 

outstanding customer experiences, 

along with PET being a cost-efficient 

and sustainable material. During the 

implementation of the packaging line, 

Sidel also shared its experience in PET 

packaging and helped design the new 

PET bottle, enabling the same shapes 

and caps to be used for both Cream 

Bell UHT milk and the Tropicana juices. 

The cap size for all bottle formats is 

33 mm, which is a common width for 

LDP, but quite uncommon for juices. 

As a result, Sidel’s packaging experts 

developed and designed an iconic 

bottle shape in three formats – 200 ml, 

500 ml and 1 L. 

prior to industrial production in order 

to ensure the bottles’ strength and 

performance across the supply chain. 

Sidel also designed specific preforms 

to reach optimized bottle weight in 

order to withstand the dry preform 

sterilization technology and avoid any 

thermal stresses on the bottle. Produced 

in white monolayer barrier PET, the 

new packaging ensures a shelf life up to 

nine months for UHT milk. Furthermore, 

all the transparent Tropicana juice 

bottles passed the demanding PepsiCo 

validation protocols. 

Taking into account the good experience 

and satisfaction with Sidel’s complete 

aseptic packaging solution installation 

in Punjab, Varun Beverages Ltd. again 

chose Sidel for the exact same scope of 

supply for a different plant, located in 

Central-Eastern India. 

fmt 

The Tropicana juices from Varun Beverages Ltd are now produced by Sidel’s Aseptic Combi Predis TM 

with top hygiene standard 

All of the bottle shapes and formats 

have been qualified internally. They 

were submitted to Finite Element 

Analysis (FEA) and on-site validations 

8 


Ingredients 

Chocolate Trends in 2021 

Chocolate is one of the most household products when it comes to snacking and indulgent goods. It is part 

of the staple diet for many consumers across the globe with high proportions of people purchasing and 

indulging in chocolate products on a daily basis. However, as consumers look to adopt a healthier lifestyle, 

how has this affected the chocolate market, and what are consumers seeking out? 

by Will Cowling 

Overall Consumption 

Across the globe consumers eat a wide 

variety of chocolate products within 

their diets. Irrespective to health 

concerns, chocolate still remains a 

staple part to consumer diets, reasons 

being consumers like to enjoy 

moments of indulgence on a regular 

basis for reward and escapism. FMCG 

Gurus insights show that 90% of global 

consumers who eat chocolate regularly 

purchase single-serve bars with half of 

these consumers stating they have one 

at least once a week. 

increased focus on seeking out betterfor-you 

offerings and moderating intake 

in categories inherently associated with 

indulgence. 

Functional Ingredients 

FMCG Gurus research shows that 40% of 

global consumers state they are seeking 

out healthier chocolate options. This 

desire to seek out chocolate products 

which can offer a nutritional boost is 

driven by consumers adopting a healthier 

lifestyle in order to improve their health 

and well-being. One key area consumers 

are looking to address is their immune 

health, as COVID-19 has left consumers 

more conscious about this than ever 

before. 

Within the chocolate market there is 

a noticeable trend that is seeing niche 

categories such as plant-based and 

functional chocolate growing. This is 

due to the consumers looking to adopt 

a healthier lifestyle, actively seeking 

out better-for-options across a number 

of snacking and indulgent categories. 

COVID-19 Impact 

COVID-19 is also something which 

has impacted the chocolate industry 

over the past 12 months. FMCG Gurus 

insights from February 2021 show 

that 40% of global consumers have 

purchased more chocolate as a result 

of COVID-19. In times of uncertainty, 

consumers turn to product categories 

inherently associated with indulgence 

for moments of escapism. As a result 

of this consumers can tend to be less 

attentive to nutritional intake as they 

prioritize taste and comfort. 

However, due to this increase in 

chocolate snacking, consumers have 

become more conscious about their 

overall health. A key concern consumers 

face is weight management with five in 

ten global consumers becoming more 

conscious about their weight due to 

COVID-19. This will result in consumers 

becoming even more conscious about 

their chocolate consumption habits 

throughout 2021 and beyond, with an 

food Marketing & Technology • April 

Key No. 99307 

Rethinking eating patterns. 

Go low, go slow, go all day. 

The traditional three meals a day have evolved to fluid meal moments. Get on board with the 

eating challenges in the new normal and offer the right bite for each break. Help consumers to 

get the most out of their day with Palatinose, providing full carbohydrate energy coupled with a 

more balanced blood sugar level. Focus on inner wellbeing with Orafti ® Inulin and Oligofructose, 

naturally sourced prebiotic fibres that improve digestive health. From your lab to their lunchbox, 

aim for functional products that are sensorially and nutritionally appealing to today’s consumers. 

Follow us on: 

www.beneo.com 

9

Ingredients 

When it comes to functional chocolate 

39% of global consumers state they 

find immune boosting claims appealing. 

This shows that there is a desire for this, 

something in which brands can look to 

adopt when targeting health-conscious 

consumers in 2021. This creates an 

opportunity for brands to create 

differentiation within the market using 

functional ingredients. 

One ingredient consumers would like 

to see used in functional chocolate 

products is Omega 3. Over the last 

decade, consumers have become more 

and more aware of the benefits of 

Omega 3, associating the ingredient 

with a variety of health benefits. FMCG 

Gurus research shows that over 60% 

of consumers would find Omega 3 

claims within functional chocolate 

products appealing. Therefore, there 

is a key opportunity for brands to 

fortify products with this ingredient. 

However, when doing so, it is crucial 

that consumers feel fully satisfied that 

the ingredient will not impact on the 

sensory element of consumption. This 

article is based on FMCG Gurus: The 

Future of Chocolate in 2021 – Global 

Report, and FMCG Gurus: COVID-19 

Survey series (4 waves across 18 

countries in April 2020, May ’20, July 

‘20, February 2021). 

fmt 

The Author 

Will Cowling, is Marketing Manager at FMCG 

Gurus, based in Enfield, UK 

10 food Marketing & Technology • April 2021

Ingredients 

A New Versatile Clean Label Ingredient 

for Bakery, Confectionery and Drinks 

Emsland Group presents their latest 

waxy potato development: Emwaxy ® 

Spray 200. 

The Emwaxy ® Spray 200 fits perfectly 

with the rapid growing demand for 

clean label alternative ingredients for 

the food industry. Emwaxy ® Spray 200 

is a clean label low DE starch derivative. 

Emwaxy ® . 

With the introduction of Emwaxy ® , 

Emsland Group introduces new 

starch solutions for the food industry. 

Emwaxy ® is produced from special 

potatoes, containing more than 99% 

amylopectin and is being cultivated 

through traditional, non-GMO 

breeding techniques. 

Based on high amylopectin potato 

starch, Emwaxy ® Spray 200 has unique 

properties. Emwaxy ® Spray 200 has 

excellent solubility and is not prone 

to retrogradation. Therefore it can be 

applied in high concentrations whilst 

staying stable. The high cohesiveness 

at high concentrations enables to 

apply Emwaxy ® Spray 200 solution as 

food glue in many food applications. 

The product has good film forming 

characteristics and therefore it can 

be successfully applied as egg wash 

replacer on baked goods. Body and 

mouthfeel enhancement or partial 

sugar replacement are further examples 

of the possibilities, which Emwaxy ® 

Spray 200 can offer. 

Characteristics of Emwaxy ® Spray 

200 

• Easy to dissolve 

• Clean label 

• Stable in solution in high dosage 

• Excellent film forming with high 

transparency and gloss 

• Potato starch based – fits in the 

‘plant-based’ trend 

• Forms smooth solutions with good 

body and mouthfeel 

For the food industry, the newly 

developed Emwaxy ® range offers a 

good start to create new innovative 

appealing products. The unique 

characteristics of Emwaxy ® serves 

todays trends e.g. easy handling, 

non-GMO, kosher & halal, gluten and 

allergen free as well as plant-based and 

clean label. 

Potential applications and 

advantages 

Application 

Bakery glaze 

Cake 

Cereal bars 

Instant 

drinks 

(coffee, tea, 

sport 

Advantage 

Cost effective vegan 

alternative for egg 

wash 

Sugar reduction opportunities 

up to 30 % 

Effective food glue 

that can replace sugar 

syrups 

Prevents lumping and 

provides excellent 

body and mouthfee 

Chewable confectionery Alternative 

for gum Arabic and gelatin 

Emsland Group experts can assist you 

selecting the right recipe and product 

for your application. 

fmt 


11

Ingredients 

Making Clean-Label Convenience 

a Reality 

With the food industry under increasing 

pressure to create innovative new or 

improved products, without the use 

of artificial additives, the challenge is 

on for processors to develop products 

which entice consumers yet remain 

affordable for all parties. Some of 

the greatest consumer demand for 

clean-label is now being felt by the 

convenience foods market*, presenting 

technical challenges to the industry, but 

also a huge opportunity for growth. 

Clean-label ingredients specialist 

KRÖNER-STÄRKE is offering solutions 

to this dilemma by developing its range 

of agglomerated ingredients, the 

use of which can provide answers to 

many of today’s product development 

challenges. 

Henrik de Vries: “As more and more people turn towards a clean-label lifestyle, the demand for a 

wider range of organic products continues to increase”. 

Currently used primarily in powdered 

food and beverage products such as 

soup mixes and instant hot chocolate, 

agglomeration involves enlarging the 

particles within a substance by joining 

together smaller particles to form a 

granulate or ‘blueberry’ structure. 

Using agglomerated ingredients can 

help food producers develop products 

which have improved flowability, 

easier lump-free stirring, and improved 

dispersibility as well as a significant 

reduction in dust during processing. 

This of course reduces wastage and 

improves plant safety. 

may be carried out using ‘wet’ methods 

where a binder is used or ‘dry’ methods 

where no binder is needed, but in 

either case no artificial additives are 

used. Additionally, they are also ideal 

for use in products developed for those 

suffering from dysphagia. 

Where keeping production costs to 

a minimum is a key concern, using 

ingredients in the form of flakes 

presents a cost-effective solution, and 

indeed many of KRÖNER-STÄRKE’s 

products are also available in flake 

form. 

Moving beyond traditional uses for 

agglomerated ingredients, KRÖNER- 

STÄRKE is developing its range to 

cover a wider variety of applications. 

