food Marketing & Technology 2/2021

food Marketing & Technology is the international magazine for executives and specialists in the food industry. We report on new marketing strategies and trends, equipment and processing methods, innovative technologies, raw materials and additives, packaging systems and other important topics of selling and purchasing marketing. In addition to factory managers and food technologists we also address the product managers and product developers in the food industry.

food Marketing & Technology is the international magazine for executives and specialists in the food industry.

We report on new marketing strategies and trends, equipment and processing methods, innovative technologies, raw materials and additives, packaging systems and other important topics of selling and purchasing marketing. In addition to factory managers and food technologists we also address the product managers and product developers in the food industry.


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2/21<br />

Vol. 35 • 31377<br />

ISSN 0932-2744<br />

Cover: Combined Dairy<br />

and Juice Filling on the<br />

Same Bottling Line<br />

Clean Label in Bakery,<br />

Confectionery and Drinks<br />

A Food Processing<br />

Approach to Plant-Based<br />

Products<br />

New Labelling<br />

Solutions for Pizza

FIRST sight. FIRST impression. FIRST spark.<br />

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FIRST—where you will gain the insights to move your work,<br />

your business, and our global <strong>food</strong> system forward.<br />

July 19-21, <strong>2021</strong><br />

Register today!<br />

Special IFT member and Solution Exchange<br />

participant discounts available.<br />

Easily source product<br />

solutions and speak<br />

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science, and trends<br />

Visiting iftevent.org to learn more<br />

and join our FIRST updates email list.<br />

Key No. 100167

Editorial<br />

Feeling Refreshed in the Springtime<br />

We started putting this issue of Food<br />

<strong>Marketing</strong> & <strong>Technology</strong> together just<br />

before Easter in Germany, where there<br />

are several holidays, making for a long<br />

weekend. This year I found it more<br />

special than usual.<br />

We are all learning from 2020 and the<br />

challenges Covid-19 has thrown at us. I<br />

found the days of reflection helpful from<br />

a personal but also a <strong>food</strong> perspective.<br />

In many countries Easter Eggs are a sign<br />

of a new life and bring hope to all who<br />

give and receive them. The tradition in<br />

Germany of painting boiled eggs and<br />

then concealing a nest, brings fun to the<br />

hiders and the seekers. It made a new<br />

start more real for me this year.<br />

New life and energy are a particular<br />

focus of <strong>food</strong>, vegetables, vitamins and<br />

also warmth and good weather. This<br />

reflects on health and wellness, as well<br />

as other topics around sustainability and<br />

the climate. Springtime is often about<br />

preparing the ground, planting seeds,<br />

caring for the crops and harvesting<br />

<strong>food</strong> later in the year. I was conscious<br />

of this too as I walked around the local<br />

countryside.<br />

Moving swiftly on from chocolate eggs,<br />

this time of year is also about shedding<br />

some of the thick winter coat we may<br />

have put on and a wish to get into<br />

(better) shape for the summer months.<br />

Hope is a healthy emotion. It grows<br />

in each of us as we take steps to do<br />

something positive, whether this means<br />

fresh air and exercise or taking enough<br />

time for inner reflection. This in turn<br />

gives a new impetus and focus on life.<br />

Whatever we plant now, we will harvest<br />

later. I feel motivated and refreshed,<br />

so whatever working methods I select<br />

today, they will surely bear fruit<br />

tomorrow.<br />

Definitely a positive result of lockdown,<br />

slowdown, home office and little travel<br />

in the last months, has been a reduction<br />

Ian Healey<br />

Editor-in-Chief<br />

in pollution and an increase in time to<br />

reflect. Both are beneficial to me as a<br />

person and a member of society. I don’t<br />

think that any of us will be the same<br />

again.<br />

Look after your new self. In body, mind<br />

and spirit. I certainly intend to.<br />

Sincerely,<br />

If you like it – subscribe!<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />

3<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

XIX International Trade Fair<br />

for Savoury Snacks & Nuts<br />

16-17 June <strong>2021</strong><br />

Hamburg, Germany<br />

Contents<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> April <strong>2021</strong><br />

1 Editorial<br />

42 Impressum<br />

Move your<br />

business<br />

forward<br />

at the worldwide fair<br />

for savoury snacks<br />

The only trade fair 100% focused<br />

on savoury snacks and nuts<br />

+ Experience the hottest trends,<br />

tastes and technologies<br />

+ Develop your business with the<br />

industry’s leading suppliers<br />

+ Connect with the decisionmakers<br />

of the industry and<br />

find international trade<br />

partners, distributors<br />

+ Meet existing customers and<br />

new prospects from around<br />

the world<br />

+ Sell your products to an<br />

audience that is ready to buy<br />

The industry-defining fair for<br />

the savoury snacks sector<br />

Ingredients<br />

9 Chocolate Trends in <strong>2021</strong><br />

11 A New Versatile Clean Label Ingredient for Bakery,<br />

Confectionery and Drinks<br />

12 Making Clean-Label Convenience a Reality<br />

13 Aloe Vera: Valuable Functional Food with Great<br />

Nutritional Benefits that Reduce Disease Risk<br />

16 Steady Increase in Plant-Based Fish Alternative Choices<br />

17 Vegan Barbecue Products<br />

Processing<br />

6 RJ Corp in India Implements New Aseptic PET <strong>Technology</strong> to<br />

Combine Dairy and Juice Filling on the Same Bottling Line<br />

18 The Right Approach can Lead to Meaty Profits From Plant-Based<br />

Products<br />

20 Making Food Processing Quality More Reliable with Vision AI<br />

24 New Automated Grading System for Fresh Green Beans<br />

26 X-Ray Ensures High Quality for Sausage Exports<br />

28 Cooking up a Storm with its Luxury Frozen Meals<br />

30 A Sustainable Competitive Advantage for Food Manufacturers<br />

Packaging<br />

36 Unconventional Labelling Solution for Pizzas<br />

38 Robotics: 25 Years of Reliable Palletizing <strong>Technology</strong><br />

Departments<br />

41 Calendar of Events<br />

Key No. 99601<br />


Vol. 35 • 31377<br />

ISSN 0932-2744<br />

Cover: Combined Dairy<br />

and Juice Filling on the<br />

Same Bottling Line<br />

Clean Label in Bakery,<br />

Confectionery and Drinks<br />

A Food Processing<br />

Approach to Plant-Based<br />

Products<br />

2/21<br />

New Labelling<br />

Solutions for Pizza<br />

Cover: RJ Corp. / Varun Beverages<br />

Ltd. / Sidel<br />

RJ Corp has installed a new aseptic combi<br />

machine in its new plant in Punjab, India.<br />

This project aims to expand PET bottling<br />

capacity and provide production flexibility<br />

for the milk brand Cream Bell as well as<br />

the Tropicana juice range. The investment<br />

marks two major achievements for RJ<br />

Corp: the company’s first step into aseptic<br />

PET bottling and also its first experience<br />

with dry preform sterilization.<br />

Our Cover Story starts on page 6.<br />

Ingredients: Clean Label Ingredients<br />

For the <strong>food</strong> industry, the newly developed Emwaxy clean<br />

label starchderivative range offers a good start to create new<br />

innovative appealing products. The unique characteristics of<br />

Emwaxy serves todays trends e.g. easy handling, non-GMO,<br />

kosher & halal, gluten and allergen free as well as plant-based<br />

and clean label. Check out the full story on page 11<br />

Processing: Plant Based Production<br />

Meat replacement products are growing in popularity with<br />

consumers, whether for ethical, environmental or nutritional<br />

reasons, and retailers are quick to jump on the bandwagon by<br />

offering an increasing range of plantbased alternatives across<br />

all their stores. How can <strong>food</strong> processors best profit from this<br />

revolution in eating habits? The choice of equipment depends<br />

on different factors. Find out more on page 18<br />

Packaging: Unconventional Pizza Packing<br />

Automatic labelling, high-quality appearance, and large area<br />

for information but still with an unobstructed view of the<br />

product - the full wrap labelling solution for pizzas and other<br />

flat <strong>food</strong> products fits the bill in every way. This solution is also<br />

significantly more cost-effective than traditional box packs.<br />

And it meets the increasing demands of the market as regards<br />

sustainability!. See page 36<br />

Key No. 97065<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • February 2016

Cover Story<br />

RJ Corp in India Implements New<br />

Aseptic PET <strong>Technology</strong> to Combine<br />

Dairy and Juice Filling on the Same<br />

Bottling Line<br />

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

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

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

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

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

Since the early nineties, the privately<br />

owned Indian company RJ Corp<br />

has made itself a multinational<br />

powerhouse with thriving businesses<br />

in beverages, fast <strong>food</strong> restaurants,<br />

retail, ice cream, dairy products,<br />

healthcare and education. Through its<br />

operating company Varun Beverages<br />

Ltd., the group is one of the largest<br />

bottling partners for PepsiCo in the<br />

world, currently holding 36 plants on<br />

the Indian subcontinent and in Africa,<br />

and producing carbonated soft drinks,<br />

water and hot-fill juices as well as LDP.<br />

When production flexibility<br />

matters<br />

With Indian consumers looking more<br />

and more for nutritional beverages,<br />

the market keeps shifting towards<br />

so-called “better-for-you” drinks. To<br />

remain competitive in light of this<br />

trend, RJ Corp decided to diversify its<br />

portfolio and put more emphasis on its<br />

100% juices with pulp and ultra-high<br />

temperature (UHT) LDP, thus gaining<br />

more production flexibility to switch<br />

product categories easily. “Managing<br />

both juices and dairy products on<br />

the same PET packaging line flexibly<br />

was essential for us, and we could<br />

make it happen only by producing in<br />

aseptic,” says Mr. R.J.S. Bagga, Director<br />

Technical & Operations at RJ Corp.<br />

“High-level <strong>food</strong> safety and hygiene<br />

standards were must-have features<br />

to answer Pepsi’s demanding quality<br />

protocol as well as to pass internal and<br />

external validations.” To face these<br />

challenges, RJ Corp decided to go with<br />

Sidel’s Aseptic Combi Predis, including<br />

dry preform sterilization. They were<br />

convinced that it is a very safe and<br />

easy-to-operate solution while visiting<br />

a French copacker that has used and<br />

trusted this technology to handle both<br />

juices and milk for more than 10 years.<br />

This technology, approved by the FDA<br />

for low-acid production since 2017,<br />

allows the beverage producer to switch<br />

easily and safely between four UHT<br />

milk flavors (white UHT milk, coffee,<br />

chocolate and mango) and various<br />

kinds of juice recipes (i.e. orange delight<br />

& 100% orange juice with pulp, mixed<br />

fruit delight and 100% mixed fruit juice,<br />

guava, apple delight and 100% apple<br />

juice, and lychee delight) on the same<br />

line. This represents a major turning<br />

point for the companies in India, which<br />

were previously producing juices in PET<br />

bottles with the hot-fill process and<br />

milk in cartons.<br />

Up to 200 hours of continuous<br />

production<br />

The investment in Sidel’s Aseptic Combi<br />

Predis marks two major achievements<br />

for RJ Corp in India: not only is this the<br />

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

6<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Cover Story<br />

RJ Corp has expanded the packaging options of LDP products for PET bottles<br />

company’s first step into aseptic PET<br />

bottling, but also its first experience<br />

with dry preform sterilization.<br />

Employing the injection of hydrogen<br />

peroxide (H 2<br />

O 2<br />

) before the oven, Sidel’s<br />

patented Predis technology requires<br />

no water consumption and can reduce<br />

the use of chemicals significantly. This<br />

is a lighthouse project for PepsiCo Inc.<br />

worldwide regarding the processing<br />

and bottling of its high-acid products<br />

– the Tropicana juices. The Aseptic<br />

Combi Predis also features a similar dry<br />

sterilization for caps, Capdis, as it was<br />

very important to optimize the cleaning<br />

process and the handling of the caps<br />

themselves to avoid deformation and<br />

ensure tightness between the cap and<br />

the bottle.<br />

“RJ Corp chose Sidel because of our<br />

long-standing expertise in PET and<br />

aseptic technologies. Their new<br />

line allows for up to 200 hours of<br />

continuous production without any<br />

stoppages for cleaning, keeping the<br />

production running steadily without<br />

any compromise on product quality.<br />

Moreover, the equipment is easy to<br />

manage, and the operators find its<br />

functions intuitive and easily accessible,”<br />

says Rohit Sawhney, Sales Director for<br />

Sidel India.<br />

Optimized and efficient aseptic<br />

PET packaging line<br />

In addition to the Aseptic Combi Predis,<br />

the complete line at RJ Corp in Punjab<br />

is equipped with a very competitive<br />

and flexible End of Line. It features<br />

the seamless shrink-wrapper VersaFilm<br />

Access, offering the best combination<br />

of production quality, performance and<br />

price at medium speed. It also includes<br />

the automatic and safe PalKombi layerby-layer<br />

palletizer working with a steady<br />

low-level pallet infeed and allowing<br />

easy access and control. To understand<br />

its line operations and maximize<br />

Overall Equipment Effectiveness, RJ<br />

Corp also invested in Sidel’s Efficiency<br />

Improvement Tool (EIT®). This modular<br />

and scalable software provides the most<br />

significant performance indicators,<br />

reports and analyses, based on live and<br />

historical data, to better understand<br />

line flow, uncover sources of efficiency<br />

loss and achieve in-depth performance<br />

evaluation. It monitors quality, losses,<br />

consumption, accumulation and traceability,<br />

and interfaces with inspection<br />

devices and business systems.<br />

To make the most of this line, specific<br />

training was delivered to enable<br />

all RJ Corp technicians to get the<br />

right understanding of aseptic PET<br />

packaging, including the Hazard<br />

Analysis Critical Control Point system<br />

(HACCP), and thus avoid any risk of<br />

contamination or detect root causes<br />

efficiently in case it happens. Since its<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />


