food Marketing & Technology 3/2021

3/21 

Vol. 35 • 31377 

ISSN 0932-2744 

Cover: Steam Generation 

for Dairy Processing 

Next Level in Chocolate 

Production 

The Right Balance for 

Perfect Noodles 

Digital Technology and 

Sustainable Solutions

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Key No. 100167

Editorial 

The Challenge to Plant-Based Products 

The trend to plant-based products is still 

relatively small, but is certainly growing. 

Products are sprouting up everywhere 

as consumers rethink and outthink their 

own motivations. Supermarkets are 

making space to try and keep up with 

their customers. Sustainable reasons 

are very honourable. Reasons of animal 

welfare are also plausible. So how far 

will the journey go and what are the 

obstacles on the way? 

For most people eating meat is still the 

normal state and they are not prepared 

to let others dictate to them. The other 

extreme is a complete rejection of all 

things beef, pork, chicken and co. And 

others still are in between, liking the 

taste and texure of meat, but plagued 

with a guilty conscience. 

A reduction in meat consumption may 

be one solution. If it is a question of 

taste, some people would rather pay 

a little more and source local better 

quality products so if they eat meat, 

then it should be good meat and not 

highly processed cheap product or a 

substitute that may taste similar, but 

often does not. The majority, however, 

are still influenced by the price over 

other aspects. Nevertheless there is 

a growth in vegetarian and vegan 

options. 

The Vegetarian Butcher is a Dutch 

company founded in Den Haag ten 

years ago by Jaap Korteweg. He uses 

a soya base to recreate the taste and 

sensory experience of meat, but with 

benefits for the planet and animals. 

The motto here is not to replace meat 

as such, but to move forwards and see 

plant-based products as the new meat. 

The traditional craftsman started with 

the aim of creating delicious food. The 

move to plant-based nutrition is seen as 

a natural progression. 

Part of the problem and maybe the 

biggest challenge is that plant-based 

products do taste differently to meatbased 

ones. For those used to a certain 

texture and flavour, a vegetarian or 

vegan version of a meat product is not the 

same. Perhaps it really is better to design 

and produce original products made 

completely of meat-free ingredients 

Does it have to be one or the other? 

An option which has also been talked 

about, possibly referring to exhibition 

parlance, is a hybrid product. This means 

that some meat is replaced by plant 

Ian Healey 

Editor-in-Chief 

protein in a product. The idea is that 

the texture and mouthfeel benefits are 

improved, but the environmental gains 

are also retained. However experts are 

not convinced that this is more than 

the worst case, since all consumers are 

equally unhappy. 

When our children were small, we gave 

them the best food we could, as any 

parent would do. Sometimes there was 

more meat, sometimes more vegetables 

or a combination. Even today, we try 

to have a balance. That’s our choice. 

We respect that others may choose 

differently and they too should find the 

best they can. One thing is for sure: the 

novelty of plant-based “meat” is giving 

way to the reality of it and that’s not at 

all bad. 

Sincerely, 

If you like it – subscribe! 

food Marketing & Technology • June 2021 

3 

food Marketing & Technology • June 2021

International Magazine June 2020 ISSN 2628-5851 

Technology & Marketing 

your easy way to stay updated 

2/20 

International Magazine October 2019 ISSN 2628-5851 


2/19 

xxx 

Contents 

food Marketing & Technology June 2021 

1 Editorial 

50 Impressum 

Ingredients 

Ingredients: Hydrocolloids in Pet Food, Acacia Gum's Versatility, Antioxidants 

Processing: Optical Sorting, Gentle Cooling, Removing Risks in Food Safety 

Ingredients Blueberries, Fiber, Seafood, Microencapsulation 

Processing Extrusion, Pumping and Dosing, Pellet Production 

Packaging Flexible Wet Packaging and Sleeving, Pouches for Treats 

Marketing Showcase India, Interzoo 2020 Preview 

FREE trial issue at food@harnisch.com 

Packaging: Pouches and Printing, Sustainability, Choosing the Right Bags 

Marketing: Ask the Vet, Company News, Updates From the Fairs 

9 Straddling the Equator for Reliable Raw Material 

Sourcing and Production 

12 “Next-Level” PGPR for Chocolate Launched 

13 Flavors Designed by Nature: Kombucha Nutrition Trend 

14 New Mood Support Patent for Saffron Extract 

15 Fat and Oils: Targeting the Positive Nutrition Trend 

16 No to Food Waste: Avoiding Economic and Ecological 

Damage by Saving Food 

PetFood PRO magazine 

wants to emphasize the 

high level of quality and 

care in the production 

of pet food through the 

choice of ingredients, the 

choice of technology and 

the choice of packaging 

materials. 