Indeed, the possibilities are endless, 

and the company is currently 

producing agglomerated wheat 

proteins, pregelatinized starches and 

pregelatinized flours based on a several 

different raw materials. These are being 

used to produce a diversity of products 

including a glaze used for pies and 

baked goods as well as a seed adhesive 

used to adhere seeds to the top of bread. 

All of the products in KRÖNER-STÄRKE’s 

range are available in an organic format, 

and depending on the raw material 

used, gluten free versions are also 

available. The agglomeration process 

Commenting on the new range, 

Commercial Manager Henrik de Vries 

said: “As more and more people turn 

towards a clean-label lifestyle, the 

demand for a wider range of organic 

products continues to increase. The 

development of our agglomerated 

ingredients is providing food 

manufacturers with the opportunity of 

producing products which are appealing 

and convenient to consumers without 

the use of artificial additives.” 

KRÖNER-STÄRKE develops bespoke 

solutions to suit individual needs across 

a wide range of foods including baked 

goods, soups and convenience products, 

battered or dietetic products, and has 

a reputation for technical excellence in 

new product development. 

fmt 


Ingredients 

Aloe Vera: Valuable Functional Food with 

Great Nutritional Benefits that Reduce 

Disease Risk 

by Rico R. Magda 

The processing of Aloe extracts has 

been one of the largest botanical 

ventures in the world today. As a 

functional food ingredient, Aloe Vera 

has entered a new level in food industry 

on a larger commercial scale. The same 

bold invasion can also be seen in the 

pharmaceutical sectors, which are always 

in need of voluminous Aloe extracts for 

newer products. The plant has more 

than 75 active components that are 

richly fortified with vitamins, minerals, 

polysaccharides and many more. 

Medicinally, Aloe has health benefits 

like antitumor, antiobesity, treating 

ulcer, and antiseptic properties, among 

others. Aloe acts as fat replacer in baked 

goods and also acts as stabilizer to fruit 

juices and other consumer products. Aloe, 

whether in form of gel, juice, powder, 

and concentrate, can be added to food 

products to increase their functionality. 

No wonder, Aloe products have now 

become a multi-billion industry. 

The Plant 

Aloe has a soft structure and grows 

domestic or wild in the tropical areas 

of the world. Its main benefits include 

food, cosmetics, and medicinal uses. 

The plant was first introduced as 

ornamental plant for both indoor and 

outdoor either as a potted or raisedbed 

plant. Many consumer products 

including pharmaceuticals, medicines, 

food preparations, and beverages now 

contain a certain amount of Aloe extracts 

that fortify the products’ usefulness. 

In 1820, Aloe vera was listed in the US 

pharmacopoeia as purgative and skin 

protectant. Later in 1930, Aloe extract 

was used for treating radiotherapy burns 

to the skin and mucuos membrane. 

The plant has a very short stem. It 

grows from 60 to 100cm tall with 

thick, spiny, fleshed green leaves. 

Yellow flowers appear on spike that 

reaches 90cm tall. Mycorrhiza in 

soil aids the plant to have better 

nutrition. Aloes are known with 

various common names in different 

countries where they thrive. Some 

common names of the plant include 

“True Aloe,” “Indian Aloe,” “Chinese 

Aloe,” “First-Aid Plant,” “Burn Aloe”, 

and more. In 1768, Carl Linnaeus 

first gave the plant the description 

of Aloe perfoliata variety vera. DNA 

comparison study suggests that the 

commercial Aloe variety is a relative 

of Aloe perryi, an endemic species 

found in Yemen. 

Aloe is believed to have originated from 

the Arab regions and later scattered 

around the world due to human 

cultivation. It becomes a natural plant 

in Africa, and in some islands like 

Canary and Madiera. In Europe, Aloe is 

found growing wild naturally in Spain, 

especially in Murcia. The cultivation of 

Aloe reached China in the 17th century 

as well as in some other Asian countries. 

Similarly, this succulent plant also spread 

in some tropical areas of Australia, South 

America, south eastern states of the 

United States and the Caribbean. 

The plant can grow both indoor and 

outdoor. It tolerates little water from the 

soil where there’s low rainfall but growth 

is checked in places with heavy frost 

and snow. It’s important to have good 

drainage as water-soaked condition 

leads to leaf shrivel or decay. Too much 

sun, on the other hand, can literally burn 

the plant. Potted plants produce a lot 

of “pups” or off-shoots emerging from 

the base of the mother plant. Crowded 

plants need re-potting to give enough 

space and prevent the building up of 

pests. 


13

Ingredients 

Commercial Cultivation of Aloe 

Species 

Large-scale cultivation is now trending 

up in various parts of the world. 

Some of these countries venturing in 

commercial Aloe farming (soil and soilless) 

include Australia, Kenya, Tanzania, 

South Africa, India, Spain, Mexico, Cuba, 

the Philippines, Bangladesh, Jamaica, 

the Dominican Republic, USA, among 

others. 

Researchers have been working hard 

building proofs on the efficacy and 

safety of Aloe extracts used as cosmetics 

or medicines. Whatever the outcome 

of some researches, marketers of 

extracts continue to claim the soothing, 

moisturizing, and healing power of 

Aloe extracts. 

There has been an increasing commercial 

use of Aloe gel as ingredient of popular 

foods like yoghurts, desserts, and 

beverages. Manufacturers are however 

advised on using Aloe gel at higher doses 

as it can impart toxicity to consumers. 

Benefits from Aloe 

The increase of incorporating Aloe 

extracts to hygienic products, however, 

cannot be ignored. The extract is used 

as an anti-irritant and as moisturizer. 

Some beauty products such as make-up, 

soaps, sunscreens, shampoos, shaving 

creams, among others contain extracts to 

improve the products’ quality. 

Medically, Aloe has some effects. It 

acts as an astringent by binding, 

constructing, and sealing some injured 

or cut areas. It effects as a laxative 

due to anthraquinones and barbaloin 

substances that stimulate bowel 

movement. Application of the extracts 

to skin help to heal minor burns, insect 

bites, and sunburn. Applying Aloe to 

skin regenerates cells, softens and 

moisturizes it besides protecting skin 

against pathogenic fungi, bacteria, and 

viruses. For minor cuts, and burns, Aloe 

heals best when the affected skin is 

not covered with bandages. Aloe heals 

faster in the open. 

Aloe leaf has latex that has laxative 

effects. This latex helps to treat colitis, 

constipation, hemorrhoids, rectal itching 

and other colon issues. There was an 

advisory from FDA to remove latex 

from their products due to few studies 

conducted on its safety. 

When Aloe juice is dried, a very adhesive 

tincture of benzoin is produced used 

in bandage. The tincture allows the 

bandage to adhere snugly to skin. 

Similarly, a mannose carbohydrate called 

acemannan is also used as an adhesive 

for dentures. 

Other benefits of Aloe need more 

research. Many users of Aloe claim 

that it can cure calluses, varicose veins, 

corns, and arthritis. It can even treat 

skin cancer. Allergy caused by Aloe is 

rare. When applying Aloe to skin, apply 

first a small amount under your arm 

or behind your ear. If rashes or some 

stings appear, stop the application. 

When you’re experiencing nausea, 

vomiting or painful stomach, stop using 

it as the laxative property of Aloe could 

make the symptoms worse. Moreover, 

Aloe is not advisable for people having 

chronic intestinal issues, which include 

ulcerative colitis, Crohn’s disease and 

irritable bowel movement. 

Aloe’s Active Nutritional and 

Medicinal Composition 

The stuff has antioxidant vitamins 

namely: A, C, and E with vitamin 

B12, folic acid, and chloline. It has 

8 enzymes including bradykinase, 

alkaline phosphatase, amylase, 

carboxypeptadase, cellulase, catalase, 

lipase, peroxidase, and aliiase. 

Twelve anthraquinones, which act as 

laxative are present including alloin and 

emodim, which serve as antibacterials, 

antiviruses, and as analgesics. Aloe is also 

fortified with minerals including zinc, 

potassium, calcium, copper, selenium, 

chromium, manganese, and sodium. 

Four fatty acids are also present in 

Aloe extracts including lupeol, betasisosterol, 

cholesterol and campesterol. 

These fatty acids are known to act 

as anti-imflammatory. Another antiimflammatory 

substances are present in 

Aloe like auxins and gibberellins, which 

help to heal wounds faster. Some sugars 

like monosaccharides (glucose, fructose) 

and polysaccharides are also found in the 

extracts. 

The popularity of Aloe extracts is due to 

some proven benefits they can give. One 

of the benefits is in healing skin issues 

including treating psoriasis, surgical 

wounds, and burn injuries. The first study 

about the extracts was conducted on skin 

conditions and healing management. 

Aloe’s gel can guard against radiation 

and thermal burns on the skin and heal 

the affected areas faster. For dry hair 

or itchy scalp, Aloe serves as a natural 

treatment while nourishing the hair to 

become strong and healthy. It also helps 

to regenerate skin tissue around the hair 

follicles while the gel’s enzymes rid off 

dead cells. 

Aloe extracts help the digestive system 

by normalizing the acid/alkaline balance, 

reduce yeast formation, and regularize 

bowel processing. A study reported 

in the Journal of Research in Medical 

Sciences suggests that Aloe extracts can 

be beneficial to people with IBS (Irritable 

Bowel Syndrome). When 30ml of Aloe 

juice was given twice a day, the level 


Ingredients 

of discomfort with IBS was decreased. 

More data, however, are needed to 

recommend it as an effective cure. 

Aloe extracts help the immune system. 

This is possible with bradykinase, an 

enzyme present in the extracts. It breaks 

down the protein into amino acids 

and the enzyme fuels the body cells to 

function properly. The zinc component 

of Aloe, on the other hand, helps in 

preventing zinc deficiency. This capacity 

of Aloe in building up the immune 

system without causing allergic effects is 

also tapped for dentistry uses. 

The plant is rich in antioxidants that 

reduces imflammation. These are vitamins 

and minerals that ward off free-radical 

damage. Vitamin A maintains healthy 

vision, neurological functions and keeps 

the skin healthy. Vitamin C protects the 

body from eye issues, skin wrinkling and 

cardiovascular diseases. Vitamin E, aside 

from fighting imflammation also slows 

down cell aging. 