Cover Story<br />

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

implementation and validation, the<br />

line has been working successfully with<br />

an output up to 36,000 bottles per<br />

hour. Overall, it expands production<br />

capabilities in terms of volume as well<br />

as a higher number of SKUs.<br />

Ensuring packaging performance<br />

across the supply chain<br />

Traditionally, in India, milk is packaged<br />

in pouches, glass bottles or cartons. By<br />

choosing Sidel’s aseptic PET packaging<br />

technology, RJ Corp has widened<br />

packaging options for its LDP products.<br />

The brand-new PET bottle assures<br />

high <strong>food</strong> quality standards and<br />

outstanding customer experiences,<br />

along with PET being a cost-efficient<br />

and sustainable material. During the<br />

implementation of the packaging line,<br />

Sidel also shared its experience in PET<br />

packaging and helped design the new<br />

PET bottle, enabling the same shapes<br />

and caps to be used for both Cream<br />

Bell UHT milk and the Tropicana juices.<br />

The cap size for all bottle formats is<br />

33 mm, which is a common width for<br />

LDP, but quite uncommon for juices.<br />

As a result, Sidel’s packaging experts<br />

developed and designed an iconic<br />

bottle shape in three formats – 200 ml,<br />

500 ml and 1 L.<br />

prior to industrial production in order<br />

to ensure the bottles’ strength and<br />

performance across the supply chain.<br />

Sidel also designed specific preforms<br />

to reach optimized bottle weight in<br />

order to withstand the dry preform<br />

sterilization technology and avoid any<br />

thermal stresses on the bottle. Produced<br />

in white monolayer barrier PET, the<br />

new packaging ensures a shelf life up to<br />

nine months for UHT milk. Furthermore,<br />

all the transparent Tropicana juice<br />

bottles passed the demanding PepsiCo<br />

validation protocols.<br />

Taking into account the good experience<br />

and satisfaction with Sidel’s complete<br />

aseptic packaging solution installation<br />

in Punjab, Varun Beverages Ltd. again<br />

chose Sidel for the exact same scope of<br />

supply for a different plant, located in<br />

Central-Eastern India.<br />

fmt<br />

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

with top hygiene standard<br />

All of the bottle shapes and formats<br />

have been qualified internally. They<br />

were submitted to Finite Element<br />

Analysis (FEA) and on-site validations<br />

8<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Ingredients<br />

Chocolate Trends in <strong>2021</strong><br />

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

of the staple diet for many consumers across the globe with high proportions of people purchasing and<br />

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

how has this affected the chocolate market, and what are consumers seeking out?<br />

by Will Cowling<br />

Overall Consumption<br />

Across the globe consumers eat a wide<br />

variety of chocolate products within<br />

their diets. Irrespective to health<br />

concerns, chocolate still remains a<br />

staple part to consumer diets, reasons<br />

being consumers like to enjoy<br />

moments of indulgence on a regular<br />

basis for reward and escapism. FMCG<br />

Gurus insights show that 90% of global<br />

consumers who eat chocolate regularly<br />

purchase single-serve bars with half of<br />

these consumers stating they have one<br />

at least once a week.<br />

increased focus on seeking out betterfor-you<br />

offerings and moderating intake<br />

in categories inherently associated with<br />

indulgence.<br />

Functional Ingredients<br />

​FMCG Gurus research shows that 40% of<br />

global consumers state they are seeking<br />

out healthier chocolate options. This<br />

desire to seek out chocolate products<br />

which can offer a nutritional boost is<br />

driven by consumers adopting a healthier<br />

lifestyle in order to improve their health<br />

and well-being. One key area consumers<br />

are looking to address is their immune<br />

health, as COVID-19 has left consumers<br />

more conscious about this than ever<br />

before.<br />

Within the chocolate market there is<br />

a noticeable trend that is seeing niche<br />

categories such as plant-based and<br />

functional chocolate growing. This is<br />

due to the consumers looking to adopt<br />

a healthier lifestyle, actively seeking<br />

out better-for-options across a number<br />

of snacking and indulgent categories.<br />

COVID-19 Impact<br />

COVID-19 is also something which<br />

has impacted the chocolate industry<br />

over the past 12 months. FMCG Gurus<br />

insights from February <strong>2021</strong> show<br />

that 40% of global consumers have<br />

purchased more chocolate as a result<br />

of COVID-19. In times of uncertainty,<br />

consumers turn to product categories<br />

inherently associated with indulgence<br />

for moments of escapism. As a result<br />

of this consumers can tend to be less<br />

attentive to nutritional intake as they<br />

prioritize taste and comfort.<br />

However, due to this increase in<br />

chocolate snacking, consumers have<br />

become more conscious about their<br />

overall health. A key concern consumers<br />

face is weight management with five in<br />

ten global consumers becoming more<br />

conscious about their weight due to<br />

COVID-19. This will result in consumers<br />

becoming even more conscious about<br />

their chocolate consumption habits<br />

throughout <strong>2021</strong> and beyond, with an<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April<br />