International Magazine April 2020 ISSN 2628-5851 

1/20 



1/19 

Recycling is 

teamwork 

Processing 

6 Decentralized Generation of Electricity and Steam – 

Berchtesgadener Land Dairy takes Matters into its own Hands 

18 Fast service from Gear Specialist Ensures Continued Roll 

Production at Fine Lady Bakeries 

20 “Cherry Time!” for Smoking and Barbecue 

22 Quality is a Nice Feeling Unilever Chooses Checkweighers 

24 Bulk Bag Discharger Ups Efficiency of Cocoa Powder line 

26 Continuously Operating Ploughshare Mixer 

27 The Right Dough Temperature Every Time 

30 Firm, Chewy, and Bouncy: GEA Strikes the Right Balance for 


32 Chicory Root Cutter CRC200 

Packaging 

33 Packaging Equipment 

34 Case Study – P.E. Labellers & Sani Trasporti 

36 Digital Technology and Sustainable Solutions: That’s How 

You Reach Generation YZ 

38 A State of Readiness 

40 325 years of paper “Made in Flensburg” 

42 How to Make Three out of Two – More Sustainable 

Packaging of Deli Products 

44 From Nice-to-Have to Must-Have: Tenyears of PROVALIN 

Ingredients Indispensable Fatty Acids, Dietary Fiber for Pets, Yeast 

Processing HPP Technology, Extruding Fish Feed, Encapsulation 

Packaging Canning, Recyclable Bags, Cartons 

Marketing The Vet's Corner, News from Fairs and Firms 

Ingredients Joint Health & Mobility, Yeast Extracts, Fiber 

Processing Batch & Continuous Mixing, Optical Sorting, Extrusion 

www.harnisch.com 

Packaging Pouches, Bags & Sacks, Tubs, Coding 

Departments 

46 Kerry Releases Webinar on Food Safety Challenges with 

Plant-based Meats 

48 FACHPACK 2021: Ready to go! 

49 Calendar of Events

Vol. 35 • 31377 

ISSN 0932-2744 




Production 



3/21 


Sustainable Solutions 

Cover: Endress+Hauser 

In order to process the raw milk that it 

receives, Berchtesgadener Land Dairy 

requires considerable amounts of 

electricity and steam, such as for the heat 

treatment system, for pasteurization 

or for the CIP system. The company has 

been generating vast quantities of the 

energy it needs with its own in-house 

system since 2016. For the measurement 

instrumentation, Berchtesgadener Land 

relies for over 25 years on the partnership 

with Endress+Hauser. 

Our Cover Story starts on page 6. 

GROW 

YOUR 

BUSINESS 

Ingredients: Chocolate Production 

PGPR (polyglycerol polyricinoleate) is used in chocolate production 

for mould optimization, flow control and viscosity reduction. 

Palsgaard’s existing product, Palsgaard(r) PGPR 4150, is already 

the market leader, but the company’s latest offering takes PGPR 

performance to new levels. See the full story on page 12 

fairtrade 

agrofood 

food + bev tec 

process & packaging 

ingredients 

bakery & confectionery 

Trade show dates 

Processing: Perfect Noodles 

Companies today are increasingly focused on healthier types of 

noodle, launching gluten-free, MSG-free, lowsalt and low-fat 

products, or noodles made using wheat, oats as well as healthier 

and fresher ingredients, with the inclusion of more vegetables 

or ground meat. GEA designs and installs turnkey process lines 

tailored to customers’ specific needs. They take care of every 

detail and aspect of noodle production. See page 30 

Iran 22 - 25 

Sept. 2021 

Ethiopia 14 – 16 

Oct. 2021 

Nigeria 26 - 28 

Oct. 2021 

Iraq 24 – 27 

Nov. 2021 

Tehran 

www.iran-foodbevtec.com 

www.iran-foodingredients.com 

Addis Ababa 

www.agrofood-ethiopia.com 

Lagos 

www.agrofood-nigeria.com 

Erbil 

www.iraq-agrofood.com 

Packaging: Digital Technology 

Generation Z and millennials are distinguished by their 

comprehensive understanding of technology and media. They 

seek information about products and companies primarily 

online and are inspired to make purchases on social media. 

New forms of advertising therefore need to be used to attract 

the attention of representatives of generation YZ. Find out 

more on page 36 

Show contacts at fairtrade Messe GmbH & Co. KG 

Iran / Iraq shows: Mr Paul März 

Tel.: +49 62 21 45 65 13 • p.maerz@fairtrade-messe.de 

Ethiopia show: Ms Dariah Pfaff 

Tel.: +49 62 21 45 65 21 • d.pfaff@fairtrade-messe.de 

Nigeria show: Ms Freyja Detjen 

Tel.: +49 62 21 45 65 19 • f.detjen@fairtrade-messe.de 

www.fairtrade-messe.de 

Key No. 97065 

food Marketing & Technology • February 2016

Cover Story 

Decentralized Generation of Electricity 

and Steam – Berchtesgadener Land Dairy 

takes Matters into its own Hands 

In order to process the raw milk that it receives, Berchtesgadener Land Dairy requires considerable amounts 

of electricity and steam, such as for the heat treatment system, for pasteurization or for the CIP (cleaning 

in place) system. Because it maintains a consistent focus on sustainability across all areas, the company 

has been generating vast quantities of the energy it needs with its own in-house system since 2016. A gas 

turbine engine, which operates at more than 90 efficiency, supplies steam, covers in excess of 50 percent 

of the dairy’s electricity needs and as a result helps the company reduce its CO 2 

footprint and conserve 

resources. For the measurement instrumentation, Berchtesgadener Land meanwhile relies on the more than 