Studies using animals and humans have 

suggested that Aloe extracts can alleviate 

chronic hyperglycemia and worrying 

lipid profile on people with diabetes. 

In two clinical trials, one tablespoon 

of gel or a placebo was given to some 

women without drug therapy resulting 

to decreased level of blood glucose and 

serum triglyceride. With the next trial, 

gel or placebo in combination with a 

commonly prescribed anti-diabetes drug 

glibenclamide was given. The same 

reduction in blood glucose and serum 

triglyceride was produced. 

More Studies Needed in 

Establishing Benefits 

Who has learned that an Aloe plant 

has so much goodness stored in its 

spiny leaves? Though a lot of goodness 

is stored in the leaves, a world of 

caution has been addressed to unwary 

consumers not to use this yellow latex 

coming from the leaves due to laxative 

effects. Latex has bitter taste and is 

removed during processing with a 

stripping agent that impairs the active 

ingredients in commercial Aloe juice. 

Gel and juice are almost similar products 

that differ only in the total mucilage 

they have. Gel has more mucilage 

than juice. This slimy substance has 

the polysacharrides that make Aloe so 

healthful. For quality Aloe products, 

the best come from harvested leaves 

cut and processed within 48 hours. 

In sourcing for Aloe products whether 

they are gel, latex, juice or extracts, 

be sure that your choice comes from 

a reputable supplier. This is to ensure 

that extraction and processing have not 

lessen Aloe’s therapeutic properties. 

Buyers should consider that. As Aloe 

products are crushed, ground, pressed, 

filtered, and stabilized, the active 

components in the extracts should 

have high amount of active ingredients. 

The International Aloe Science Council 

has made a certification program in 

evaluating the quality and quantity 

in commercial products. Alternatively, 

you can grow your Aloe plant indoor in 

pots or greenhouse or outdoor to have 

the amazing and inexpensive benefits 

of the plant right on your own reach. 

Fresh is, indeed, always the best. fmt 

The Author 

Rico R.Magda is a plant biologist and lecturer 

at the University of the Philippines, 

Los Banos, and regular contributor to Food 

Marketing & Technology. 

When there‘s nothing left... 

fmt 

...there was EMWAXY inside! 

100 

Get in touch 

Contact emwaxy@emsland-group.de 

% EMWAXY 

100 % Taste 

® 

Key No. 100101 


15

Ingredients 

Steady Increase in Plant-Based Fish 

Alternative Choices 

Plant-based alternatives to fish and 

seafood are the future, not just in terms 

of nutrition, but also ecologically. One 

reason is that they appeal to younger 

consumers like Generation Z. According 

to Innova Market Insights, at 32 percent 

worldwide this is the largest population 

segment. It accordingly will have a 

major influence on consumer behavior 

in the coming decades. For this target 

group, health and well-being are just 

as important as environmental and 

climate protection, animal welfare and 

social factors. Plant-based alternatives 

to fish and seafood thus not only 

offer new indulgence experiences 

for flexitarians, they also meet the 

demands of the rising generation. 

Environmental organizations already 

advise cutting back on consumption 

of ocean fish and seafood, due to 

overfishing. Microbiology is another 

factor. Due to the thermal processes 

in their manufacture, plant-based 

alternatives to smoked fish and sushi 

are microbiologically much safer than 

traditional fish products. 

For this growth area, Planteneers has 

already developed various product 

ideas with which manufacturers can 

make alternatives to breaded fish, fish 

sticks, filets and more. For example, a 

plant-based alternative to salmon filet 

is in the pipeline. These plant-based 

solutions are based on a diverse range 

of protein texturates that give products 

a very fish-like, tender bite. Florian 

Bark, Product Manager Planteneers, 

explains: “The right choice of texturate 

is indispensable in order to get as close 

as possible to the animal product. Plant 

protein concentrates are also important 

in order to match the protein content of 

the final product to that of the original. 

In addition, we have a large portfolio 

of algae-based hydrocolloids that are 

perfect for making alternatives to fish 

and seafood.” 

Among the company’s new products 

are fiildTex for alternatives to tuna 

pieces. With it, customers can use 

standard meat and fish production 

machinery to make alternative tuna 

that looks and tastes like canned 

tunafish, and can be used in many 

ways. Another innovation is fiildFish 

for alternatives to sushi-style raw fish 

and smoked products like smoked 

salmon. These plant-based products 

impress with typical fish structure 

and texture. But what makes them 

special is the flexible recipe – different 

fish alternatives can be created by 

adjusting the specific flavor and color. 

The end products can be readily sliced 

and are also freeze-thaw stable. This 

makes them very well suited for 

convenience products. 

fmt 

Photos: Planteneers 


Ingredients 

Vegan Barbecue Products 

From burger patties and bratwurst, to barbecue skewers and meatballs – pea protein-based products 

promise flavorsome, flame-grilled enjoyment 

The Kulmbach-based spice expert RAPS, a partner of the meat industry and the butcher’s trade for more 

than 95 years, is bringing even more variety to the market with its new veggie concepts: With recipes based 

on pea protein, RAPS offers functionality and flavor from a single supplier, and addresses the demands of 

manufacturers who want to expand their barbecue range with diverse, plant-based applications. 

Meat-free products for vegans, 

vegetarians and flexitarians is one of 

the fastest-growing segments in the 

food industry. According to a recent 

report by the Smart Protein Project, 

sales of plant-based alternative products 

in Germany increased by 97 per cent 

between 2018 and 2020. With its savory 

seasonings and functional concepts for 

meat alternatives, RAPS proves that 

ditching meat does not mean sacrificing 

enjoyment. In addition to products 

based on soy or wheat, new concepts 

with pea protein have also been created. 

With the help of numerous recipe ideas, 

food producers can address a large 

target group and create products that 

convince both with typical bite and 

pleasant mouthfeel, as well as best taste 

thanks to RAPS’ spice blends. 

The diverse application possibilities 

include meat-free versions of barbecue 

classics such as burger patties, coarse 

and fine grilled sausages, meatballs 

(also with creamy fillings such as 

jalapeno cheese sauce), barbecue 

skewers and cevapcici. When it comes 

to sensory characteristics, the products 

are very similar to the originals, thus 

appealing to “die-hard” barbecue fans. 

Product-specific firmness and texture 

can be adjusted in the production 

process, and all recipes can be easily 

implemented with standard meat 

processing equipment. Thanks to excellent 

freezing and thawing stability, 

frozen products are possible too. 

As consumer demands become 

more individual and diverse, such 

requirements must be reflected on 

supermarket shelves. “With new vegan 

recipes, we want to make barbecue 

enjoyment possible for everyone thanks 

to the versatility of pea protein,” says 

Josefine Schneider, product manager at 

RAPS. “In addition, we pay attention to 

short ingredient lists and a nutritionally 

valuable composition. Of course, this 

is also reflected in the labelling, which 

means we have been able to develop 

many recipes with Nutri Score A or B.” 

Photos: RAPS 

In addition to the grill range, RAPS offers 

other vegan and vegetarian product 

concepts – for example, for wieners, 

cold cuts, schnitzel, vegetable and fresh 

spreads, fish fingers, meat and tuna 

salads. Thanks to the manufacturer’s 

comprehensive portfolio, the products 

can be further individualized and refined 

with specific seasonings, marinades or 

dipping sauces. 

fmt 


17

Processing 

The Right Approach Can Lead to Meaty 

Profits From Plant-Based Products 

Nils Beyer, Food Application Technologist at GEA Food Solutions discusses the growing trend towards plantbased 

eating habits and how the food processing sector can take advantage of technology to meet the 

demand for a wider variety of products. 

Meat replacement products are 

growing in popularity with consumers, 

whether for ethical, environmental or 

nutritional reasons, and retailers are 

quick to jump on the bandwagon by 

offering an increasing range of plantbased 

alternatives across all their stores. 

But is this trend just a flash in the pan 

involving a minority of consumers, or 

is it something bigger than that and, if 

so, how can food processors best profit 

from this revolution in eating habits? 

Extensive consumer research carried 

out in four European countries last 

year found that more than one third of 

those asked were either reducing their 

meat intake or planning to reduce 

their meat consumption.* Rather 

than only counting those who already 

classify themselves as vegetarian or 

vegan, if we look at the numbers of 

people reducing their meat intake, the 

move towards this lifestyle is much 

more significant and widespread than 

was previously thought. The challenge 

for manufacturers is to create the 

perfect protein substitute for meat in 

taste and texture, which was also high 

on the wanted list according to the 

research. 

Taste is becoming everything in the eyes 

of the discerning consumer so when 

considering a food concept, it’s important 

that equipment and ingredients work 

well together. Consistency of products 

is also vital as the upstream process of 

preparing the mix for meat replacement 

products has the biggest impact upon 

the success of operations further down 

the line to provide wholesome, delicious 

and exciting food. 

A strong need to expand meat 

alternative choices beyond the typical 

veggie burgers we’re all familiar 

with has also been identified. Food 

processors are having to demonstrate 

more and more culinary creativity and, 

while there is no silver bullet, the latest 

multi-faceted high-speed equipment 

can provide this competitive edge with 

the flexibility and power to design 

exciting vegetarian options and meatreplacement 

products that will satisfy a 

much wider audience. 

It’s vital to strike the right balance 

between natural appearance, color, 

flavor and texture on the one hand, and 

optimal binding characteristics of the 

ingredients mix on the other. Water 

and fat binding are very important, as 

well as the sustainability aspect of how 

products are designed. Choosing the 

right equipment can help bring to the 

market the new and innovative ranges 

that not only look like the real thing but 

taste just as good. 

GEA recommends to manufacturers 

proven solutions that offer complete 

process control by preparing all the 

components, whether making plantbased 

meat substitute burgers, mimic 

chicken coated nuggets, veggie fish 

sticks or vegan sausages. The choice 

of equipment for developing meat 

alternative products will depend on the 

application, the volume and on what the 

customer is trying to achieve. 

The latest high-tech solutions can be 

programmed to cover all the stages in the 

process in a fast, reliable and controlled 

way such as rehydration under vacuum of 

texturized vegetable proteins (TVP), mixing 

of oil and methylcellulose binder, highspeed 

cutting for optimal emulsification, 

cutting and cooling of the fat complement 

such as coconut butter and the final 

mixing of all ingredients, including spices 

and flavorings, ready for forming. 