Key No. 99307<br />

Rethinking eating patterns.<br />

Go low, go slow, go all day.<br />

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

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

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

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

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

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

Follow us on:<br />

www.beneo.com<br />


Ingredients<br />

When it comes to functional chocolate<br />

39% of global consumers state they<br />

find immune boosting claims appealing.<br />

This shows that there is a desire for this,<br />

something in which brands can look to<br />

adopt when targeting health-conscious<br />

consumers in <strong>2021</strong>. This creates an<br />

opportunity for brands to create<br />

differentiation within the market using<br />

functional ingredients.<br />

One ingredient consumers would like<br />

to see used in functional chocolate<br />

products is Omega 3. Over the last<br />

decade, consumers have become more<br />

and more aware of the benefits of<br />

Omega 3, associating the ingredient<br />

with a variety of health benefits. FMCG<br />

Gurus research shows that over 60%<br />

of consumers would find Omega 3<br />

claims within functional chocolate<br />

products appealing. Therefore, there<br />

is a key opportunity for brands to<br />

fortify products with this ingredient.<br />

However, when doing so, it is crucial<br />

that consumers feel fully satisfied that<br />

the ingredient will not impact on the<br />

sensory element of consumption. This<br />

article is based on FMCG Gurus: The<br />

Future of Chocolate in <strong>2021</strong> – Global<br />

Report, and FMCG Gurus: COVID-19<br />

Survey series (4 waves across 18<br />

countries in April 2020, May ’20, July<br />

‘20, February <strong>2021</strong>).<br />

fmt<br />

The Author<br />

Will Cowling, is <strong>Marketing</strong> Manager at FMCG<br />

Gurus, based in Enfield, UK<br />

10 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Ingredients<br />

A New Versatile Clean Label Ingredient<br />

for Bakery, Confectionery and Drinks<br />

Emsland Group presents their latest<br />

waxy potato development: Emwaxy ®<br />

Spray 200.<br />

The Emwaxy ® Spray 200 fits perfectly<br />

with the rapid growing demand for<br />

clean label alternative ingredients for<br />

the <strong>food</strong> industry. Emwaxy ® Spray 200<br />

is a clean label low DE starch derivative.<br />

Emwaxy ® .<br />

With the introduction of Emwaxy ® ,<br />

Emsland Group introduces new<br />

starch solutions for the <strong>food</strong> industry.<br />

Emwaxy ® is produced from special<br />

potatoes, containing more than 99%<br />

amylopectin and is being cultivated<br />

through traditional, non-GMO<br />

breeding techniques.<br />

Based on high amylopectin potato<br />

starch, Emwaxy ® Spray 200 has unique<br />

properties. Emwaxy ® Spray 200 has<br />

excellent solubility and is not prone<br />

to retrogradation. Therefore it can be<br />

applied in high concentrations whilst<br />

staying stable. The high cohesiveness<br />

at high concentrations enables to<br />

apply Emwaxy ® Spray 200 solution as<br />

<strong>food</strong> glue in many <strong>food</strong> applications.<br />

The product has good film forming<br />

characteristics and therefore it can<br />

be successfully applied as egg wash<br />

replacer on baked goods. Body and<br />

mouthfeel enhancement or partial<br />

sugar replacement are further examples<br />

of the possibilities, which Emwaxy ®<br />

Spray 200 can offer.<br />

Characteristics of Emwaxy ® Spray<br />

200<br />

• Easy to dissolve<br />

• Clean label<br />

• Stable in solution in high dosage<br />

• Excellent film forming with high<br />

transparency and gloss<br />

• Potato starch based – fits in the<br />

‘plant-based’ trend<br />

• Forms smooth solutions with good<br />

body and mouthfeel<br />

For the <strong>food</strong> industry, the newly<br />

developed Emwaxy ® range offers a<br />

good start to create new innovative<br />

appealing products. The unique<br />

characteristics of Emwaxy ® serves<br />

todays trends e.g. easy handling,<br />

non-GMO, kosher & halal, gluten and<br />

allergen free as well as plant-based and<br />

clean label.<br />

Potential applications and<br />

advantages<br />

Application<br />

Bakery glaze<br />

Cake<br />

Cereal bars<br />

Instant<br />

drinks<br />

(coffee, tea,<br />

sport<br />

Advantage<br />

Cost effective vegan<br />

alternative for egg<br />

wash<br />

Sugar reduction opportunities<br />

up to 30 %<br />

Effective <strong>food</strong> glue<br />

that can replace sugar<br />

syrups<br />

Prevents lumping and<br />

provides excellent<br />

body and mouthfee<br />

Chewable confectionery Alternative<br />

for gum Arabic and gelatin<br />

Emsland Group experts can assist you<br />

selecting the right recipe and product<br />

for your application.<br />

fmt<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />


Ingredients<br />

Making Clean-Label Convenience<br />

a Reality<br />

With the <strong>food</strong> industry under increasing<br />

pressure to create innovative new or<br />

improved products, without the use<br />

of artificial additives, the challenge is<br />

on for processors to develop products<br />

which entice consumers yet remain<br />

affordable for all parties. Some of<br />

the greatest consumer demand for<br />

clean-label is now being felt by the<br />

convenience <strong>food</strong>s market*, presenting<br />

technical challenges to the industry, but<br />

also a huge opportunity for growth.<br />

Clean-label ingredients specialist<br />

KRÖNER-STÄRKE is offering solutions<br />

to this dilemma by developing its range<br />

of agglomerated ingredients, the<br />

use of which can provide answers to<br />

many of today’s product development<br />

challenges.<br />

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

wider range of organic products continues to increase”.<br />

Currently used primarily in powdered<br />

<strong>food</strong> and beverage products such as<br />

soup mixes and instant hot chocolate,<br />

agglomeration involves enlarging the<br />

particles within a substance by joining<br />

together smaller particles to form a<br />

granulate or ‘blueberry’ structure.<br />

Using agglomerated ingredients can<br />

help <strong>food</strong> producers develop products<br />

which have improved flowability,<br />

easier lump-free stirring, and improved<br />

dispersibility as well as a significant<br />

reduction in dust during processing.<br />

This of course reduces wastage and<br />

improves plant safety.<br />

may be carried out using ‘wet’ methods<br />

where a binder is used or ‘dry’ methods<br />

where no binder is needed, but in<br />

either case no artificial additives are<br />

used. Additionally, they are also ideal<br />

for use in products developed for those<br />

suffering from dysphagia.<br />

Where keeping production costs to<br />

a minimum is a key concern, using<br />

ingredients in the form of flakes<br />

presents a cost-effective solution, and<br />

indeed many of KRÖNER-STÄRKE’s<br />

products are also available in flake<br />

form.<br />

Moving beyond traditional uses for<br />

agglomerated ingredients, KRÖNER-<br />

STÄRKE is developing its range to<br />

cover a wider variety of applications.<br />

Indeed, the possibilities are endless,<br />

and the company is currently<br />

producing agglomerated wheat<br />

proteins, pregelatinized starches and<br />

pregelatinized flours based on a several<br />

different raw materials. These are being<br />

used to produce a diversity of products<br />

including a glaze used for pies and<br />

baked goods as well as a seed adhesive<br />

used to adhere seeds to the top of bread.<br />

All of the products in KRÖNER-STÄRKE’s<br />

range are available in an organic format,<br />

and depending on the raw material<br />

used, gluten free versions are also<br />

available. The agglomeration process<br />

Commenting on the new range,<br />

Commercial Manager Henrik de Vries<br />

said: “As more and more people turn<br />

towards a clean-label lifestyle, the<br />

demand for a wider range of organic<br />

products continues to increase. The<br />

development of our agglomerated<br />

ingredients is providing <strong>food</strong><br />

manufacturers with the opportunity of<br />

producing products which are appealing<br />

and convenient to consumers without<br />

the use of artificial additives.”<br />

KRÖNER-STÄRKE develops bespoke<br />

solutions to suit individual needs across<br />

a wide range of <strong>food</strong>s including baked<br />

goods, soups and convenience products,<br />

battered or dietetic products, and has<br />

a reputation for technical excellence in<br />

new product development.<br />

fmt<br />

12 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Ingredients<br />

Aloe Vera: Valuable Functional Food with<br />

Great Nutritional Benefits that Reduce<br />

Disease Risk<br />

by Rico R. Magda<br />

The processing of Aloe extracts has<br />

been one of the largest botanical<br />

ventures in the world today. As a<br />

functional <strong>food</strong> ingredient, Aloe Vera<br />

has entered a new level in <strong>food</strong> industry<br />

on a larger commercial scale. The same<br />

bold invasion can also be seen in the<br />

pharmaceutical sectors, which are always<br />

in need of voluminous Aloe extracts for<br />

newer products. The plant has more<br />

than 75 active components that are<br />

richly fortified with vitamins, minerals,<br />

polysaccharides and many more.<br />

Medicinally, Aloe has health benefits<br />

like antitumor, antiobesity, treating<br />

ulcer, and antiseptic properties, among<br />

others. Aloe acts as fat replacer in baked<br />

goods and also acts as stabilizer to fruit<br />

juices and other consumer products. Aloe,<br />

whether in form of gel, juice, powder,<br />

and concentrate, can be added to <strong>food</strong><br />

products to increase their functionality.<br />

No wonder, Aloe products have now<br />

become a multi-billion industry.<br />

The Plant<br />

Aloe has a soft structure and grows<br />

domestic or wild in the tropical areas<br />

of the world. Its main benefits include<br />

<strong>food</strong>, cosmetics, and medicinal uses.<br />

The plant was first introduced as<br />

ornamental plant for both indoor and<br />

outdoor either as a potted or raisedbed<br />

plant. Many consumer products<br />

including pharmaceuticals, medicines,<br />

<strong>food</strong> preparations, and beverages now<br />

contain a certain amount of Aloe extracts<br />

that fortify the products’ usefulness.<br />

In 1820, Aloe vera was listed in the US<br />

pharmacopoeia as purgative and skin<br />

protectant. Later in 1930, Aloe extract<br />

was used for treating radiotherapy burns<br />

to the skin and mucuos membrane.<br />

The plant has a very short stem. It<br />

grows from 60 to 100cm tall with<br />

thick, spiny, fleshed green leaves.<br />

Yellow flowers appear on spike that<br />

reaches 90cm tall. Mycorrhiza in<br />

soil aids the plant to have better<br />

nutrition. Aloes are known with<br />

various common names in different<br />

countries where they thrive. Some<br />

common names of the plant include<br />

“True Aloe,” “Indian Aloe,” “Chinese<br />

Aloe,” “First-Aid Plant,” “Burn Aloe”,<br />

and more. In 1768, Carl Linnaeus<br />

first gave the plant the description<br />

of Aloe perfoliata variety vera. DNA<br />

comparison study suggests that the<br />

commercial Aloe variety is a relative<br />

of Aloe perryi, an endemic species<br />

found in Yemen.<br />

Aloe is believed to have originated from<br />

the Arab regions and later scattered<br />

around the world due to human<br />

cultivation. It becomes a natural plant<br />

in Africa, and in some islands like<br />

Canary and Madiera. In Europe, Aloe is<br />

found growing wild naturally in Spain,<br />

especially in Murcia. The cultivation of<br />

Aloe reached China in the 17th century<br />

as well as in some other Asian countries.<br />

Similarly, this succulent plant also spread<br />

in some tropical areas of Australia, South<br />

America, south eastern states of the<br />

United States and the Caribbean.<br />

The plant can grow both indoor and<br />

outdoor. It tolerates little water from the<br />

soil where there’s low rainfall but growth<br />

is checked in places with heavy frost<br />

and snow. It’s important to have good<br />

drainage as water-soaked condition<br />

leads to leaf shrivel or decay. Too much<br />

sun, on the other hand, can literally burn<br />

the plant. Potted plants produce a lot<br />

of “pups” or off-shoots emerging from<br />

the base of the mother plant. Crowded<br />

plants need re-potting to give enough<br />

space and prevent the building up of<br />

pests.<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />


Ingredients<br />

Commercial Cultivation of Aloe<br />

Species<br />

Large-scale cultivation is now trending<br />

up in various parts of the world.<br />

Some of these countries venturing in<br />

commercial Aloe farming (soil and soilless)<br />

include Australia, Kenya, Tanzania,<br />

South Africa, India, Spain, Mexico, Cuba,<br />

the Philippines, Bangladesh, Jamaica,<br />

the Dominican Republic, USA, among<br />

others.<br />

Researchers have been working hard<br />

building proofs on the efficacy and<br />

safety of Aloe extracts used as cosmetics<br />

or medicines. Whatever the outcome<br />

of some researches, marketers of<br />

extracts continue to claim the soothing,<br />

moisturizing, and healing power of<br />

Aloe extracts.<br />

There has been an increasing commercial<br />

use of Aloe gel as ingredient of popular<br />

<strong>food</strong>s like yoghurts, desserts, and<br />

beverages. Manufacturers are however<br />

advised on using Aloe gel at higher doses<br />

as it can impart toxicity to consumers.<br />

Benefits from Aloe<br />

The increase of incorporating Aloe<br />

extracts to hygienic products, however,<br />

cannot be ignored. The extract is used<br />

as an anti-irritant and as moisturizer.<br />

Some beauty products such as make-up,<br />

soaps, sunscreens, shampoos, shaving<br />

creams, among others contain extracts to<br />

improve the products’ quality.<br />

Medically, Aloe has some effects. It<br />

acts as an astringent by binding,<br />

constructing, and sealing some injured<br />

or cut areas. It effects as a laxative<br />

due to anthraquinones and barbaloin<br />

substances that stimulate bowel<br />

movement. Application of the extracts<br />

to skin help to heal minor burns, insect<br />

bites, and sunburn. Applying Aloe to<br />

skin regenerates cells, softens and<br />

moisturizes it besides protecting skin<br />

against pathogenic fungi, bacteria, and<br />

viruses. For minor cuts, and burns, Aloe<br />

heals best when the affected skin is<br />

not covered with bandages. Aloe heals<br />

faster in the open.<br />

Aloe leaf has latex that has laxative<br />

effects. This latex helps to treat colitis,<br />

constipation, hemorrhoids, rectal itching<br />

and other colon issues. There was an<br />

advisory from FDA to remove latex<br />

from their products due to few studies<br />

conducted on its safety.<br />

When Aloe juice is dried, a very adhesive<br />

tincture of benzoin is produced used<br />

in bandage. The tincture allows the<br />

bandage to adhere snugly to skin.<br />

Similarly, a mannose carbohydrate called<br />

acemannan is also used as an adhesive<br />

for dentures.<br />

Other benefits of Aloe need more<br />

research. Many users of Aloe claim<br />

that it can cure calluses, varicose veins,<br />

corns, and arthritis. It can even treat<br />

skin cancer. Allergy caused by Aloe is<br />

rare. When applying Aloe to skin, apply<br />

first a small amount under your arm<br />

or behind your ear. If rashes or some<br />

stings appear, stop the application.<br />

When you’re experiencing nausea,<br />

vomiting or painful stomach, stop using<br />

it as the laxative property of Aloe could<br />

make the symptoms worse. Moreover,<br />

Aloe is not advisable for people having<br />

chronic intestinal issues, which include<br />

ulcerative colitis, Crohn’s disease and<br />

irritable bowel movement.<br />

Aloe’s Active Nutritional and<br />

Medicinal Composition<br />

The stuff has antioxidant vitamins<br />

namely: A, C, and E with vitamin<br />

B12, folic acid, and chloline. It has<br />

8 enzymes including bradykinase,<br />

alkaline phosphatase, amylase,<br />

carboxypeptadase, cellulase, catalase,<br />

lipase, peroxidase, and aliiase.<br />

Twelve anthraquinones, which act as<br />

laxative are present including alloin and<br />

emodim, which serve as antibacterials,<br />

antiviruses, and as analgesics. Aloe is also<br />

fortified with minerals including zinc,<br />

potassium, calcium, copper, selenium,<br />

chromium, manganese, and sodium.<br />

Four fatty acids are also present in<br />

Aloe extracts including lupeol, betasisosterol,<br />

cholesterol and campesterol.<br />

These fatty acids are known to act<br />

as anti-imflammatory. Another antiimflammatory<br />

substances are present in<br />

Aloe like auxins and gibberellins, which<br />

help to heal wounds faster. Some sugars<br />

like monosaccharides (glucose, fructose)<br />

and polysaccharides are also found in the<br />

extracts.<br />

The popularity of Aloe extracts is due to<br />

some proven benefits they can give. One<br />

of the benefits is in healing skin issues<br />

including treating psoriasis, surgical<br />

wounds, and burn injuries. The first study<br />

about the extracts was conducted on skin<br />

conditions and healing management.<br />

Aloe’s gel can guard against radiation<br />

and thermal burns on the skin and heal<br />

the affected areas faster. For dry hair<br />

or itchy scalp, Aloe serves as a natural<br />

treatment while nourishing the hair to<br />

become strong and healthy. It also helps<br />

to regenerate skin tissue around the hair<br />

follicles while the gel’s enzymes rid off<br />

dead cells.<br />

Aloe extracts help the digestive system<br />

by normalizing the acid/alkaline balance,<br />

reduce yeast formation, and regularize<br />

bowel processing. A study reported<br />

in the Journal of Research in Medical<br />

Sciences suggests that Aloe extracts can<br />

be beneficial to people with IBS (Irritable<br />

Bowel Syndrome). When 30ml of Aloe<br />

juice was given twice a day, the level<br />

14 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Ingredients<br />

of discomfort with IBS was decreased.<br />

More data, however, are needed to<br />

recommend it as an effective cure.<br />

Aloe extracts help the immune system.<br />

This is possible with bradykinase, an<br />

enzyme present in the extracts. It breaks<br />

down the protein into amino acids<br />

and the enzyme fuels the body cells to<br />

function properly. The zinc component<br />

of Aloe, on the other hand, helps in<br />

preventing zinc deficiency. This capacity<br />

of Aloe in building up the immune<br />

system without causing allergic effects is<br />

also tapped for dentistry uses.<br />

The plant is rich in antioxidants that<br />

reduces imflammation. These are vitamins<br />

and minerals that ward off free-radical<br />

damage. Vitamin A maintains healthy<br />

vision, neurological functions and keeps<br />

the skin healthy. Vitamin C protects the<br />

body from eye issues, skin wrinkling and<br />

cardiovascular diseases. Vitamin E, aside<br />

from fighting imflammation also slows<br />

down cell aging.<br />

Studies using animals and humans have<br />

suggested that Aloe extracts can alleviate<br />

chronic hyperglycemia and worrying<br />

lipid profile on people with diabetes.<br />

In two clinical trials, one tablespoon<br />

of gel or a placebo was given to some<br />

women without drug therapy resulting<br />

to decreased level of blood glucose and<br />

serum triglyceride. With the next trial,<br />

gel or placebo in combination with a<br />

commonly prescribed anti-diabetes drug<br />

glibenclamide was given. The same<br />

reduction in blood glucose and serum<br />

triglyceride was produced.<br />

More Studies Needed in<br />

Establishing Benefits<br />

Who has learned that an Aloe plant<br />

has so much goodness stored in its<br />

spiny leaves? Though a lot of goodness<br />

is stored in the leaves, a world of<br />

caution has been addressed to unwary<br />

consumers not to use this yellow latex<br />

coming from the leaves due to laxative<br />

effects. Latex has bitter taste and is<br />

removed during processing with a<br />

stripping agent that impairs the active<br />

ingredients in commercial Aloe juice.<br />

Gel and juice are almost similar products<br />

that differ only in the total mucilage<br />

they have. Gel has more mucilage<br />

than juice. This slimy substance has<br />

the polysacharrides that make Aloe so<br />

healthful. For quality Aloe products,<br />

the best come from harvested leaves<br />

cut and processed within 48 hours.<br />

In sourcing for Aloe products whether<br />

they are gel, latex, juice or extracts,<br />

be sure that your choice comes from<br />

a reputable supplier. This is to ensure<br />

that extraction and processing have not<br />

lessen Aloe’s therapeutic properties.<br />

Buyers should consider that. As Aloe<br />

products are crushed, ground, pressed,<br />

filtered, and stabilized, the active<br />

components in the extracts should<br />

have high amount of active ingredients.<br />

The International Aloe Science Council<br />

has made a certification program in<br />

evaluating the quality and quantity<br />

in commercial products. Alternatively,<br />

you can grow your Aloe plant indoor in<br />

pots or greenhouse or outdoor to have<br />

the amazing and inexpensive benefits<br />

of the plant right on your own reach.<br />

Fresh is, indeed, always the best. fmt<br />

The Author<br />

Rico R.Magda is a plant biologist and lecturer<br />

at the University of the Philippines,<br />

Los Banos, and regular contributor to Food<br />

<strong>Marketing</strong> & <strong>Technology</strong>.<br />

When there‘s nothing left...<br />

fmt<br />

...there was EMWAXY inside!<br />

100<br />

Get in touch<br />

Contact emwaxy@emsland-group.de<br />

% EMWAXY<br />

100 % Taste<br />

®<br />

Key No. 100101<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />


Ingredients<br />

Steady Increase in Plant-Based Fish<br />

Alternative Choices<br />

Plant-based alternatives to fish and<br />

sea<strong>food</strong> are the future, not just in terms<br />

of nutrition, but also ecologically. One<br />

reason is that they appeal to younger<br />

consumers like Generation Z. According<br />

to Innova Market Insights, at 32 percent<br />

worldwide this is the largest population<br />

segment. It accordingly will have a<br />

major influence on consumer behavior<br />

in the coming decades. For this target<br />

group, health and well-being are just<br />

as important as environmental and<br />

climate protection, animal welfare and<br />

social factors. Plant-based alternatives<br />

to fish and sea<strong>food</strong> thus not only<br />

offer new indulgence experiences<br />

for flexitarians, they also meet the<br />

demands of the rising generation.<br />

Environmental organizations already<br />

advise cutting back on consumption<br />

of ocean fish and sea<strong>food</strong>, due to<br />

overfishing. Microbiology is another<br />

factor. Due to the thermal processes<br />

in their manufacture, plant-based<br />

alternatives to smoked fish and sushi<br />

are microbiologically much safer than<br />

traditional fish products.<br />

For this growth area, Planteneers has<br />

already developed various product<br />

ideas with which manufacturers can<br />

make alternatives to breaded fish, fish<br />

sticks, filets and more. For example, a<br />

plant-based alternative to salmon filet<br />

is in the pipeline. These plant-based<br />

solutions are based on a diverse range<br />

of protein texturates that give products<br />

a very fish-like, tender bite. Florian<br />

Bark, Product Manager Planteneers,<br />

explains: “The right choice of texturate<br />

is indispensable in order to get as close<br />

as possible to the animal product. Plant<br />

protein concentrates are also important<br />

in order to match the protein content of<br />

the final product to that of the original.<br />

In addition, we have a large portfolio<br />

of algae-based hydrocolloids that are<br />

perfect for making alternatives to fish<br />

and sea<strong>food</strong>.”<br />

Among the company’s new products<br />

are fiildTex for alternatives to tuna<br />

pieces. With it, customers can use<br />

standard meat and fish production<br />

machinery to make alternative tuna<br />

that looks and tastes like canned<br />

tunafish, and can be used in many<br />

ways. Another innovation is fiildFish<br />

for alternatives to sushi-style raw fish<br />

and smoked products like smoked<br />

salmon. These plant-based products<br />

impress with typical fish structure<br />

and texture. But what makes them<br />

special is the flexible recipe – different<br />

fish alternatives can be created by<br />

adjusting the specific flavor and color.<br />

The end products can be readily sliced<br />

and are also freeze-thaw stable. This<br />

makes them very well suited for<br />

convenience products.<br />

fmt<br />

Photos: Planteneers<br />

16 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Ingredients<br />

Vegan Barbecue Products<br />

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

promise flavorsome, flame-grilled enjoyment<br />

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

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

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

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

Meat-free products for vegans,<br />

vegetarians and flexitarians is one of<br />

the fastest-growing segments in the<br />

<strong>food</strong> industry. According to a recent<br />

report by the Smart Protein Project,<br />

sales of plant-based alternative products<br />

in Germany increased by 97 per cent<br />

between 2018 and 2020. With its savory<br />

seasonings and functional concepts for<br />

meat alternatives, RAPS proves that<br />

ditching meat does not mean sacrificing<br />

enjoyment. In addition to products<br />

based on soy or wheat, new concepts<br />

with pea protein have also been created.<br />

With the help of numerous recipe ideas,<br />

<strong>food</strong> producers can address a large<br />

target group and create products that<br />

convince both with typical bite and<br />

pleasant mouthfeel, as well as best taste<br />

thanks to RAPS’ spice blends.<br />

The diverse application possibilities<br />

include meat-free versions of barbecue<br />

classics such as burger patties, coarse<br />

and fine grilled sausages, meatballs<br />

(also with creamy fillings such as<br />

jalapeno cheese sauce), barbecue<br />

skewers and cevapcici. When it comes<br />

to sensory characteristics, the products<br />

are very similar to the originals, thus<br />

appealing to “die-hard” barbecue fans.<br />

Product-specific firmness and texture<br />

can be adjusted in the production<br />

process, and all recipes can be easily<br />

implemented with standard meat<br />

processing equipment. Thanks to excellent<br />

freezing and thawing stability,<br />

frozen products are possible too.<br />

As consumer demands become<br />

more individual and diverse, such<br />

requirements must be reflected on<br />

supermarket shelves. “With new vegan<br />

recipes, we want to make barbecue<br />

enjoyment possible for everyone thanks<br />

to the versatility of pea protein,” says<br />

Josefine Schneider, product manager at<br />

RAPS. “In addition, we pay attention to<br />

short ingredient lists and a nutritionally<br />

valuable composition. Of course, this<br />

is also reflected in the labelling, which<br />

means we have been able to develop<br />

many recipes with Nutri Score A or B.”<br />

Photos: RAPS<br />

In addition to the grill range, RAPS offers<br />

other vegan and vegetarian product<br />

concepts – for example, for wieners,<br />

cold cuts, schnitzel, vegetable and fresh<br />

spreads, fish fingers, meat and tuna<br />

salads. Thanks to the manufacturer’s<br />

comprehensive portfolio, the products<br />

can be further individualized and refined<br />

with specific seasonings, marinades or<br />

dipping sauces.<br />

fmt<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />


Processing<br />

The Right Approach Can Lead to Meaty<br />

Profits From Plant-Based Products<br />

Nils Beyer, Food Application Technologist at GEA Food Solutions discusses the growing trend towards plantbased<br />

eating habits and how the <strong>food</strong> processing sector can take advantage of technology to meet the<br />

demand for a wider variety of products.<br />

Meat replacement products are<br />

growing in popularity with consumers,<br />

whether for ethical, environmental or<br />

nutritional reasons, and retailers are<br />

quick to jump on the bandwagon by<br />

offering an increasing range of plantbased<br />

alternatives across all their stores.<br />

But is this trend just a flash in the pan<br />

involving a minority of consumers, or<br />

is it something bigger than that and, if<br />

so, how can <strong>food</strong> processors best profit<br />

from this revolution in eating habits?<br />

Extensive consumer research carried<br />

out in four European countries last<br />

year found that more than one third of<br />

those asked were either reducing their<br />

meat intake or planning to reduce<br />

their meat consumption.* Rather<br />

than only counting those who already<br />

classify themselves as vegetarian or<br />

vegan, if we look at the numbers of<br />

people reducing their meat intake, the<br />

move towards this lifestyle is much<br />

more significant and widespread than<br />

was previously thought. The challenge<br />

for manufacturers is to create the<br />

perfect protein substitute for meat in<br />

taste and texture, which was also high<br />

on the wanted list according to the<br />

research.<br />

Taste is becoming everything in the eyes<br />

of the discerning consumer so when<br />

considering a <strong>food</strong> concept, it’s important<br />

that equipment and ingredients work<br />

well together. Consistency of products<br />

is also vital as the upstream process of<br />

preparing the mix for meat replacement<br />

products has the biggest impact upon<br />

the success of operations further down<br />

the line to provide wholesome, delicious<br />

and exciting <strong>food</strong>.<br />

A strong need to expand meat<br />

alternative choices beyond the typical<br />

veggie burgers we’re all familiar<br />

with has also been identified. Food<br />

processors are having to demonstrate<br />

more and more culinary creativity and,<br />

while there is no silver bullet, the latest<br />

multi-faceted high-speed equipment<br />

can provide this competitive edge with<br />

the flexibility and power to design<br />

exciting vegetarian options and meatreplacement<br />

products that will satisfy a<br />

much wider audience.<br />

It’s vital to strike the right balance<br />

between natural appearance, color,<br />

flavor and texture on the one hand, and<br />

optimal binding characteristics of the<br />

ingredients mix on the other. Water<br />

and fat binding are very important, as<br />

well as the sustainability aspect of how<br />

products are designed. Choosing the<br />

right equipment can help bring to the<br />

market the new and innovative ranges<br />

that not only look like the real thing but<br />

taste just as good.<br />

GEA recommends to manufacturers<br />

proven solutions that offer complete<br />

process control by preparing all the<br />

components, whether making plantbased<br />

meat substitute burgers, mimic<br />

chicken coated nuggets, veggie fish<br />

sticks or vegan sausages. The choice<br />

of equipment for developing meat<br />

alternative products will depend on the<br />

application, the volume and on what the<br />

customer is trying to achieve.<br />

The latest high-tech solutions can be<br />

programmed to cover all the stages in the<br />

process in a fast, reliable and controlled<br />

way such as rehydration under vacuum of<br />

texturized vegetable proteins (TVP), mixing<br />

of oil and methylcellulose binder, highspeed<br />

cutting for optimal emulsification,<br />

cutting and cooling of the fat complement<br />

such as coconut butter and the final<br />

mixing of all ingredients, including spices<br />

and flavorings, ready for forming.<br />

To get the best results mixing and<br />

cutting, a range of equipment needs to<br />

be available that can handle all manner<br />

of ingredients that can be added to this<br />

process depending on the recipe, such<br />

as purified pea-protein, soy, extruded<br />

sunflower, extruded peas, wheat protein<br />

and gluten with the end result the same<br />

– thoroughly mixed, smooth patties that<br />

will have the mouth feel and juiciness of<br />

real meat.<br />

18 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Processing<br />

are being developed and tested<br />

in industrial conditions, including<br />

plant-based tacos, ribs, sausages, fish<br />

alternatives, pulled Mexican ‘chicken’<br />

and flavored ‘chickenless’ donuts<br />

with pesto-spinach, BBQ beetroot and<br />

carrot-curry coating.<br />

Naturally, before any decisions are<br />

made, <strong>food</strong> manufacturers need<br />

reassurance that any equipment<br />

purchased will prove to be a profitable<br />

investment. Feasibility studies, process<br />

improvements and R&D tests all need<br />

to continue, even during the current<br />

Covid-19 crisis.<br />

Next to mixing of ingredients,<br />

equipment that has a built-in vacuum<br />

feature will help intensify fresh and<br />

appetizing colors while contributing to<br />

exceptional fat binding and the higher<br />

density of the mix, leading to improved<br />

formability, with minimum waste during<br />

production.<br />

the Netherlands. Pooling together<br />

expertise with companies such as<br />

Griffith Foods, in process know-how,<br />

ingredients, and technology, exciting<br />

new meat-free product concepts<br />

GEA has a wide range of equipment<br />

to meet the needs of <strong>food</strong> producers.<br />

The company’s engineers and <strong>food</strong><br />

technologists work closely with customers<br />

to ensure that their whole production<br />

lines are productive, sustainable, creative,<br />

reliable, and efficient with the lowest<br />

possible total cost of ownership and total<br />

security of outcome.<br />

fmt<br />

* https://griffith<strong>food</strong>s.com/viewpoints/the-lostmillions-alternative-protein-white-paper/<br />

When it comes to vegetarian and meat<br />

replacement products, preparation of<br />

the mix is just part of the story. Having<br />

the right equipment is a good start, but<br />

having a thorough knowledge about<br />

the ingredients being used, and how<br />

those ingredients are likely to behave<br />

throughout the process will allow much<br />

greater control of the final outcome.<br />

For example, with products that are<br />

intended to mimic meat, water binding<br />

and retention are essential and these<br />

properties can be influenced by different<br />

factors at different stages during the<br />

process. Rehydrating proteins such as<br />

TVP under vacuum as opposed to other<br />

methods is not only quicker, it also<br />

allows greater water retention, thus<br />

increasing yields and avoiding the use of<br />

additives to achieve this.<br />

Want modern<br />

shapes?<br />



GEA works in collaboration with<br />

ingredient suppliers and product<br />

development companies testing out<br />

and developing new concepts at<br />

the GEA technology center in Bakel,<br />


www.<strong>food</strong>extrusion.de<br />

Key No. 99030<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />


Processing<br />

Making Food Processing Quality<br />

More Reliable with Vision AI<br />

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

faster and more efficient to implement. Data Spree from Berlin shows us how.<br />