To get the best results mixing and 

cutting, a range of equipment needs to 

be available that can handle all manner 

of ingredients that can be added to this 

process depending on the recipe, such 

as purified pea-protein, soy, extruded 

sunflower, extruded peas, wheat protein 

and gluten with the end result the same 

– thoroughly mixed, smooth patties that 

will have the mouth feel and juiciness of 

real meat. 


Processing 

are being developed and tested 

in industrial conditions, including 

plant-based tacos, ribs, sausages, fish 

alternatives, pulled Mexican ‘chicken’ 

and flavored ‘chickenless’ donuts 

with pesto-spinach, BBQ beetroot and 

carrot-curry coating. 

Naturally, before any decisions are 

made, food manufacturers need 

reassurance that any equipment 

purchased will prove to be a profitable 

investment. Feasibility studies, process 

improvements and R&D tests all need 

to continue, even during the current 

Covid-19 crisis. 

Next to mixing of ingredients, 

equipment that has a built-in vacuum 

feature will help intensify fresh and 

appetizing colors while contributing to 

exceptional fat binding and the higher 

density of the mix, leading to improved 

formability, with minimum waste during 

production. 

the Netherlands. Pooling together 

expertise with companies such as 

Griffith Foods, in process know-how, 

ingredients, and technology, exciting 

new meat-free product concepts 

GEA has a wide range of equipment 

to meet the needs of food producers. 

The company’s engineers and food 

technologists work closely with customers 

to ensure that their whole production 

lines are productive, sustainable, creative, 

reliable, and efficient with the lowest 

possible total cost of ownership and total 

security of outcome. 

fmt 

* https://griffithfoods.com/viewpoints/the-lostmillions-alternative-protein-white-paper/ 

When it comes to vegetarian and meat 

replacement products, preparation of 

the mix is just part of the story. Having 

the right equipment is a good start, but 

having a thorough knowledge about 

the ingredients being used, and how 

those ingredients are likely to behave 

throughout the process will allow much 

greater control of the final outcome. 

For example, with products that are 

intended to mimic meat, water binding 

and retention are essential and these 

properties can be influenced by different 

factors at different stages during the 

process. Rehydrating proteins such as 

TVP under vacuum as opposed to other 

methods is not only quicker, it also 

allows greater water retention, thus 

increasing yields and avoiding the use of 

additives to achieve this. 

Want modern 

shapes? 

USE OUR TECHNOLOGIES 

TO CREATE DEMAND! 

GEA works in collaboration with 

ingredient suppliers and product 

development companies testing out 

and developing new concepts at 

the GEA technology center in Bakel, 

SCHAAF TECHNOLOGIE GMBH 

www.foodextrusion.de 

Key No. 99030 


19

Processing 

Making Food Processing Quality 

More Reliable with Vision AI 

AI (Artificial Intelligence) makes quality inspections via image processing not only better, but also easier, 

faster and more efficient to implement. Data Spree from Berlin shows us how. 

In the food industry in particular, 

efficiency along the entire value chain is 

an essential competitive factor. Reliable 

automation of manufacturing and 

quality assurance processes is crucial for 

a modern and efficient factory. 

Traditional quality solutions 

- error-prone, complicated, 

expensive 

Classical image processing has to 

be programmed from scratch in a 

very complex way. Algorithms are 

developed manually by experts, which 

often requires a lot of know-how and 

time. At the same time, complex tasks, 

such as different or difficult defect 

images, cannot be mapped at all or only 

with great difficulty using these classic 

solutions. All this leads to high costs and 

to the fact that quality requirements 

often cannot be completely fulfilled. 

Figure 1 Development and integration process of Vision AI quality assurance 

This is why the food industry must 

use Vision AI in the future 

With Vision AI, quality inspections can 

be automated reliably and quickly 

during ongoing operations. With Data 

Spree’s Deep Learning DS software, 

these solutions can be implemented 

efficiently and easily. The first step 

is to simply capture images of good 

and defective products. Then the 

assignment of the images into “Ok” 

and “Not Ok”, also called annotation 

or labeling, takes place. The Data 

Spree actively supports here with 

annotation tools and services. 

Finally, the AI iteratively trains the 


Processing 

OUR KNOW-HOW. YOUR STEP AHEAD 

recognition and correct assignment of the “Ok” and “Not Ok” examples. 

The AI works on the basis of an interconnection of nerve cells similar to 

the human brain. Here, the AI independently learns to distinguish good 

from bad products based on image data. As with the human brain, the 

accuracy of the AI is continuously improving. With Deep Learning DS, 

you can quickly and easily perform this “learning process” yourself. Data 

Spree also offers the complete process up to productive integration into 

the plant as a service. 

DCS DAXNER 

CONTAINER SYSTEMS 

For contamination-free handling of 

powders and granulates 

This method can be used to quickly detect a wide variety of complex defect 

patterns, such as various surface defects, cracks, fractures, color defects and 

much more - and all without a single line of programming code. Quality 

assurance solutions can thus be implemented very efficiently and robustly. 

Even in just a few hours, operational prototypes can be created in some cases. 

Data Spree’s fast AI models additionally ensure good real-time capability in 

high-frequency production operations. Another advantage is the flexibility 

of the learning system. If products, product features or defects change at 

some point due to production changes, the AI can be easily “fed” with 

new images and retrained. In this way, it is possible to react quickly and 

effectively to changes in production without having to start from scratch or 

buy a new solution. 

Figure 2 The AI detects and localizes a wide variety of error patterns and deviations in 

real time 

Example: Quality assurance of cookies 

In the quality assurance process of cookie products, the AI can reliably 

distinguish “Ok” from “Not Ok” objects. The output shows the result and 

a heatmap. The red area in the heatmap is the AI’s basis for deciding 

whether an object is classified as “Ok” or “Not Ok” 

Here, the AI can easily detect a wide variety of defect patterns and 

deviations from the “Ok” state. The AI detects and localizes obvious 

defects such as holes, large cracks or fractures. But also more difficult 

defect patterns, such as small fractures and spalling or surface defects. 

The trained AI can independently detect and localize every possible defect 

variant or variable deviation, even if the defect did not explicitly occur in 

the training data set. 

+ NO CROSS CONTAMINATION 

+ HYGIENIC DESIGN 

+ ENERGY EFFICIENCY 

+ FLEXIBILITY 

With AI from Data Spree, all possible error cases are thus detected 

here. In the past, this quality monitoring would have required complex 

algorithms to be programmed by hand to detect a wide variety of 

deviations and defect types. With Vision AI from Data Spree these times 

are over. Especially for tasks with high error variability, learning AI 

systems are excellently suited. This means that especially in the quality 

inspection of food and baked goods, it is always worth taking a look at 

the topic of AI. 

fmt 


Key No. 99907 

Daxner HEADQUARTERS AUSTRIA 

Worldwide Powder Handling 

T +43 / 7242 / 44 227-0 • office@daxner.com 

Daxner GERMANY 

Daxner UK 

Daxner USA 

Daxner SOUTH-EAST ASIA 

Daxner RUSSIA 

Daxner LATAM 

21 

www.daxner.com

Processing 

Schubert for future 

TRAILBLAZER IN SUSTAINABILITY 

Schubert is not only a market and innovation leader, but also a real trailblazer in sustainability. 

And not only in its own group of companies, where it has long been committed to 

the 17 UNESCO Sustainable Development Goals. 

Schubert has been leveraging the topic of sustainability for many years to give its customers 

a decisive edge in the highly competitive consumer goods market. For example, with the development 

of sustainable packaging and machines that can process environmentally friendly 

materials. 

3D printing: Less waste is the goal 

With the Schubert PARTBOX, customers all over the world can 

print 3D format parts on demand and directly on site. This saves 

countless transport kilometres – and therefore up to 89% CO 2 

when compared to delivered parts. 

Sustainability pays off 

Sustainable packaging as a competitive advantage: Schubert-Consulting 

supports customers from all sectors in the development and optimisation 

of sustainable packaging and processes – from the selection 

of suitable materials and implementation on appropriate machinery, 

to the design of a sustainable supply chain. 

CO 2 

SAVINGS 

MACHINES 

SUSTAINABILITY 

Long live sustainability 

The Speedline was one of Schubert’s first praline packing lines 

and is still in operation today after more than 30 years. A good 

investment for the customer and a perfect example of resource 

conservation made by Schubert. 

1988–2020 

THE LONGEST SERVICE LIFE OF A SCHUBERT 

PRALINE PACKING LINE TO DATE 

MATERIALS 

Schubert 

Consulting 

AT 

ORGANISAT 

A 

Interfaces 

Material flow 

Factory layout 

ION + PROCESSES 

Reliability 

Digitalisation 

Automation 

Preventing instead of wasting 

Thanks to state-of-the-art manufacturing 

technologies and precisely planned production 

processes, the wastage at Schubert has been 

steadily decreasing for years. 

Key No. 99896 

MORE 

500 

THAN 

ARE AVOIDED ANNUALLY 

22 food Marketing & Technology • April 2021 

TONS 

OF REJECTS

Processing 

Sustainability creates demand 

Schubert machines are exceptionally durable and therefore in demand 

worldwide. And there are always new innovations that ensure even greater 

efficiency. The result: Sales growth that has been well above the industry 

average for years. 

20 

10 

5 

0 

– 5 

8,0 

0,8 

2016 

5,4 

5,0 

8,0 9,0 

2,8 

–1,7 

2017 2018 2019 

Sources: Schubert, VDMA 

Thinking not in terms of quarters, but in generations 

As a family business, Schubert thinks sustainably by its very nature – 

currently with three generations in the company: Gerhard Schubert, 

sons Gerald and Ralf, and grandsons Johannes and Peter. 

3 

A family business in 

its third generation 

Experience turnover plus 

with Schubert 

Mechanical and systems engineering 

in Germany 

Schubert is growing – and is using as little space as possible by concentrating 

at the Crailsheim site. Did you know that 50% of the offices and 

hall areas at Schubert are heated and air-conditioned using geothermal 

energy? 