In the <strong>food</strong> industry in particular,<br />

efficiency along the entire value chain is<br />

an essential competitive factor. Reliable<br />

automation of manufacturing and<br />

quality assurance processes is crucial for<br />

a modern and efficient factory.<br />

Traditional quality solutions<br />

- error-prone, complicated,<br />

expensive<br />

Classical image processing has to<br />

be programmed from scratch in a<br />

very complex way. Algorithms are<br />

developed manually by experts, which<br />

often requires a lot of know-how and<br />

time. At the same time, complex tasks,<br />

such as different or difficult defect<br />

images, cannot be mapped at all or only<br />

with great difficulty using these classic<br />

solutions. All this leads to high costs and<br />

to the fact that quality requirements<br />

often cannot be completely fulfilled.<br />

Figure 1 Development and integration process of Vision AI quality assurance<br />

This is why the <strong>food</strong> industry must<br />

use Vision AI in the future<br />

With Vision AI, quality inspections can<br />

be automated reliably and quickly<br />

during ongoing operations. With Data<br />

Spree’s Deep Learning DS software,<br />

these solutions can be implemented<br />

efficiently and easily. The first step<br />

is to simply capture images of good<br />

and defective products. Then the<br />

assignment of the images into “Ok”<br />

and “Not Ok”, also called annotation<br />

or labeling, takes place. The Data<br />

Spree actively supports here with<br />

annotation tools and services.<br />

Finally, the AI iteratively trains the<br />

20 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Processing<br />


recognition and correct assignment of the “Ok” and “Not Ok” examples.<br />

The AI works on the basis of an interconnection of nerve cells similar to<br />

the human brain. Here, the AI independently learns to distinguish good<br />

from bad products based on image data. As with the human brain, the<br />

accuracy of the AI is continuously improving. With Deep Learning DS,<br />

you can quickly and easily perform this “learning process” yourself. Data<br />

Spree also offers the complete process up to productive integration into<br />

the plant as a service.<br />



For contamination-free handling of<br />

powders and granulates<br />

This method can be used to quickly detect a wide variety of complex defect<br />

patterns, such as various surface defects, cracks, fractures, color defects and<br />

much more - and all without a single line of programming code. Quality<br />

assurance solutions can thus be implemented very efficiently and robustly.<br />

Even in just a few hours, operational prototypes can be created in some cases.<br />

Data Spree’s fast AI models additionally ensure good real-time capability in<br />

high-frequency production operations. Another advantage is the flexibility<br />

of the learning system. If products, product features or defects change at<br />

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

new images and retrained. In this way, it is possible to react quickly and<br />

effectively to changes in production without having to start from scratch or<br />

buy a new solution.<br />

Figure 2 The AI detects and localizes a wide variety of error patterns and deviations in<br />

real time<br />

Example: Quality assurance of cookies<br />

In the quality assurance process of cookie products, the AI can reliably<br />

distinguish “Ok” from “Not Ok” objects. The output shows the result and<br />

a heatmap. The red area in the heatmap is the AI’s basis for deciding<br />

whether an object is classified as “Ok” or “Not Ok”<br />

Here, the AI can easily detect a wide variety of defect patterns and<br />

deviations from the “Ok” state. The AI detects and localizes obvious<br />

defects such as holes, large cracks or fractures. But also more difficult<br />

defect patterns, such as small fractures and spalling or surface defects.<br />

The trained AI can independently detect and localize every possible defect<br />

variant or variable deviation, even if the defect did not explicitly occur in<br />

the training data set.<br />





With AI from Data Spree, all possible error cases are thus detected<br />

here. In the past, this quality monitoring would have required complex<br />

algorithms to be programmed by hand to detect a wide variety of<br />

deviations and defect types. With Vision AI from Data Spree these times<br />

are over. Especially for tasks with high error variability, learning AI<br />

systems are excellently suited. This means that especially in the quality<br />

inspection of <strong>food</strong> and baked goods, it is always worth taking a look at<br />

the topic of AI.<br />

fmt<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />

Key No. 99907<br />


Worldwide Powder Handling<br />

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

Daxner GERMANY<br />

Daxner UK<br />

Daxner USA<br />

Daxner SOUTH-EAST ASIA<br />

Daxner RUSSIA<br />

Daxner LATAM<br />

21<br />


Processing<br />

Schubert for future<br />


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

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

the 17 UNESCO Sustainable Development Goals.<br />

Schubert has been leveraging the topic of sustainability for many years to give its customers<br />

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

of sustainable packaging and machines that can process environmentally friendly<br />

materials.<br />

3D printing: Less waste is the goal<br />

With the Schubert PARTBOX, customers all over the world can<br />

print 3D format parts on demand and directly on site. This saves<br />

countless transport kilometres – and therefore up to 89% CO 2<br />

when compared to delivered parts.<br />

Sustainability pays off<br />

Sustainable packaging as a competitive advantage: Schubert-Consulting<br />

supports customers from all sectors in the development and optimisation<br />

of sustainable packaging and processes – from the selection<br />

of suitable materials and implementation on appropriate machinery,<br />

to the design of a sustainable supply chain.<br />

CO 2<br />




Long live sustainability<br />

The Speedline was one of Schubert’s first praline packing lines<br />

and is still in operation today after more than 30 years. A good<br />

investment for the customer and a perfect example of resource<br />

conservation made by Schubert.<br />

1988–2020<br />




Schubert<br />

Consulting<br />

AT<br />


A<br />

Interfaces<br />

Material flow<br />

Factory layout<br />


Reliability<br />

Digitalisation<br />

Automation<br />

Preventing instead of wasting<br />

Thanks to state-of-the-art manufacturing<br />

technologies and precisely planned production<br />

processes, the wastage at Schubert has been<br />

steadily decreasing for years.<br />

Key No. 99896<br />

MORE<br />

500<br />

THAN<br />


22 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />

TONS<br />


Processing<br />

Sustainability creates demand<br />

Schubert machines are exceptionally durable and therefore in demand<br />

worldwide. And there are always new innovations that ensure even greater<br />

efficiency. The result: Sales growth that has been well above the industry<br />

average for years.<br />

20<br />

10<br />

5<br />

0<br />

– 5<br />

8,0<br />

0,8<br />

2016<br />

5,4<br />

5,0<br />

8,0 9,0<br />

2,8<br />

–1,7<br />

2017 2018 2019<br />

Sources: Schubert, VDMA<br />

Thinking not in terms of quarters, but in generations<br />

As a family business, Schubert thinks sustainably by its very nature –<br />

currently with three generations in the company: Gerhard Schubert,<br />

sons Gerald and Ralf, and grandsons Johannes and Peter.<br />

3<br />

A family business in<br />

its third generation<br />

Experience turnover plus<br />

with Schubert<br />

Mechanical and systems engineering<br />

in Germany<br />

Schubert is growing – and is using as little space as possible by concentrating<br />

at the Crailsheim site. Did you know that 50% of the offices and<br />

hall areas at Schubert are heated and air-conditioned using geothermal<br />

energy?<br />

WLZ (goods logistics<br />

centre) was<br />

completed 2002<br />

Hall 2 was completed in<br />

2 construction phases<br />

in 1996 and 2008<br />

The Casino (canteen)<br />

was completed in 1994<br />

Hall 1 South was completed<br />

in 7 construction<br />

phases 1972-1990<br />

Renewable packaging: Cardboard instead of film<br />

Schubert is supporting the move away from unsustainable plastic<br />

packaging. In many cases, the changeover to cardboard is also<br />

possible on existing machines. This means that the packaging can<br />

even add visual appeal and value thanks to excellent printability<br />

of the carton.<br />

In planning<br />

The administration<br />

building was completed<br />

in 2006<br />

Brains instead of kilometres<br />

Clever packaging solutions from Schubert can save not only packaging<br />

material but also space during transport. The same amount of goods<br />

can be moved with fewer journeys – and with significantly less CO 2<br />

consumption.<br />


− 28%<br />

Hall 1 North was<br />

completed in 2015<br />

306<br />

TONS<br />


PER YEAR<br />

Figures from a completed order<br />

Year<br />

2000<br />

Year<br />

2020<br />

100 TRUCKS<br />


Figures from a completed order<br />

With smaller packaging and space-saving<br />

packed products, more goods can be transported<br />

on a pallet and supply chains<br />

become more efficient.<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />

23<br />


Processing<br />

New Automated Grading System for<br />

Fresh Green Beans<br />

Key <strong>Technology</strong>, a member of the<br />

Duravant family of operating companies,<br />

introduces a new automated grading<br />

system for fresh green beans. This<br />

turn-key solution automatically removes<br />

defective green beans and<br />

foreign material (FM), while also<br />

separating green beans in clusters or<br />

with attached stems and then directing<br />

them for further processing. This<br />

integrated grading solution, consisting<br />

of Key’s Iso-Flo® vibratory and rotary<br />

separation equipment combined with<br />

a VERYX® digital sorter, significantly<br />

reduces labor requirements, increases<br />

throughput and achieves consistent<br />

product quality, even during times of<br />

high incoming defect rates.<br />

“Prior to this development, most fresh<br />

pack green bean lines had to rely<br />

extensively on manual labor, which<br />

is expensive, hard to find and often<br />

unreliable – packers need a better<br />

option. With our new automated<br />

grading system, customers are able<br />

to reduce the number of manual<br />

graders by up to 70 percent,” said<br />

Jeff Nielsen, Area Sales Manager at<br />

Key. “Additionally, the system’s high<br />

throughput achieves faster grading and<br />

packing, handling the same number<br />

of loads in a shorter period of time<br />

to create a shorter workday or work<br />

week for the entire packing house. This<br />

enables the grower to harvest and pack<br />

ahead of incoming adverse weather<br />

conditions that can destroy his crops<br />

and lower his pack-out rates.”<br />

This automated grading system<br />

removes product with defects such<br />

as tip rot, wind scars and wormhole<br />

damage as well as a wide range of<br />

FM including rocks, insects and animal<br />

parts, glass, metal, cardboard, corn<br />

cobs and roots, cotton stalks, peanuts<br />

and more. The Iso-Flo vibratory<br />

feed shakers ensure good product<br />

spread while the rotary separator<br />

removes small particles and small FM.<br />

The VERYX digital sorter separates<br />

incoming product into three streams.<br />

The ‘accept’ stream sends good green<br />

beans with no clusters or stems on<br />

to final inspection and packaging.<br />

A second sort stream is dedicated<br />

to green beans in clusters or with<br />

attached stems, which are directed<br />

for further processing to recover<br />

more good beans. A third sort stream<br />

collects green beans with defects and<br />

FM, which go to waste.<br />

“With manual packing, packers must<br />

staff their grading lines for the highest<br />

incoming defect rates. When defect<br />

rates spike, it causes ‘per box’ costs<br />

to increase, supply to tighten, prices<br />

to go up and the hourly throughput<br />

to drop to a crawl. Key’s integrated<br />

solution including VERYX flips this<br />

scenario – the packer maintains higher<br />

throughput rates with less labor for a<br />

lower ‘per box’ cost and greater ‘per<br />

box’ profit,” said Nielsen. “The impact<br />

on profitability as well as quality of life<br />

for operators, managers and employees<br />

is impressive. The resulting shorter work<br />

days reduce worker fatigue, accidents<br />

and preventative maintenance. Packers<br />

24 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Processing<br />

often tell me that, for the first time in their lives, they feel like<br />

they have control over what they’re sending to their customers.”<br />

VERYX is equipped with Key’s powerful information analytics<br />

software, which collects data about every object flowing<br />

through the sorter. The segmented data can be used to profile<br />

incoming field loads in terms of its quality and defect rates.<br />

These quality profiles can be used to manage payment plans for<br />

growers. Insight into the product condition of individual loads<br />

is also valuable for understanding the impact of various field<br />

locations and growing practices on the quality of the green<br />

beans that come into the line for packing.<br />

Inspecting the product entirely in air, Key’s belt-fed VERYX<br />

sorter is ideal for products with challenging shapes like green<br />

beans. The sorter’s LED lighting system is designed to minimize<br />

shadows for accurate inspection of each green bean and<br />

detection of stems, product clusters and any defects that may<br />

appear on the surface of the bean. Positioning the inspection<br />

sensors away from product splatter sustains accurate inspection<br />

throughout long production cycles. VERYX is designed to run<br />

unattended during normal operation.<br />

Firm, chewy and bouncy:<br />

the right balance for<br />

noodles<br />

VERYX features next-generation cameras and laser scanners that<br />

offer twice the resolution of previous sensor technology to find<br />

smaller FM and defects. Key’s unique Pixel Fusion technology<br />

combines pixel-level input from multiple cameras and laser<br />

sensors, producing higher contrasts to find even the most<br />

difficult-to-detect product conditions and foreign materials.<br />

Intelligent air ejectors target each object at the optimal<br />

location to cleanly separate it from the product stream without<br />

inadvertently removing surrounding objects, maximizing<br />

both product quality and yield. VERYX is available in different<br />

inspection widths to satisfy a range of capacity requirements.<br />

In addition to VERYX, this versatile grading system can be<br />

configured with a variety of vibratory and mechanical solutions<br />

to optimize overall system performance. Key’s Iso-Flo® shakers<br />

can be designed to remove small, broken and curved beans.<br />

A PSG separator combined with an integrated Iso-Flo feeding<br />

shaker can size the product by length and diameter to remove<br />

short and thin green beans, as well as other small objects<br />

such as insects, loose stems, soil and small rocks. Robust and<br />

long lasting, Key’s vibratory and mechanical systems enhance<br />

sanitation with features such as open designs, fully-welded<br />

frames, stainless steel bed surfaces, oil-free drives and more. fmt<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />

Enhance the taste of your noodles with<br />

GEA technology: a stronger, chewier<br />

texture with a pleasant bite-feel.<br />

At GEA we have developed processing<br />

technologies for noodles starting from their<br />

unique taste.<br />

We have focused on encapsulating a history<br />

of consumption going back thousands<br />

of years in a high-quality and completely<br />

versatile product, suitable for every<br />

preparation and recipe.<br />

Discover<br />

GEA’s noodles processing technology<br />

gea.com/noodles<br />

Key No. 98838<br />

25<br />

Key No. 99510

Processing<br />

X-Ray Inspection Ensures High Quality<br />

for Sausage Exports<br />

An X-ray inspection system from Ishida<br />

is enabling leading German meat and<br />

sausage manufacturer Goldschmaus<br />

Natur to meet the highest quality<br />

standards required for the export of its<br />

Frankfurter sausages to Japan.<br />

The Ishida IX-GA-2475, which has been<br />

designed for inspecting small products<br />

at high speeds, has been installed at<br />

Goldschmaus Natur’s factory in Garrel,<br />

Münsterland to check for foreign bodies<br />

in unpacked Frankfurter sausages<br />

produced according to a special recipe<br />

for the Japanese restaurant and<br />

catering industry.<br />

The sausages are taken to the<br />

production line in strings on special<br />

smoke trolleys and manually fed onto<br />

the processing line. Once cut from the<br />

strings, the individual sausages pass<br />

through the X-ray system at high speed,<br />

separated by only a few centimeters.<br />

The patented technology behind<br />

Ishida’s X-ray inspection systems is<br />

based on software incorporating<br />

an intelligent genetic algorithm. By<br />

analysing image data over a number<br />

of generations, the machine achieves<br />

an extremely high level of inspection<br />

accuracy. Since similar contaminants<br />

are usually found again and again in<br />

sausage manufacture, the system can be<br />

optimized to look for these objects. This<br />

collects valuable visual and numerical<br />

information that helps to eliminate<br />

recurring sources of contamination.<br />

In this way, Goldschmaus Natur can<br />

demonstrate that its production and<br />

packaging processes are properly and<br />

correctly performed.<br />

The Ishida IX-GA 2475 is operating at<br />

a belt speed of 60 meters per minute,<br />

inspecting up to 200 sausages per<br />

minute. While the X-ray inspection<br />

system could potentially deliver even<br />

better performance, this is limited by<br />

the upstream cutter.<br />

Despite its high speed, the system<br />

reliably detects foreign bodies such as<br />

pieces of metal, glass and plastic as well<br />

as gristle and bone. The requirement<br />

to reliably detect pieces of metal with<br />

a diameter of 0.6 mm, glass with a<br />

diameter of 2 mm and plastic with a<br />

diameter of 5 mm has been fulfilled, as<br />

regular functional checks with specially<br />

prepared products demonstrate.<br />

In addition, the system is also able to<br />

reject sausages that exhibit other flaws<br />

such as clumps of herbs or damaged<br />

items. A special high-speed reject<br />

arm directs rejected sausages into a<br />

reject bin. The data log collects all<br />

information and helps to eliminate<br />

recurring sources of contamination,<br />

while also providing confirmation that<br />

the production processes are properly<br />

and correctly set up.<br />

The new X-ray inspection system is used<br />

by Goldschmaus Natur mainly in a twoshift<br />

operation and, thanks to its IP 65<br />

protection rating, can easily withstand<br />

the humid production environment.<br />

It did not take long for the operators<br />

to familiarize themselves with this<br />

largely maintenance-free machine. The<br />

easy-to-use X-ray system features an<br />

automatic set-up function and is ready<br />

within 90 seconds. Fine adjustments<br />

can be made during operation without<br />

interrupting the production. Up to 100<br />

programmable pre-sets allow rapid<br />

product changeovers.<br />

For operations manager Michael<br />

Schmolke, the benefits of this X-ray<br />

inspection system are clear: “It can find<br />

all sorts of foreign bodies – and not just<br />

metal. Also, no other system on the<br />

market can check for foreign bodies at<br />

such high speeds.”<br />

Photos: Ishida Europe<br />

Goldschmaus’ customers, too, have<br />

been informed about the new X-ray<br />

inspection system, which sends out<br />

a clear message that Goldschmaus<br />

Natur is committed to maintaining the<br />

highest standards of quality control. fmt<br />

26 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Packaging<br />



For meat analog and extender production,<br />

rely on the pioneer of the process for textured<br />

vegetable proteins by extrusion. Wenger began<br />

the worldwide initiative over 50 years ago, and<br />

continues to lead with ever expanding options<br />

today.<br />

High moisture meat analogs (HMMAs) produced on<br />

Wenger twin screw extruders mimic whole muscle<br />

meat, with similar characteristics for moisture,<br />

protein and fat contents, as well as a densely<br />

layered, somewhat fibrous structure.<br />

After extrusion, HMMAs may be cut, sliced or<br />

shredded – and then further processed or frozen.<br />

In addition to soy proteins or wheat gluten<br />

ingredients, alternative protein sources can be used<br />

for texture, mouthfeel and appearance objectives.<br />

Discover the latest in cutting edge extrusion<br />

processing and product development assistance.<br />

Email info@wenger.com now.<br />

Key No. 99332<br />



<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong> 27

Processing<br />

Cooking up a Storm with its Luxury<br />

Frozen Meals<br />

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

of its luxury hand-prepared meals by 50%.<br />

COOK’s founding statement is to<br />

“cook using the same ingredients and<br />

techniques as you would at home, so<br />

everything looks and tastes homemade”,<br />

a philosophy that has enabled COOK<br />

to bring innovation to the UK frozen<br />

ready meal sector. Supplying the rapidly<br />

increasing consumer demand for quality<br />

ready to cook <strong>food</strong>, COOK have seen<br />

record annual revenues year on year.<br />

The ‘hands on’ approach within its<br />

production kitchens include chefs<br />

stirring dishes with large paddles,<br />

and manually ladling and garnishing<br />

each dish by hand, just home cooking<br />

on a much larger scale.<br />

An existing production kitchen at full<br />

capacity and a plan to double sales<br />

within 5 years led to COOK to acquire a<br />

new site in Sittingbourne, Kent, UK, to<br />

enable an increase in volume of its ready<br />

to cook meals. As part of the expansion<br />

project, the recently awarded ‘feel good’<br />

brand invested in freezing technology<br />

that would improve efficiency and<br />

the quality of its best-selling gourmet<br />

recipes.<br />

Project details<br />

Following extensive product trials at<br />

their laboratory test facility in Suffolk,<br />

Starfrost designed and manufactured<br />

a bespoke Helix spiral freezer system,<br />

that would effectively freeze the<br />

ready to cook meals whilst locking<br />

in the freshness and quality of the<br />

ingredients.<br />

Quote<br />

“The spiral freezer has delivered a 50%<br />

increase in production capacity, improved<br />

product quality and created a better<br />

working environment within our production<br />

kitchens.” - Ben Walker of COOK.<br />

Since the installation of the Helix<br />

spiral freezer, COOK has reduced<br />

manual labor and improved<br />

production efficiency as well seeing<br />

a range of operational benefits,<br />

including increased factory space<br />

and significantly reduced processing<br />

times.<br />

The compact automated freezer<br />

designed for COOK has removed the<br />

need for large rack trolleys within the<br />

production kitchens, an operational<br />

requirement for blast freezers. The<br />

new freezer also features an energy<br />

efficient design that operates with<br />

CO 2<br />

refrigeration, a long term<br />

refrigeration solution that is not<br />

subject to phase out regulations.<br />

Samuel Welch, UK Sales<br />

Manager at Starfrost:<br />

“COOK are <strong>food</strong> specialists of<br />

hand prepared ready meals. We<br />

understood immediately that the<br />

company and its products are<br />

focused on quality. Partnering with<br />

a firm such as COOK is something<br />

we value at Starfrost and our key<br />

focus was to find a cooling solution<br />

that would seamlessly fit within the<br />

business and processing line.<br />

The next spiral freezer project for<br />

COOK, currently being manufactured,<br />

is a duplicate model of the recently<br />

installed Helix, designed to freeze<br />

3,600 meals per hour, and will<br />

deliver the same energy efficient and<br />

maximized capacity benefits.” fmt<br />

28 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Processing<br />

Ben Walker, Head of Pioneer at<br />

COOK, discusses the project and the<br />

investment of freezing equipment in a<br />

Q&A below:<br />

Can you briefly outline the details of<br />

the freezing project?<br />

We wanted to upgrade from static<br />

blast freezing to a continuous freezing<br />

method within our ready to cook meal<br />

production.<br />

Why did COOK require a new<br />

freezing solution?<br />

Due to increased demand of our<br />

products and our business expansion<br />

plans, we needed to increase the<br />

volume of our frozen ready meal<br />

range and wanted to invest in the<br />

latest freezing technology within our<br />

production kitchens.<br />

Were there any key requirements<br />

for the project?<br />

Fundamental to the project was<br />

finding a freezing system and process<br />

that maintained the quality of our<br />

ingredients and meals.<br />

Can you describe your selection<br />

process and what criteria you were<br />

looking for in a supplier?<br />

Our chosen supplier of freezing<br />

equipment had to deliver a solution<br />

that matched our expectations and<br />

requirements for quality. We selected<br />

Starfrost to help us achieve this, we felt<br />

confident the team could provide us<br />

with a bespoke solution that would fit<br />

within our business. They understood<br />

the complexities of the project and<br />

most importantly our company focus<br />

on product quality. We were pleased to<br />

partner with Starfrost and are currently<br />

working on an additional project for<br />

another spiral freezer.<br />

Which freezing method was<br />

implemented and how has it met<br />

your project requirements?<br />

Working with our team and specification<br />

for our products, Starfrost designed and<br />

installed a Helix spiral freezer. It’s an<br />

automated freezing system which means<br />

our products are consistently frozen<br />

and at a reduced time in comparison to<br />

blast freezing. We’ve seen a significant<br />

boost in terms of output, we have<br />

now increased production capacity by<br />

50%. With the addition of the second<br />

spiral freezer this summer we plan a<br />

further 30% increase, bringing our total<br />

expected throughput up by 80%.<br />

Are there any additional benefits<br />

of the freezing system, if so what<br />

difference has that made to your<br />

production kitchen?<br />

The Helix spiral freezer gives us<br />

operational flexibility which matches<br />

our home style cooking processes at<br />

COOK. We’ve been able to reduce<br />

contact handling of the product and<br />

now have an end to end line solution.<br />

The combined benefits of the new<br />

freezing system deliver a higher quality<br />

end product that keep our production<br />

to more stringent timelines - which for<br />

any chef, is a must!<br />

fmt<br />

HYGIENIC DESIGN Rotary Valve Easy Clean Twice<br />

Key No. 99936<br />

Hygienic Design<br />

Easy Cleaning<br />

Replaceable<br />

seal cartridge<br />

FDA–certified<br />

elastomers<br />

ATEX Protection System<br />

EHEDG Type EL Class II<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />


JAUDT Dosiertechnik<br />

Maschinenfabrik GmbH<br />

Raiffeisenstraße 3-5<br />

D-86167 Augsburg<br />

29<br />

e-mail: verkauf@jaudt.de<br />


Processing<br />

Flow-wrapping machine from Schubert packs with ecological films<br />

A Sustainable Competitive Advantage for<br />

Food Manufacturers<br />

The shift towards increasingly individualized packaging and sustainable materials is especially noticeable<br />

in the <strong>food</strong> industry. Companies that want to face these market trends with confidence need a high degree<br />

of flexibility in their production. With a Flowpacker from Schubert, manufacturers in the <strong>food</strong> sector can<br />