WLZ (goods logistics 

centre) was 

completed 2002 

Hall 2 was completed in 

2 construction phases 

in 1996 and 2008 

The Casino (canteen) 

was completed in 1994 

Hall 1 South was completed 

in 7 construction 

phases 1972-1990 

Renewable packaging: Cardboard instead of film 

Schubert is supporting the move away from unsustainable plastic 

packaging. In many cases, the changeover to cardboard is also 

possible on existing machines. This means that the packaging can 

even add visual appeal and value thanks to excellent printability 

of the carton. 

In planning 

The administration 

building was completed 

in 2006 

Brains instead of kilometres 

Clever packaging solutions from Schubert can save not only packaging 

material but also space during transport. The same amount of goods 

can be moved with fewer journeys – and with significantly less CO 2 

consumption. 

MATERIAL SAVINGS 

− 28% 

Hall 1 North was 

completed in 2015 

306 

TONS 

OF PLASTIC SAVED 

PER YEAR 

Figures from a completed order 

Year 

2000 

Year 

2020 

100 TRUCKS 

LESS PER YEAR 

Figures from a completed order 

With smaller packaging and space-saving 

packed products, more goods can be transported 

on a pallet and supply chains 

become more efficient. 


23 

www.schubert.group/en/sustainability.html

Processing 

New Automated Grading System for 

Fresh Green Beans 

Key Technology, a member of the 

Duravant family of operating companies, 

introduces a new automated grading 

system for fresh green beans. This 

turn-key solution automatically removes 

defective green beans and 

foreign material (FM), while also 

separating green beans in clusters or 

with attached stems and then directing 

them for further processing. This 

integrated grading solution, consisting 

of Key’s Iso-Flo® vibratory and rotary 

separation equipment combined with 

a VERYX® digital sorter, significantly 

reduces labor requirements, increases 

throughput and achieves consistent 

product quality, even during times of 

high incoming defect rates. 

“Prior to this development, most fresh 

pack green bean lines had to rely 

extensively on manual labor, which 

is expensive, hard to find and often 

unreliable – packers need a better 

option. With our new automated 

grading system, customers are able 

to reduce the number of manual 

graders by up to 70 percent,” said 

Jeff Nielsen, Area Sales Manager at 

Key. “Additionally, the system’s high 

throughput achieves faster grading and 

packing, handling the same number 

of loads in a shorter period of time 

to create a shorter workday or work 

week for the entire packing house. This 

enables the grower to harvest and pack 

ahead of incoming adverse weather 

conditions that can destroy his crops 

and lower his pack-out rates.” 

This automated grading system 

removes product with defects such 

as tip rot, wind scars and wormhole 

damage as well as a wide range of 

FM including rocks, insects and animal 

parts, glass, metal, cardboard, corn 

cobs and roots, cotton stalks, peanuts 

and more. The Iso-Flo vibratory 

feed shakers ensure good product 

spread while the rotary separator 

removes small particles and small FM. 

The VERYX digital sorter separates 

incoming product into three streams. 

The ‘accept’ stream sends good green 

beans with no clusters or stems on 

to final inspection and packaging. 

A second sort stream is dedicated 

to green beans in clusters or with 

attached stems, which are directed 

for further processing to recover 

more good beans. A third sort stream 

collects green beans with defects and 

FM, which go to waste. 

“With manual packing, packers must 

staff their grading lines for the highest 

incoming defect rates. When defect 

rates spike, it causes ‘per box’ costs 

to increase, supply to tighten, prices 

to go up and the hourly throughput 

to drop to a crawl. Key’s integrated 

solution including VERYX flips this 

scenario – the packer maintains higher 

throughput rates with less labor for a 

lower ‘per box’ cost and greater ‘per 

box’ profit,” said Nielsen. “The impact 

on profitability as well as quality of life 

for operators, managers and employees 

is impressive. The resulting shorter work 

days reduce worker fatigue, accidents 

and preventative maintenance. Packers 


Processing 

often tell me that, for the first time in their lives, they feel like 

they have control over what they’re sending to their customers.” 

VERYX is equipped with Key’s powerful information analytics 

software, which collects data about every object flowing 

through the sorter. The segmented data can be used to profile 

incoming field loads in terms of its quality and defect rates. 

These quality profiles can be used to manage payment plans for 

growers. Insight into the product condition of individual loads 

is also valuable for understanding the impact of various field 

locations and growing practices on the quality of the green 

beans that come into the line for packing. 

Inspecting the product entirely in air, Key’s belt-fed VERYX 

sorter is ideal for products with challenging shapes like green 

beans. The sorter’s LED lighting system is designed to minimize 

shadows for accurate inspection of each green bean and 

detection of stems, product clusters and any defects that may 

appear on the surface of the bean. Positioning the inspection 

sensors away from product splatter sustains accurate inspection 

throughout long production cycles. VERYX is designed to run 

unattended during normal operation. 

Firm, chewy and bouncy: 

the right balance for 

noodles 

VERYX features next-generation cameras and laser scanners that 

offer twice the resolution of previous sensor technology to find 

smaller FM and defects. Key’s unique Pixel Fusion technology 

combines pixel-level input from multiple cameras and laser 

sensors, producing higher contrasts to find even the most 

difficult-to-detect product conditions and foreign materials. 

Intelligent air ejectors target each object at the optimal 

location to cleanly separate it from the product stream without 

inadvertently removing surrounding objects, maximizing 

both product quality and yield. VERYX is available in different 

inspection widths to satisfy a range of capacity requirements. 

In addition to VERYX, this versatile grading system can be 

configured with a variety of vibratory and mechanical solutions 

to optimize overall system performance. Key’s Iso-Flo® shakers 

can be designed to remove small, broken and curved beans. 

A PSG separator combined with an integrated Iso-Flo feeding 

shaker can size the product by length and diameter to remove 

short and thin green beans, as well as other small objects 

such as insects, loose stems, soil and small rocks. Robust and 

long lasting, Key’s vibratory and mechanical systems enhance 

sanitation with features such as open designs, fully-welded 

frames, stainless steel bed surfaces, oil-free drives and more. fmt 


Enhance the taste of your noodles with 

GEA technology: a stronger, chewier 

texture with a pleasant bite-feel. 

At GEA we have developed processing 

technologies for noodles starting from their 

unique taste. 

We have focused on encapsulating a history 

of consumption going back thousands 

of years in a high-quality and completely 

versatile product, suitable for every 

preparation and recipe. 

Discover 

GEA’s noodles processing technology 

gea.com/noodles 

Key No. 98838 

25 

Key No. 99510

Processing 

X-Ray Inspection Ensures High Quality 

for Sausage Exports 

An X-ray inspection system from Ishida 

is enabling leading German meat and 

sausage manufacturer Goldschmaus 

Natur to meet the highest quality 

standards required for the export of its 

Frankfurter sausages to Japan. 

The Ishida IX-GA-2475, which has been 

designed for inspecting small products 

at high speeds, has been installed at 

Goldschmaus Natur’s factory in Garrel, 

Münsterland to check for foreign bodies 

in unpacked Frankfurter sausages 

produced according to a special recipe 

for the Japanese restaurant and 

catering industry. 

The sausages are taken to the 

production line in strings on special 

smoke trolleys and manually fed onto 

the processing line. Once cut from the 

strings, the individual sausages pass 

through the X-ray system at high speed, 

separated by only a few centimeters. 

The patented technology behind 

Ishida’s X-ray inspection systems is 

based on software incorporating 

an intelligent genetic algorithm. By 

analysing image data over a number 

of generations, the machine achieves 

an extremely high level of inspection 

accuracy. Since similar contaminants 

are usually found again and again in 

sausage manufacture, the system can be 

optimized to look for these objects. This 

collects valuable visual and numerical 

information that helps to eliminate 

recurring sources of contamination. 

In this way, Goldschmaus Natur can 

demonstrate that its production and 

packaging processes are properly and 

correctly performed. 

The Ishida IX-GA 2475 is operating at 

a belt speed of 60 meters per minute, 

inspecting up to 200 sausages per 

minute. While the X-ray inspection 

system could potentially deliver even 

better performance, this is limited by 

the upstream cutter. 

Despite its high speed, the system 

reliably detects foreign bodies such as 

pieces of metal, glass and plastic as well 

as gristle and bone. The requirement 

to reliably detect pieces of metal with 

a diameter of 0.6 mm, glass with a 

diameter of 2 mm and plastic with a 

diameter of 5 mm has been fulfilled, as 

regular functional checks with specially 

prepared products demonstrate. 

In addition, the system is also able to 

reject sausages that exhibit other flaws 

such as clumps of herbs or damaged 

items. A special high-speed reject 

arm directs rejected sausages into a 

reject bin. The data log collects all 

information and helps to eliminate 

recurring sources of contamination, 

while also providing confirmation that 

the production processes are properly 

and correctly set up. 

The new X-ray inspection system is used 

by Goldschmaus Natur mainly in a twoshift 

operation and, thanks to its IP 65 

protection rating, can easily withstand 

the humid production environment. 

It did not take long for the operators 

to familiarize themselves with this 

largely maintenance-free machine. The 

easy-to-use X-ray system features an 

automatic set-up function and is ready 

within 90 seconds. Fine adjustments 

can be made during operation without 

interrupting the production. Up to 100 

programmable pre-sets allow rapid 

product changeovers. 

For operations manager Michael 

Schmolke, the benefits of this X-ray 

inspection system are clear: “It can find 

all sorts of foreign bodies – and not just 

metal. Also, no other system on the 

market can check for foreign bodies at 

such high speeds.” 

Photos: Ishida Europe 

Goldschmaus’ customers, too, have 

been informed about the new X-ray 

inspection system, which sends out 

a clear message that Goldschmaus 

Natur is committed to maintaining the 

highest standards of quality control. fmt 


Packaging 

SIMULATE WHOLE MUSCLE MEATS 

IN LOOK, TASTE AND NUTRITION. 

For meat analog and extender production, 

rely on the pioneer of the process for textured 

vegetable proteins by extrusion. Wenger began 

the worldwide initiative over 50 years ago, and 

continues to lead with ever expanding options 

today. 

High moisture meat analogs (HMMAs) produced on 

Wenger twin screw extruders mimic whole muscle 

meat, with similar characteristics for moisture, 

protein and fat contents, as well as a densely 

layered, somewhat fibrous structure. 

After extrusion, HMMAs may be cut, sliced or 

shredded – and then further processed or frozen. 

In addition to soy proteins or wheat gluten 

ingredients, alternative protein sources can be used 

for texture, mouthfeel and appearance objectives. 

Discover the latest in cutting edge extrusion 

processing and product development assistance. 

Email info@wenger.com now. 

Key No. 99332 

PHONE: 785.284.2133 | EMAIL: INFO@WENGER.COM | WENGER.COM 

USA | BELGIUM | TAIWAN | BRASIL | CHINA 

food Marketing & Technology • April 2021 27

Processing 

Cooking up a Storm with its Luxury 

Frozen Meals 

The premium and recently awarded ‘feel good’ brand COOK has expanded its kitchens and increased capacity 

of its luxury hand-prepared meals by 50%. 

COOK’s founding statement is to 

“cook using the same ingredients and 

techniques as you would at home, so 

everything looks and tastes homemade”, 

a philosophy that has enabled COOK 

to bring innovation to the UK frozen 

ready meal sector. Supplying the rapidly 

increasing consumer demand for quality 

ready to cook food, COOK have seen 

record annual revenues year on year. 

The ‘hands on’ approach within its 

production kitchens include chefs 

stirring dishes with large paddles, 

and manually ladling and garnishing 

each dish by hand, just home cooking 

on a much larger scale. 

An existing production kitchen at full 

capacity and a plan to double sales 

within 5 years led to COOK to acquire a 

new site in Sittingbourne, Kent, UK, to 

enable an increase in volume of its ready 

to cook meals. As part of the expansion 

project, the recently awarded ‘feel good’ 

brand invested in freezing technology 

that would improve efficiency and 

the quality of its best-selling gourmet 

recipes. 

Project details 

Following extensive product trials at 

their laboratory test facility in Suffolk, 

Starfrost designed and manufactured 

a bespoke Helix spiral freezer system, 

that would effectively freeze the 

ready to cook meals whilst locking 

in the freshness and quality of the 

ingredients. 

Quote 

“The spiral freezer has delivered a 50% 

increase in production capacity, improved 

product quality and created a better 

working environment within our production 

kitchens.” - Ben Walker of COOK. 

Since the installation of the Helix 

spiral freezer, COOK has reduced 

manual labor and improved 

production efficiency as well seeing 

a range of operational benefits, 

including increased factory space 

and significantly reduced processing 

times. 

The compact automated freezer 

designed for COOK has removed the 

need for large rack trolleys within the 

production kitchens, an operational 

requirement for blast freezers. The 

new freezer also features an energy 

efficient design that operates with 

CO 2 

refrigeration, a long term 

refrigeration solution that is not 

subject to phase out regulations. 

Samuel Welch, UK Sales 

Manager at Starfrost: 

“COOK are food specialists of 

hand prepared ready meals. We 

understood immediately that the 

company and its products are 

focused on quality. Partnering with 

a firm such as COOK is something 

we value at Starfrost and our key 

focus was to find a cooling solution 

that would seamlessly fit within the 

business and processing line. 

The next spiral freezer project for 

COOK, currently being manufactured, 

is a duplicate model of the recently 

installed Helix, designed to freeze 

3,600 meals per hour, and will 

deliver the same energy efficient and 

maximized capacity benefits.” fmt 


Processing 

Ben Walker, Head of Pioneer at 

COOK, discusses the project and the 

investment of freezing equipment in a 

Q&A below: 

Can you briefly outline the details of 

the freezing project? 

We wanted to upgrade from static 

blast freezing to a continuous freezing 

method within our ready to cook meal 

production. 

Why did COOK require a new 

freezing solution? 

Due to increased demand of our 

products and our business expansion 

plans, we needed to increase the 

volume of our frozen ready meal 

range and wanted to invest in the 

latest freezing technology within our 

production kitchens. 

Were there any key requirements 

for the project? 

Fundamental to the project was 

finding a freezing system and process 

that maintained the quality of our 

ingredients and meals. 

Can you describe your selection 

process and what criteria you were 

looking for in a supplier? 

Our chosen supplier of freezing 

equipment had to deliver a solution 

that matched our expectations and 

requirements for quality. We selected 

Starfrost to help us achieve this, we felt 

confident the team could provide us 

with a bespoke solution that would fit 

within our business. They understood 

the complexities of the project and 

most importantly our company focus 

on product quality. We were pleased to 

partner with Starfrost and are currently 

working on an additional project for 

another spiral freezer. 

Which freezing method was 

implemented and how has it met 

your project requirements? 

Working with our team and specification 

for our products, Starfrost designed and 

installed a Helix spiral freezer. It’s an 

automated freezing system which means 

our products are consistently frozen 

and at a reduced time in comparison to 

blast freezing. We’ve seen a significant 

boost in terms of output, we have 

now increased production capacity by 

50%. With the addition of the second 

spiral freezer this summer we plan a 

further 30% increase, bringing our total 

expected throughput up by 80%. 

Are there any additional benefits 

of the freezing system, if so what 

difference has that made to your 

production kitchen? 

The Helix spiral freezer gives us 

operational flexibility which matches 

our home style cooking processes at 

COOK. We’ve been able to reduce 

contact handling of the product and 

now have an end to end line solution. 

The combined benefits of the new 

freezing system deliver a higher quality 

end product that keep our production 

to more stringent timelines - which for 

any chef, is a must! 

fmt 

HYGIENIC DESIGN Rotary Valve Easy Clean Twice 

Key No. 99936 

Hygienic Design 

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Replaceable 

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elastomers 

ATEX Protection System 

EHEDG Type EL Class II 


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JAUDT Dosiertechnik 

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Raiffeisenstraße 3-5 

D-86167 Augsburg 

29 

e-mail: verkauf@jaudt.de 

www.jaudt.de

Processing 

Flow-wrapping machine from Schubert packs with ecological films 

A Sustainable Competitive Advantage for 

Food Manufacturers 

The shift towards increasingly individualized packaging and sustainable materials is especially noticeable 

in the food industry. Companies that want to face these market trends with confidence need a high degree 

of flexibility in their production. With a Flowpacker from Schubert, manufacturers in the food sector can 

position themselves strongly to meet these and future requirements. This is because the robot-assisted flowwrapping 

machine is so flexible that it can easily keep up with the new packaging trends. It is even possible 

to switch between conventional and recyclable films or trays on a single line. This is one of the reasons why 

a long-established manufacturer from France also packs its diverse range of biscuits and pastries with a new 

Flowpacker. 

Today, no food manufacturer can 

afford to ignore the market’s need 

for rapidly changing, individually 

tailored packaging solutions that 

also conserve resources. The latter 

is a special challenge in the case of 

packaging into flowpacks. There 

is a good reason why composite 

films have conquered the world 

thanks to their ease of processing 

and product-protecting properties. 

However, the shift towards materials 

that are more recyclable will become 

increasingly pronounced and is likely 

to be irreversible in the long term. 

The answer to these developments is 

flexibility. Companies that can change 

their packaging processes quickly 

and as needed gain a competitive 

edge in the marketplace, especially 

when it comes to environmentally 

conscious consumers and future 

trends. With the Flowpacker flowwrapping 

machine from Schubert, 

manufacturers of almost any product 

can capitalize on a packaging 

machine that combines effective 

packaging solutions with extremely 

Both plastic trays, and trays or boards made of cardboard can be processed in the bakery’s flow-wrapping machine. 

variable processes – thanks to its 

modular design and the use of highly 

developed robot technology. 

A seamless and highly flexible 

packaging process in a single line 

This is based on a machine concept 

that integrates the entire packaging 

process seamlessly, efficiently and in an 

exceptionally flexible manner into one 

TLM line. Firstly, in the Flowpacker, the 

products are fed to the flow-wrapping 

unit by pick & place robots which can 

be adapted to the customer’s desired 


Processing 

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256 colours 

Individually selectable: 

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Sensor switching 

Process malfunction 

Compact design 

15 cm 

Hygienic 

adapter system 

Key No. 99290 

Adjustment via 

smartphone 

www.vega.com/vegabar 


31

Processing 

output range and types of products. 

Secondly, the combination of state-ofthe-art 

sealing technologies and the 

unique flying cross-sealing unit makes 

it possible to gently and reliably process 

both conventional composite films in 

cold- and heat-sealing processes, as well 

as mono films and paper-based films. And 

thirdly, the formats in the Flowpacker 

can be changed very easily and quickly 

thanks to the format parts which are 

customized by Schubert. The integrated 

concept therefore offers companies in 

the food industry outstanding flexibility 

on several levels – namely unrestricted 

choice of product, packaging material 

and sealing technology. 

Long-established company 

benefits from the Flowpacker’s 

flexibility 

The medium-sized, heritage bakery 

from the French Alsace also counts on 

A long-established bakery in Alsace packs its 

biscuits and pastries with recyclable packaging 

materials using Schubert’s flow-wrapping 

machine. 

this flexibility. A wide range of fine 

pastries and biscuits are produced at 

the company’s facilities, including many 

products in organic quality, wafers and 

biscuits with and without chocolate, 

in layers or fully coated – and all in a 

wide variety of sizes. Packaging ranges 

from conventional to recyclable films, 

from plastic trays to cardboard trays 

and U-boards. The different sizes and 

consistencies of the products, as well as 

the quick change from one packaging 

Easily exchangeable format parts, such as the forming shoulder here, make format changes in the Flowpacker quick and easy. 


Processing 

to another, are no problem for the 

flow-wrapping machine. Easy-tochange 

format parts based on the 

plug & play principle facilitate easy 

handling for the machine operators. 

The individual gripping and suction 

tools on the pick & place robots can 

be changed in just a few steps. 

The two-part forming shoulders 

developed by Schubert can also 

be replaced quickly and without 

requiring subsequent adjustment. 

The packaging machine manufacturer 

uses forming shoulders 

in the Flowpacker without sharp 

edges for all film variants. This is 

because during packaging, the 

film is pulled over the forming 

shoulders at top speed and formed 

into a tube, which places great 

stress on the film and components. 