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

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

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

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

Flowpacker.<br />

Today, no <strong>food</strong> manufacturer can<br />

afford to ignore the market’s need<br />

for rapidly changing, individually<br />

tailored packaging solutions that<br />

also conserve resources. The latter<br />

is a special challenge in the case of<br />

packaging into flowpacks. There<br />

is a good reason why composite<br />

films have conquered the world<br />

thanks to their ease of processing<br />

and product-protecting properties.<br />

However, the shift towards materials<br />

that are more recyclable will become<br />

increasingly pronounced and is likely<br />

to be irreversible in the long term.<br />

The answer to these developments is<br />

flexibility. Companies that can change<br />

their packaging processes quickly<br />

and as needed gain a competitive<br />

edge in the marketplace, especially<br />

when it comes to environmentally<br />

conscious consumers and future<br />

trends. With the Flowpacker flowwrapping<br />

machine from Schubert,<br />

manufacturers of almost any product<br />

can capitalize on a packaging<br />

machine that combines effective<br />

packaging solutions with extremely<br />

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

variable processes – thanks to its<br />

modular design and the use of highly<br />

developed robot technology.<br />

A seamless and highly flexible<br />

packaging process in a single line<br />

This is based on a machine concept<br />

that integrates the entire packaging<br />

process seamlessly, efficiently and in an<br />

exceptionally flexible manner into one<br />

TLM line. Firstly, in the Flowpacker, the<br />

products are fed to the flow-wrapping<br />

unit by pick & place robots which can<br />

be adapted to the customer’s desired<br />

30 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Processing<br />

We bring colour into view!<br />

Compact pressure sensor switches with 360° custom-colour status display<br />

NEW!<br />

Status display<br />

also for two-wire<br />

sensors.<br />

256 colours<br />

Individually selectable:<br />

Measurement in progress<br />

Sensor switching<br />

Process malfunction<br />

Compact design<br />

15 cm<br />

Hygienic<br />

adapter system<br />

Key No. 99290<br />

Adjustment via<br />

smartphone<br />

www.vega.com/vegabar<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />


Processing<br />

output range and types of products.<br />

Secondly, the combination of state-ofthe-art<br />

sealing technologies and the<br />

unique flying cross-sealing unit makes<br />

it possible to gently and reliably process<br />

both conventional composite films in<br />

cold- and heat-sealing processes, as well<br />

as mono films and paper-based films. And<br />

thirdly, the formats in the Flowpacker<br />

can be changed very easily and quickly<br />

thanks to the format parts which are<br />

customized by Schubert. The integrated<br />

concept therefore offers companies in<br />

the <strong>food</strong> industry outstanding flexibility<br />

on several levels – namely unrestricted<br />

choice of product, packaging material<br />

and sealing technology.<br />

Long-established company<br />

benefits from the Flowpacker’s<br />

flexibility<br />

The medium-sized, heritage bakery<br />

from the French Alsace also counts on<br />

A long-established bakery in Alsace packs its<br />

biscuits and pastries with recyclable packaging<br />

materials using Schubert’s flow-wrapping<br />

machine.<br />

this flexibility. A wide range of fine<br />

pastries and biscuits are produced at<br />

the company’s facilities, including many<br />

products in organic quality, wafers and<br />

biscuits with and without chocolate,<br />

in layers or fully coated – and all in a<br />

wide variety of sizes. Packaging ranges<br />

from conventional to recyclable films,<br />

from plastic trays to cardboard trays<br />

and U-boards. The different sizes and<br />

consistencies of the products, as well as<br />

the quick change from one packaging<br />

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

32 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Processing<br />

to another, are no problem for the<br />

flow-wrapping machine. Easy-tochange<br />

format parts based on the<br />

plug & play principle facilitate easy<br />

handling for the machine operators.<br />

The individual gripping and suction<br />

tools on the pick & place robots can<br />

be changed in just a few steps.<br />

The two-part forming shoulders<br />

developed by Schubert can also<br />

be replaced quickly and without<br />

requiring subsequent adjustment.<br />

The packaging machine manufacturer<br />

uses forming shoulders<br />

in the Flowpacker without sharp<br />

edges for all film variants. This is<br />

because during packaging, the<br />

film is pulled over the forming<br />

shoulders at top speed and formed<br />

into a tube, which places great<br />

stress on the film and components.<br />

Paper-based films are especially<br />

susceptible to tearing or wrinkling,<br />

and also wear down the material of<br />

the forming shoulders permanently.<br />

Therefore, to achieve an ideal result,<br />

the format parts are individually<br />

adapted to a packaging material by<br />

hardened and coated surfaces.<br />

Thanks to specially developed forming shoulders, the Flowpacker from Schubert can process not only<br />

mono films but also paper-based films.<br />

Sealing times are accurate to<br />

the millisecond<br />

To keep all options open when<br />

choosing films, a flow-wrapping<br />

machine’s sealing system is also<br />

of particular importance for <strong>food</strong><br />

manufacturers. This is because<br />

ecological films require exceptionally<br />

gentle sealing technologies due to<br />

the sensitive nature of the material.<br />

Thanks to its state-of-the-art sealing<br />

systems, the Flowpacker processes<br />

laminated films as well as the<br />

new sustainable variants – right<br />

through to paper-based films. The<br />

TLM machine can switch between<br />

different types of film without<br />

requiring much effort. This is due in<br />

part to the flying cross-sealing unit:<br />

It is the only cross-sealing system on<br />

the market which allows complete<br />

control over the entire duration of<br />

the sealing process. The sealing time<br />

can be selected to the millisecond<br />

and always remains constant due to<br />

the design of the sealing robot. The<br />

unit compensates for fluctuating<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April<br />

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Go GEA CutMaster!<br />

Making the perfect mix for vegetarian and meat-replacement<br />

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together the components of the perfect burger or nugget, quickly,<br />

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better hygiene - perfect for high-speed plate or rotary forming.<br />

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Tel +49 6461 801 217<br />

gea.com/contact<br />

33<br />

Key No. 99749<br />

Learn more

Processing<br />

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

production speeds by moving with or<br />

against each flowpack on the conveyor<br />

as required. This means that mono films<br />

and paper-based films can be sealed<br />

perfectly and without damage in the<br />

packaging machine.<br />

Schubert also uses specially developed<br />

heating elements as its latest sealing<br />

system for longitudinal sealing.<br />

The five-by-five-millimeter ceramic<br />

elements can be controlled individually,<br />

heat up very quickly and, above<br />

all, cool down again in the shortest<br />

possible time. This means that the<br />

heat supply at the sealing seam can be<br />

precisely controlled at every point – in<br />

terms of temperature and time. Both<br />

are decisive for a consistently high<br />

and process-reliable sealing quality.<br />

Furthermore, every Flowpacker with<br />

heat-sealing technology and a flying<br />

cross-sealing unit can process both<br />

classic composite films and cold-seal<br />

films. This is because the sealing<br />

systems can be converted to coldsealing<br />

in a very short time. Older coldsealing<br />

films can also be processed well<br />

in the Flowpacker, as the glue joints in<br />

the longitudinal sealing unit can be<br />

easily preheated if necessary due to<br />

the available heating elements.<br />

High processing quality and<br />

excellent machine efficiency<br />

The exceptional flexibility in terms of<br />

product specifications and packaging<br />

material is one thing about the<br />

Schubert flow-wrapping machine,<br />

and the high processing quality and<br />

machine efficiency are another:<br />

Thanks to the robot-assisted processes,<br />

especially sensitive products such<br />

as Alsatian pastries, are packaged<br />

extremely gently. Long conveyor belts<br />

are superfluous. Instead, F4 robots<br />

place the biscuits flexibly and gently<br />

into the trays or directly into the<br />

chain. Breakage, damage and rejects<br />

are therefore minimized. Moreover,<br />

the Schubert image processing system<br />

inspects the goods in each Flowpacker<br />

to ensure that they are in perfect<br />

condition. Only products that meet<br />

the specified quality criteria are picked<br />

up and packed by the pick & place<br />

robots. At the bakery, an incidentlight<br />

scanner is used for this purpose.<br />

Depending on the requirements,<br />

however, 3D image processing can also<br />

be used in the flow-wrapping machine,<br />

and for example, record and assess the<br />

product height.<br />

With the flow-wrapping machine,<br />

manufacturers in the <strong>food</strong> industry<br />

in particular can benefit from highly<br />

flexible and reliable packaging processes:<br />

The wide range of options in the choice<br />

of packaging, the products to be<br />

packaged and the options on recyclable<br />

materials make the Flowpacker a futureproof<br />

packaging machine which can<br />

accommodate the fast-moving <strong>food</strong><br />

industry in every respect.<br />

fmt<br />

34 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Packaging<br />


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<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong> 35<br />

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Packaging<br />

Unconventional Labelling Solution for<br />

Pizzas and the Like<br />

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

view of the product - the full wrap labelling solution from MULTIVAC for pizzas and other flat <strong>food</strong> products<br />

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

it meets the increasing demands of the market as regards sustainability.<br />

Generally fresh or frozen pizzas,<br />

tortillas, pitta breads, quiches, tart<br />

bases and other flat products are<br />

packed in hinged trays, thermoformed<br />

packs, standard trays or simply in<br />

film. They are often packed using a<br />

pre-printed film with top and bottom<br />

labels or a cardboard sleeve. In the<br />

case of pizzas in particular, it is usual<br />

to pack them in a complete box.<br />

“Thinking outside the box”<br />

Full wrap labelling from MULTIVAC<br />

redefines the packaging and labelling<br />

of such products. The L 310 full wrap<br />

conveyor belt labeller is the ideal<br />

solution. This highly flexible model<br />

with its driven, extra-narrow transport<br />

conveyors makes the C labelling and D<br />

labelling of packs possible at speeds<br />

up to 120 packs per minute. The label<br />

width is up to a maximum of 500 mm.<br />

The labeller can also be equipped<br />

with an integrated printer, as well as<br />

a zero downtime function and label/<br />

print monitoring for maximum output,<br />

efficiency and process reliability at<br />

even the highest throughput.<br />

High level of flexibility in terms<br />

of materials<br />

MULTIVAC offers a wide range of<br />

suitable label materials and adhesives,<br />

so that the packs can be labelled<br />

perfectly on the machine. In addition<br />

to PP and PET labels, the range also<br />

includes sustainable materials made<br />

of paper or from renewable sources.<br />

“By matching the label material to the<br />

packaging material, we can ensure<br />

that the constituent parts of the pack<br />

can be separated to meet the recycling<br />

requirements. Adhesives, which can<br />

be dissolved or washed off, enable<br />

the individual packaging components<br />

to be easily separated, so that they<br />

can then be directed to the particular<br />

recycling stream,” explains Michael<br />

Reffke, Product Manager at MULTIVAC<br />

Marking & Inspection.<br />

36<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Packaging<br />

Another benefit: Thanks to the use of<br />

particularly light label material, the concept<br />

also contributes to improving the CO 2<br />

balance,<br />

since the transport weight of the packs is<br />

reduced along the entire supply chain to the<br />

consumer. “If full wrap labels are used instead of<br />

cardboard sleeves, the weight of the banderole<br />

can be halved,” adds Michael Reffke. “A full<br />

wrap label instead of a standard-size pizza box<br />

saves over 65 g of pack weight. Also not to be<br />

ignored for the producer are the savings in<br />

terms of license charges for the collection and<br />

disposal or recycling of the retail packs.”<br />

New dimension of added value<br />

When compared with previous packaging<br />

concepts for pizzas and similar products, full<br />

wrap labelling does not just win in terms of<br />

output and sustainability. When it comes to<br />

appeal at the point of sale and the usable area<br />

for promotion, this new and unconventional<br />

concept for such products outscores top and<br />

bottom labelling by far. It is also in no way<br />

inferior to cardboard sleeves, as well as being<br />

significantly more efficient than a complete<br />

box. It also offers consumers the benefit, that<br />

they can have a close look at the product before<br />

buying it.<br />

Even where the lowest-cost material is used,<br />

this packaging concept is still highly impressive<br />

at the point of sale with its high-quality look<br />

and feel, since the print design, shape and type<br />

of material can be individually adapted to the<br />

product and brand.<br />

fmt<br />

Cutting-Edge<br />

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by Thorwesten Vent offer signifi cant advantages.<br />


Daimlerring 39, 59269 Beckum / Germany<br />

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thorwesten.vent@thorwesten.com<br />

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Key No. 99677<br />

TWV_<strong>food</strong><strong>Marketing</strong><strong>Technology</strong>_02_<strong>2021</strong>_92x244_4c_Anz_Food_EN.indd 1<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong> 37<br />

TWV_<strong>food</strong><strong>Marketing</strong><strong>Technology</strong>_02_<strong>2021</strong>_92x244_4c_Anz_Food_EN.indd 1 15.02.21 14:12