Paper-based films are especially 

susceptible to tearing or wrinkling, 

and also wear down the material of 

the forming shoulders permanently. 

Therefore, to achieve an ideal result, 

the format parts are individually 

adapted to a packaging material by 

hardened and coated surfaces. 

Thanks to specially developed forming shoulders, the Flowpacker from Schubert can process not only 

mono films but also paper-based films. 

Sealing times are accurate to 

the millisecond 

To keep all options open when 

choosing films, a flow-wrapping 

machine’s sealing system is also 

of particular importance for food 

manufacturers. This is because 

ecological films require exceptionally 

gentle sealing technologies due to 

the sensitive nature of the material. 

Thanks to its state-of-the-art sealing 

systems, the Flowpacker processes 

laminated films as well as the 

new sustainable variants – right 

through to paper-based films. The 

TLM machine can switch between 

different types of film without 

requiring much effort. This is due in 

part to the flying cross-sealing unit: 

It is the only cross-sealing system on 

the market which allows complete 

control over the entire duration of 

the sealing process. The sealing time 

can be selected to the millisecond 

and always remains constant due to 

the design of the sealing robot. The 

unit compensates for fluctuating 

food Marketing & Technology • April 

Going vegetarian? 

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Making the perfect mix for vegetarian and meat-replacement 

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quality, reduced power consumption, less use of additives, and 

better hygiene - perfect for high-speed plate or rotary forming. 

GEA Food Solutions Germany GmbH 

Tel +49 6461 801 217 

gea.com/contact 

33 

Key No. 99749 

Learn more

Processing 

With the state-of-the-art sealing technologies, both conventional and sustainable flow-wrapping films can be used in the same line. 

production speeds by moving with or 

against each flowpack on the conveyor 

as required. This means that mono films 

and paper-based films can be sealed 

perfectly and without damage in the 

packaging machine. 

Schubert also uses specially developed 

heating elements as its latest sealing 

system for longitudinal sealing. 

The five-by-five-millimeter ceramic 

elements can be controlled individually, 

heat up very quickly and, above 

all, cool down again in the shortest 

possible time. This means that the 

heat supply at the sealing seam can be 

precisely controlled at every point – in 

terms of temperature and time. Both 

are decisive for a consistently high 

and process-reliable sealing quality. 

Furthermore, every Flowpacker with 

heat-sealing technology and a flying 

cross-sealing unit can process both 

classic composite films and cold-seal 

films. This is because the sealing 

systems can be converted to coldsealing 

in a very short time. Older coldsealing 

films can also be processed well 

in the Flowpacker, as the glue joints in 

the longitudinal sealing unit can be 

easily preheated if necessary due to 

the available heating elements. 

High processing quality and 

excellent machine efficiency 

The exceptional flexibility in terms of 

product specifications and packaging 

material is one thing about the 

Schubert flow-wrapping machine, 

and the high processing quality and 

machine efficiency are another: 

Thanks to the robot-assisted processes, 

especially sensitive products such 

as Alsatian pastries, are packaged 

extremely gently. Long conveyor belts 

are superfluous. Instead, F4 robots 

place the biscuits flexibly and gently 

into the trays or directly into the 

chain. Breakage, damage and rejects 

are therefore minimized. Moreover, 

the Schubert image processing system 

inspects the goods in each Flowpacker 

to ensure that they are in perfect 

condition. Only products that meet 

the specified quality criteria are picked 

up and packed by the pick & place 

robots. At the bakery, an incidentlight 

scanner is used for this purpose. 

Depending on the requirements, 

however, 3D image processing can also 

be used in the flow-wrapping machine, 

and for example, record and assess the 

product height. 

With the flow-wrapping machine, 

manufacturers in the food industry 

in particular can benefit from highly 

flexible and reliable packaging processes: 

The wide range of options in the choice 

of packaging, the products to be 

packaged and the options on recyclable 

materials make the Flowpacker a futureproof 

packaging machine which can 

accommodate the fast-moving food 

industry in every respect. 

fmt 


Packaging 

PROCESS TECHNOLOGY&COMPONENTS 

© NETZSCH 

The cross-sectoral media platform 

for suppliers and users in two languages: 

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Exclusive information around the pump 

and compressor industry as well as 

systems and components 

Developments and trends 

First-hand future technology 

Targeted at international trade 

shows for 2021 

Special issue for the Russian market 

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food Marketing & Technology • April 2021 35 

Dr. Harnisch Verlags GmbH · Eschenstr. 25 · 90441 Nuremberg · Tel.: +49 (0) 911 - 2018 0 · info@harnisch.com · www.harnisch.com

Packaging 

Unconventional Labelling Solution for 

Pizzas and the Like 

Automatic labelling, high-quality appearance, and large area for information but still with an unobstructed 

view of the product - the full wrap labelling solution from MULTIVAC for pizzas and other flat food products 

fits the bill in every way. This solution is also significantly more cost-effective than traditional box packs. And 

it meets the increasing demands of the market as regards sustainability. 

Generally fresh or frozen pizzas, 

tortillas, pitta breads, quiches, tart 

bases and other flat products are 

packed in hinged trays, thermoformed 

packs, standard trays or simply in 

film. They are often packed using a 

pre-printed film with top and bottom 

labels or a cardboard sleeve. In the 

case of pizzas in particular, it is usual 

to pack them in a complete box. 

“Thinking outside the box” 

Full wrap labelling from MULTIVAC 

redefines the packaging and labelling 

of such products. The L 310 full wrap 

conveyor belt labeller is the ideal 

solution. This highly flexible model 

with its driven, extra-narrow transport 

conveyors makes the C labelling and D 

labelling of packs possible at speeds 

up to 120 packs per minute. The label 

width is up to a maximum of 500 mm. 

The labeller can also be equipped 

with an integrated printer, as well as 

a zero downtime function and label/ 

print monitoring for maximum output, 

efficiency and process reliability at 

even the highest throughput. 

High level of flexibility in terms 

of materials 

MULTIVAC offers a wide range of 

suitable label materials and adhesives, 

so that the packs can be labelled 

perfectly on the machine. In addition 

to PP and PET labels, the range also 

includes sustainable materials made 

of paper or from renewable sources. 

“By matching the label material to the 

packaging material, we can ensure 

that the constituent parts of the pack 

can be separated to meet the recycling 

requirements. Adhesives, which can 

be dissolved or washed off, enable 

the individual packaging components 

to be easily separated, so that they 

can then be directed to the particular 

recycling stream,” explains Michael 

Reffke, Product Manager at MULTIVAC 

Marking & Inspection. 

36 


Packaging 

Another benefit: Thanks to the use of 

particularly light label material, the concept 

also contributes to improving the CO 2 

balance, 

since the transport weight of the packs is 

reduced along the entire supply chain to the 

consumer. “If full wrap labels are used instead of 

cardboard sleeves, the weight of the banderole 

can be halved,” adds Michael Reffke. “A full 

wrap label instead of a standard-size pizza box 

saves over 65 g of pack weight. Also not to be 

ignored for the producer are the savings in 

terms of license charges for the collection and 

disposal or recycling of the retail packs.” 

New dimension of added value 

When compared with previous packaging 

concepts for pizzas and similar products, full 

wrap labelling does not just win in terms of 

output and sustainability. When it comes to 

appeal at the point of sale and the usable area 

for promotion, this new and unconventional 

concept for such products outscores top and 

bottom labelling by far. It is also in no way 

inferior to cardboard sleeves, as well as being 

significantly more efficient than a complete 

box. It also offers consumers the benefit, that 

they can have a close look at the product before 

buying it. 

Even where the lowest-cost material is used, 

this packaging concept is still highly impressive 

at the point of sale with its high-quality look 

and feel, since the print design, shape and type 

of material can be individually adapted to the 

product and brand. 

fmt 

Cutting-Edge 

Explosion Protection 

for the Food Industry 

For safety and protection of your production lines, 

Thorwesten Vent recommends the use of self re-clo sing, 

reusable explosion vents including anti-condensation 

trace heating with dryers, silo and fi lter applications. 

Do you want to increase product safety and plant 

availability? The certifi ed, patented explosion devices 

by Thorwesten Vent offer signifi cant advantages. 

THORWESTEN VENT GmbH 

Daimlerring 39, 59269 Beckum / Germany 

Phone: +49 2521 9391-0 

thorwesten.vent@thorwesten.com 

www.thorwesten.com 

Key No. 99677 

TWV_foodMarketingTechnology_02_2021_92x244_4c_Anz_Food_EN.indd 1 

food Marketing & Technology • April 2021 37 

TWV_foodMarketingTechnology_02_2021_92x244_4c_Anz_Food_EN.indd 1 15.02.21 14:12

Packaging 

Robotics: 25 Years of Reliable 

Palletizing Technology 

• Expert team develops smart and powerful robots 

• Systems optimally designed for many different tasks 

• KHS to introduce more standardized systems and virtual commissioning in the future 

KHS has been using robots successfully for 25 years, especially in the packaging and palletizing sections of 

its lines. These high-tech systems master tasks such as sorting, distribution, depalletizing, palletizing and 

stacking efficiently, flexibly and economically. In the future KHS wishes to make greater use of standardized 

systems and solutions in order to give its customers even faster lead times. Virtual commissioning also 

features heavily in the company’s plans for the future. 

The use of robots in the packaging 

and palletizing process steps is on the 

increase both in KHS’ single machine 

business and in its line projects. They 

are considered to be extremely reliable 

and low maintenance and provide 

secure production. They often perform 

several tasks at the same time and are 

valued as a future-proof investment. 

All that needs doing when setting up 

new functions is to replace the specific 

tool and modify the programming. 

Moreover, these intelligent machines 

produce at a low cost and are easy to 

operate. It is thus no surprise to learn 

that a growing number of bottlers in 

the beverage industry wish to make 

greater use of ‘colleague robot’. 

Many years of expertise 

KHS has been making successful use 

of robot technology on its production 

lines for 25 years now. The Dortmund 

systems supplier thus has a wealth of 

experience and expertise in this field 

of application. KHS masterminded 

its first projects in the palletizing 

section for customers in Gerolstein 

and Regensburg back in 1996. As 

the maximum weight that could be 

processed by the robots then in use was 

subject to certain restrictions, to start 

with they were not used to palletize 

full layers. Initially, typical applications 

included palletizing and depalletizing, 

packing and unpacking of returnable 

crates and keg palletizing. 

Since the beginning of the 2000s KHS 

has worked with the KUKA company 

based in Augsburg, Germany. Back 

then, the systems designed by the 

Packs of six non-returnable PET bottles prior to gentle but precise pickup by the clamping jaws: two grouping robots wait for the KHS commissioning 

engineer to give them the go-ahead. 

38 


Packaging 

international automation specialist 

were able to manage greater weights 

and used the same machine control 

system as that found in KHS equipment 

at that time. KHS also relies on 

technology manufactured by Japanese 

electronics and mechanical engineering 

company FANUC. “If someone’s already 

using a certain system, they don’t 

want to switch to another one. It’s 

almost a question of religion,” explains 

Christoph Wiesenack, palletizing product 

manager in Worms. 

As KHS has profound knowledge of 

both suppliers’ systems, it is secondary 

which components the expert team 

works with. “However good the robots 

are, they’re only brought to life when 

used properly,” he emphasizes. This 

is where KHS comes into play. “With 

our experience we know where and 

for which functions robots can be 

constructively used. Our concrete tasks 

are programming and the manufacture 

and configuration of tools and 

peripherals – from pallet conveyors 

through grouping and unloading 

tables to centering.” 

with the help of the motor’s power 

input and can thus grip and process 

products very gently – even sensitive 

packs such as our new paper pack,” 

Wiesenack states. 

Robot grouping at KHS is now largely 

standardized – both with respect 

to the table, its position and the 

programming. Variants have one to 

three robots and are available with 

one to four infeed lanes. “Our product 

center is experienced in this without us 

having to clarify much more here,” says 

Wiesenack. Accordingly, the number 

of grouping robots installed to date is 

high and currently amounts to about 

600, with 50 new ones added each year. 

Robots for more efficient loading and 

sorting 

Besides grouping, KHS currently also 

uses robots to palletize non-returnable 

packs and for other applications such 

as sorting and distribution. In kegging 

robots are used to unload and palletize 

kegs, for instance. Image processing 

systems enable further functions to 

be incorporated, such as keg turning 

on demand, fitting position detection 

At the KHS assembly shop in Worms a robot destined for keg processing is tested in operation before 

being shipped to the customer. 

KHS’ specialist field: robot 

grouping 

The Dortmund systems manufacturer 

has been using robots for grouping 

since 2004, a process in which packs are 

formed into layers. “This application 

is our bread and butter, so to speak,” 

smiles Wiesenack. Since the beginning 

the team in Worms has continued to 

develop its robotics, particularly the 

robot heads. “These are the tools at the 

end of the robot arms that come into 

direct contact with bottles, cans, packs, 

cartons or crates. Hardly anyone knows 

better than we do what has to be 

taken into account for products to be 

processed flawlessly.” This is why KHS 

engineers these product-contacting 

parts itself. Special functions integrated 

into the heads include crash protection, 

for instance, that prevents packs and 

machines from damage. There is also 

a compensation system that reduces 

wear and abrasion and an extremely 

simple clamping jaw changeover: the 

packs to be grouped are gripped by 

the servo-motorized jaws and pushed 

into the required position. “We set the 

clamping pressure to a defined value 

food Marketing & Technology • April 2021 39

Packaging 

and identification of the layer pattern 

on the pallet. The systems can also 

adjust the process steps to suit the 

current kegging situation. Automatic 

tool changeovers can be provided as an 

option for most robot applications and 

also retrofitted on demand. 

KHS’ expertise is particularly important 

when special functions are required 

that standard machines cannot 

perform, for example during loading 

or sorting. One example of this is in 

operation at RHODIUS Mineralquellen 

in Burgbrohl, where segregated bottles 

and crates are packed and palletized 

according to type on one machine. 

Here, the robot picks segregated 

crates of returnables comprising 

mainly foreign bottles from the line 

and places them on pallets for removal 

from the line. It also packs segregated 

empty bottles into empty crates and 

places these by type according to a set 

pattern back onto pallets that are then 

ready for discharge. With this, during 

production the system generates 

sorted empties for later processing 

more or less as a by-product. Flexible 

adaptation to the sorting rate means 

that functions can be assigned as 

required during the shift. 

One very different special application 

has been developed in the course 

of KHS’ cooperation with one of the 

world’s leading soft drinks producers. 

Over the past five years KHS installed 

several robot applications here for 

Stays cool even when working at full capacity: the KHS Innopal RK repacks segregated bottles into 

crates and places these onto pallets by type. 

Some customers prefer KUKA robots, others those made by FANUC – KHS has profound knowledge 

of the systems manufactured by both suppliers. 

the preparation of basic soft drinks 

components required at the company’s 

various production sites to mix its 

finished beverages. In this example, 

too, the team of experts from KHS 

developed a number of line-specific 

palletizing systems. The future viability 

of the systems has also proved itself 

here; following the move to a new 

facility, by decoupling certain functions 

and through rearrangement of the 

palletizing section a palletizing robot 

already supplied was assigned two 

more lines for palletizing, increasing 

the palletizing capacity in the process. 

The customer was extremely satisfied 

with the results. 

Fewer tasks, greater performance 

It goes without saying that even 

robots have their limits. “It’s like with 

people; they too can only perform 

a certain number of tasks within a 

given time,” Wiesenack comments. 

“The more functions we include on 

a machine, the lower the output in 

containers per hour.” If groupings 

process up to 144,000 cans per hour, 

for example, combined palletizing 

cells in the lower or medium capacity 

range are used. The output here 

depends on the number of functions 

to be carried out, such as picking 

and placing packs onto pallets, layer 

formation and processing pallet liners 

and empty pallets. The palletizing 

cell permits complete, fully automatic 

palletizing, including pallet and pallet 

liner handling, in a relatively small 

space of just 35 square meters. 

Future standardization 

In the future Wiesenack also wants to 

make loading stations as uniform as 

possible so as to offer standardized 

systems as for grouping that enable 

faster lead times and incur less 

cost. “Our palletizing cell for the 

low capacity range is a first step in 

this direction,” he tells us. “We can 

imagine that we’ll achieve higher 

outputs on standardized systems 

in the future because the focus is 

solely on palletizing; we can then 

get the most out of the robot here. 

40 


Events 

On customized systems, where the 

accent is on flexibility rather than just 

palletizing, we’re bound by the setup 

and specified tasks.” 

The specialists in Worms are 

also planning to extend virtual 

commissioning and rely more heavily 

on the digital twin in order to exploit 

further potential for increasing 

efficiency. Synergies are to be used 

for this purpose: robots are usually 

equipped with a digital environment 

by their manufacturers, meaning that 

KHS can also commission these virtually. 

All it then has to do is integrate its tools 

into the existing environment. fmt 

At KHS robots are used for manipulation during pack conveying, among other things, such as here in 

the distribution of wrap-around cartons. 

The Author 

Christoph Wiesenack has worked with robot 

applications for the beverage industry at 

KHS for seven years now. 

Q2 2021 

31 May-2 June 

Middle East Africa agrofood 

fairtrade Messe GmbH & Co. KG 

Kurfürsten Anlage 36, 

69115 Heidelberg, Germany 

Tel.: +49-6221/4565-0 

Fax: +49-6221/4565-25 

info@fairtrade-messe.de 

www.virtual-africa.com 

www.fairtrade-messe.de 

16-17 June 2021 

Hamburg, Germany 

Snackex 

European Snacks Association 

Rue des Deux Eglises, 26 

1000 Brussels, Belgium 

Tel: +32-2 538 20 39 

Email: esa@esasnacks.eu 

www.snackex.com 

18-21 July 

Chicago, IL, USA 

IFT Food Expo - first 

Institute of Food Technologists 

252 W. Van Buren, 

Suite 1000, Chicago, IL 60607 

Tel.: +1-312-782-8424 

Fax: +1-312-782-8348 

www.ift.org 

Virtual 

Let’s meet here 


Virtual 


Q3/4 2021 

28-30 September 

Nuremberg, Germany 

Fach Pack 

NürnbergMesse GmbH, 

Messezentrum, 

90471 Nuremberg 

Tel.: +49-911-8606-0 

Fax: +49-911-8606-8228 

www.fachpack.de 


5-7 October 

Palexpo, Le Grand-Saconnex, Switzerland 

Vitafoods Europe 

Informa Exhibitions, 

5 Howick Place, 


London SW1P 1WG, 

Great Britain 

Tel.: +44 20 337 73111 

www.vitafoods.eu.com 

30 November-2 December 

Frankfurt, Germany 

Food ingredients Europe 

Informa Markets 


PO Box 12740, de Entree 73, 

Toren A, 1100 AS Amsterdam Zuid Oost, 

The Netherlands 

Tel.: +31-20-409 9544 

Fax: +31-20-363 2616 

www.ubm.com 


41

Last Page 

Advertiser’s Index • April 2021 

Key No. Page Company Location 

99307 9 BENEO GmbH Mannheim, Germany 

99907 21 Daxner Bulk Solids Technology Wels, Austria 

100101 15 Emsland-Stärke GmbH Emlichheim, Germany 

99601 4 European Snack Association Brussels, Belgium 

97065 5 fairtrade GmbH & Co. KG Heidelberg, Germany 

99749 33 GEA Food Solutions Bakel, The Netherlands 

99896 22,23 Gerhard Schubert GmbH Crailsheim, Germany 

100167 Cover 2 Institute of Food Technologists Chicago, IL, USA 

99937 29 Jaudt Dosiertechnik Augsburg, Germany 

99510 25 Pavan S.p.A. Galliera Veneta, Italy 

99030 19 Schaaf Technologie GmbH Bad Camberg, Germany 

99677 37 Thorwesten Vent GmbH Beckum, Germany 

99412 Cover 4 URSCHEL Chesterton, IN, USA 

99290 31 VEGA Grieshaber KG Schiltach, Germany 

99333 27 WENGER Manufacturing, Inc. Sabetha, KS, USA 

Whilst every effort is made to ensure the accuracy of this information, we appreciate your comments and corrections if 

something should be not quite right. 

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Packaging Meat 

Events Updates 

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