Packaging<br />

Robotics: 25 Years of Reliable<br />

Palletizing <strong>Technology</strong><br />

• Expert team develops smart and powerful robots<br />

• Systems optimally designed for many different tasks<br />

• KHS to introduce more standardized systems and virtual commissioning in the future<br />

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

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

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

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

features heavily in the company’s plans for the future.<br />

The use of robots in the packaging<br />

and palletizing process steps is on the<br />

increase both in KHS’ single machine<br />

business and in its line projects. They<br />

are considered to be extremely reliable<br />

and low maintenance and provide<br />

secure production. They often perform<br />

several tasks at the same time and are<br />

valued as a future-proof investment.<br />

All that needs doing when setting up<br />

new functions is to replace the specific<br />

tool and modify the programming.<br />

Moreover, these intelligent machines<br />

produce at a low cost and are easy to<br />

operate. It is thus no surprise to learn<br />

that a growing number of bottlers in<br />

the beverage industry wish to make<br />

greater use of ‘colleague robot’.<br />

Many years of expertise<br />

KHS has been making successful use<br />

of robot technology on its production<br />

lines for 25 years now. The Dortmund<br />

systems supplier thus has a wealth of<br />

experience and expertise in this field<br />

of application. KHS masterminded<br />

its first projects in the palletizing<br />

section for customers in Gerolstein<br />

and Regensburg back in 1996. As<br />

the maximum weight that could be<br />

processed by the robots then in use was<br />

subject to certain restrictions, to start<br />

with they were not used to palletize<br />

full layers. Initially, typical applications<br />

included palletizing and depalletizing,<br />

packing and unpacking of returnable<br />

crates and keg palletizing.<br />

Since the beginning of the 2000s KHS<br />

has worked with the KUKA company<br />

based in Augsburg, Germany. Back<br />

then, the systems designed by the<br />

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<br />

engineer to give them the go-ahead.<br />

38<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Packaging<br />

international automation specialist<br />

were able to manage greater weights<br />

and used the same machine control<br />

system as that found in KHS equipment<br />

at that time. KHS also relies on<br />

technology manufactured by Japanese<br />

electronics and mechanical engineering<br />

company FANUC. “If someone’s already<br />

using a certain system, they don’t<br />

want to switch to another one. It’s<br />

almost a question of religion,” explains<br />

Christoph Wiesenack, palletizing product<br />

manager in Worms.<br />

As KHS has profound knowledge of<br />

both suppliers’ systems, it is secondary<br />

which components the expert team<br />

works with. “However good the robots<br />

are, they’re only brought to life when<br />

used properly,” he emphasizes. This<br />

is where KHS comes into play. “With<br />

our experience we know where and<br />

for which functions robots can be<br />

constructively used. Our concrete tasks<br />

are programming and the manufacture<br />

and configuration of tools and<br />

peripherals – from pallet conveyors<br />

through grouping and unloading<br />

tables to centering.”<br />

with the help of the motor’s power<br />

input and can thus grip and process<br />

products very gently – even sensitive<br />

packs such as our new paper pack,”<br />

Wiesenack states.<br />

Robot grouping at KHS is now largely<br />

standardized – both with respect<br />

to the table, its position and the<br />

programming. Variants have one to<br />

three robots and are available with<br />

one to four infeed lanes. “Our product<br />

center is experienced in this without us<br />

having to clarify much more here,” says<br />

Wiesenack. Accordingly, the number<br />

of grouping robots installed to date is<br />

high and currently amounts to about<br />

600, with 50 new ones added each year.<br />

Robots for more efficient loading and<br />

sorting<br />

Besides grouping, KHS currently also<br />

uses robots to palletize non-returnable<br />

packs and for other applications such<br />

as sorting and distribution. In kegging<br />

robots are used to unload and palletize<br />

kegs, for instance. Image processing<br />

systems enable further functions to<br />

be incorporated, such as keg turning<br />

on demand, fitting position detection<br />

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

being shipped to the customer.<br />

KHS’ specialist field: robot<br />

grouping<br />

The Dortmund systems manufacturer<br />

has been using robots for grouping<br />

since 2004, a process in which packs are<br />

formed into layers. “This application<br />

is our bread and butter, so to speak,”<br />

smiles Wiesenack. Since the beginning<br />

the team in Worms has continued to<br />

develop its robotics, particularly the<br />

robot heads. “These are the tools at the<br />

end of the robot arms that come into<br />

direct contact with bottles, cans, packs,<br />

cartons or crates. Hardly anyone knows<br />

better than we do what has to be<br />

taken into account for products to be<br />

processed flawlessly.” This is why KHS<br />

engineers these product-contacting<br />

parts itself. Special functions integrated<br />

into the heads include crash protection,<br />

for instance, that prevents packs and<br />

machines from damage. There is also<br />

a compensation system that reduces<br />

wear and abrasion and an extremely<br />

simple clamping jaw changeover: the<br />

packs to be grouped are gripped by<br />

the servo-motorized jaws and pushed<br />

into the required position. “We set the<br />

clamping pressure to a defined value<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong> 39

Packaging<br />

and identification of the layer pattern<br />

on the pallet. The systems can also<br />

adjust the process steps to suit the<br />

current kegging situation. Automatic<br />

tool changeovers can be provided as an<br />

option for most robot applications and<br />

also retrofitted on demand.<br />

KHS’ expertise is particularly important<br />

when special functions are required<br />

that standard machines cannot<br />

perform, for example during loading<br />

or sorting. One example of this is in<br />

operation at RHODIUS Mineralquellen<br />

in Burgbrohl, where segregated bottles<br />

and crates are packed and palletized<br />

according to type on one machine.<br />

Here, the robot picks segregated<br />

crates of returnables comprising<br />

mainly foreign bottles from the line<br />

and places them on pallets for removal<br />

from the line. It also packs segregated<br />

empty bottles into empty crates and<br />

places these by type according to a set<br />

pattern back onto pallets that are then<br />

ready for discharge. With this, during<br />

production the system generates<br />

sorted empties for later processing<br />

more or less as a by-product. Flexible<br />

adaptation to the sorting rate means<br />

that functions can be assigned as<br />

required during the shift.<br />

One very different special application<br />

has been developed in the course<br />

of KHS’ cooperation with one of the<br />

world’s leading soft drinks producers.<br />

Over the past five years KHS installed<br />

several robot applications here for<br />

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

crates and places these onto pallets by type.<br />

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

of the systems manufactured by both suppliers.<br />

the preparation of basic soft drinks<br />

components required at the company’s<br />

various production sites to mix its<br />

finished beverages. In this example,<br />

too, the team of experts from KHS<br />

developed a number of line-specific<br />

palletizing systems. The future viability<br />

of the systems has also proved itself<br />

here; following the move to a new<br />

facility, by decoupling certain functions<br />

and through rearrangement of the<br />

palletizing section a palletizing robot<br />

already supplied was assigned two<br />

more lines for palletizing, increasing<br />

the palletizing capacity in the process.<br />

The customer was extremely satisfied<br />

with the results.<br />

Fewer tasks, greater performance<br />

It goes without saying that even<br />

robots have their limits. “It’s like with<br />

people; they too can only perform<br />

a certain number of tasks within a<br />

given time,” Wiesenack comments.<br />

“The more functions we include on<br />

a machine, the lower the output in<br />

containers per hour.” If groupings<br />

process up to 144,000 cans per hour,<br />

for example, combined palletizing<br />

cells in the lower or medium capacity<br />

range are used. The output here<br />

depends on the number of functions<br />

to be carried out, such as picking<br />

and placing packs onto pallets, layer<br />

formation and processing pallet liners<br />

and empty pallets. The palletizing<br />

cell permits complete, fully automatic<br />

palletizing, including pallet and pallet<br />

liner handling, in a relatively small<br />

space of just 35 square meters.<br />

Future standardization<br />

In the future Wiesenack also wants to<br />

make loading stations as uniform as<br />

possible so as to offer standardized<br />

systems as for grouping that enable<br />

faster lead times and incur less<br />

cost. “Our palletizing cell for the<br />

low capacity range is a first step in<br />

this direction,” he tells us. “We can<br />

imagine that we’ll achieve higher<br />

outputs on standardized systems<br />

in the future because the focus is<br />

solely on palletizing; we can then<br />

get the most out of the robot here.<br />

40<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Events<br />

On customized systems, where the<br />

accent is on flexibility rather than just<br />

palletizing, we’re bound by the setup<br />

and specified tasks.”<br />

The specialists in Worms are<br />

also planning to extend virtual<br />

commissioning and rely more heavily<br />

on the digital twin in order to exploit<br />

further potential for increasing<br />

efficiency. Synergies are to be used<br />

for this purpose: robots are usually<br />

equipped with a digital environment<br />

by their manufacturers, meaning that<br />

KHS can also commission these virtually.<br />

All it then has to do is integrate its tools<br />

into the existing environment. fmt<br />

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

the distribution of wrap-around cartons.<br />

The Author<br />

Christoph Wiesenack has worked with robot<br />

applications for the beverage industry at<br />

KHS for seven years now.<br />

Q2 <strong>2021</strong><br />

31 May-2 June<br />

Middle East Africa agro<strong>food</strong><br />

fairtrade Messe GmbH & Co. KG<br />

Kurfürsten Anlage 36,<br />

69115 Heidelberg, Germany<br />

Tel.: +49-6221/4565-0<br />

Fax: +49-6221/4565-25<br />

info@fairtrade-messe.de<br />

www.virtual-africa.com<br />

www.fairtrade-messe.de<br />

16-17 June <strong>2021</strong><br />

Hamburg, Germany<br />

Snackex<br />

European Snacks Association<br />

Rue des Deux Eglises, 26<br />

1000 Brussels, Belgium<br />

Tel: +32-2 538 20 39<br />

Email: esa@esasnacks.eu<br />

www.snackex.com<br />

18-21 July<br />

Chicago, IL, USA<br />

IFT Food Expo - first<br />

Institute of Food Technologists<br />

252 W. Van Buren,<br />

Suite 1000, Chicago, IL 60607<br />

Tel.: +1-312-782-8424<br />

Fax: +1-312-782-8348<br />

www.ift.org<br />

Virtual<br />

Let’s meet here<br />

Let’s meet here<br />

Virtual<br />

Let’s meet here<br />

Q3/4 <strong>2021</strong><br />

28-30 September<br />

Nuremberg, Germany<br />

Fach Pack<br />

NürnbergMesse GmbH,<br />

Messezentrum,<br />

90471 Nuremberg<br />

Tel.: +49-911-8606-0<br />

Fax: +49-911-8606-8228<br />

www.fachpack.de<br />

Let’s meet here<br />

5-7 October<br />

Palexpo, Le Grand-Saconnex, Switzerland<br />

Vita<strong>food</strong>s Europe<br />

Informa Exhibitions,<br />

5 Howick Place,<br />

Let’s meet here<br />

London SW1P 1WG,<br />

Great Britain<br />

Tel.: +44 20 337 73111<br />

www.vita<strong>food</strong>s.eu.com<br />

30 November-2 December<br />

Frankfurt, Germany<br />

Food ingredients Europe<br />

Informa Markets<br />

Let’s meet here<br />

PO Box 12740, de Entree 73,<br />

Toren A, 1100 AS Amsterdam Zuid Oost,<br />

The Netherlands<br />

Tel.: +31-20-409 9544<br />

Fax: +31-20-363 2616<br />

www.ubm.com<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong><br />


Last Page<br />

Advertiser’s Index • April <strong>2021</strong><br />

Key No. Page Company Location<br />

99307 9 BENEO GmbH Mannheim, Germany<br />

99907 21 Daxner Bulk Solids <strong>Technology</strong> Wels, Austria<br />

100101 15 Emsland-Stärke GmbH Emlichheim, Germany<br />

99601 4 European Snack Association Brussels, Belgium<br />

97065 5 fairtrade GmbH & Co. KG Heidelberg, Germany<br />

99749 33 GEA Food Solutions Bakel, The Netherlands<br />

99896 22,23 Gerhard Schubert GmbH Crailsheim, Germany<br />

100167 Cover 2 Institute of Food Technologists Chicago, IL, USA<br />

99937 29 Jaudt Dosiertechnik Augsburg, Germany<br />

99510 25 Pavan S.p.A. Galliera Veneta, Italy<br />

99030 19 Schaaf Technologie GmbH Bad Camberg, Germany<br />

99677 37 Thorwesten Vent GmbH Beckum, Germany<br />

99412 Cover 4 URSCHEL Chesterton, IN, USA<br />

99290 31 VEGA Grieshaber KG Schiltach, Germany<br />

99333 27 WENGER Manufacturing, Inc. Sabetha, KS, USA<br />

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

something should be not quite right.<br />


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PREVIEW • JUNE <strong>2021</strong><br />

Dairy Production<br />

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Packaging Meat<br />

Events Updates<br />

… and lots more<br />

42 <strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • April <strong>2021</strong>

Vol. 35 • 31377<br />

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