25 year partnership with Endress+Hauser. 

by Florian Kraftschik 

“To sterilize the 148 storage, 

sterilization and butter ageing tanks, 

steam is injected over a longer period 

of time,” says Florian Lexhaller, head 

engineer at the dairy. Large quantities 

of steam are also used for the process 

control technology. On average the 

dairy utilizes 7 to 8 tons of steam per 

hour, with up to 10 tons during peak 

periods. 

Because the production of steam 

consumes large amounts of energy, 

and given that the steam boilers were 

getting on in years, management saw 

significant savings potential in the 

area of energy consumption and CO 2 

emissions. 

Gas turbine for energy and steam 

production 

Instead of drawing energy from the 

public grid for the plant technology 

and the production of steam, the idea 

was for the dairy to generate its own 

electricity and produce steam from 

residual heat. The advantage of this 

solution is that energy production can 

be designed more efficiently. Since the 

plant uses both electricity and steam, 

this solution leads to a more reliable 

energy supply system while significantly 

reducing the risk of downtime. 

Berchtesgadener Land worked 

together with a plant engineering 

partner to carry-out the retrofit while 

the plant was still in operation. The 1.6 

MW gas turbine from Kawasaki, which 

was connected to the dairy’s network 

in 2016, produces around half of the 

plant’s electricity needs. The residual 

heat from the turbine is then diverted 

to a recovery boiler that generates 

5 tons of steam per hour. The steam 

production is supplemented by two 

peak-load boilers from Bosch, each of 

which can generate 10 tons of steam 

per hour at a pressure of 10 bar. 

Low-temperature heating for 

further efficiency improvements 

As if that were not enough, the residual 

heat is then used for a warm water 

system containing a 200,000-liter buffer 

The steam is transported throughout the entire 

dairy operation with a piping system. 

Vortex flowmeters and steam computers: the steam measurement instruments differ from those used 

for the milk production process. 

6 


Cover Story 

tank. This so-called low-temperature 

heating system will eventually be used 

for all of the buildings so that building 

heating systems can be deinstalled. 

The CIP systems and the milk heating 

system for curd cheese will also be 

fed by the low-temperature heating 

system. A heating network for the 

entire company has already been 

installed. Using this cascade of heat 

exchangers, the 530 °C turbine exhaust 

will be cooled down to 50 °C before it 

leaves the exhaust pipe. 

More reliable supply of energy 

and steam 

With a peak capacity of 25 tons of 

steam per hour, the dairy is positioned 

to produce twice the amount of steam 

than it currently needs. The aim was 

to be prepared for increased capacity 

in the future while ensuring there is 

a constant supply. If a steam boiler or 

even the gas turbine goes down, the 

plant continues to be supplied with 

steam. Electricity can then be drawn 

from the public grid on short notice to 

keep the plant operational. Because the 

dairy runs completely on steam heat, a 

continuous supply is essential. Without 

steam, production comes to a halt. 

Even if bottlenecks in the public grid 

occur, the gas turbine still generates 

enough electricity to keep important 

systems for cooling the milk and the 

products up and running, thus providing 

another way to significantly reduce the 

risk of production downtime. 

The peak-load tank is a vital part of the redundant design of the energy center. 

expand the gas power plant. The 

installation of a second turbine is also 

conceivable, which would help the 

company take a further step toward 

energy self-sufficiency, although there 

are currently no concrete plans for an 

expansion. 

Measurement technology 

provides additional downtime 

protection 

Florian Lexhaller understands the 

importance of selecting the right 

measurement technology when it 

comes to ensuring that the process 

control system for the milk production, 

the cleaning systems, the energy center 

and the dairy’s energy distribution 

network all operate smoothly. To do 

this he delved deep into the matter, 

becoming intimately familiar with the 

measurement instruments used in the 

plant. New measurement instruments 

are regularly inspected with test 

applications. In addition, the equipment 

specifications list standard types, which 

means the spare instrument inventory 

can be kept lean. “When we install a 

new system, we provide our partners 

exact specifications that outline what 

the instrumentation should look like,” 

reports Lexhaller. “We are satisfied 

with the quality and reliability of the 

instruments from Endress+Hauser,” 

says the chief engineer who adds that 

“the instruments have proven their 

worth, especially when it comes to 

reliability.” 

Favorable conditions 

The location in Piding offered highly 

favorable conditions for the realization 

of the energy center with a gas 

turbine. A high-pressure gas line that 

transports natural gas at a pressure of 

70 bar is located just a short distance 

from Berchtesgadener Land Dairy. A 

reduction station then reduces the 

pressure to 16 bar for the gas turbine. 

The natural gas is supplied in gas form 

by Erdgas Südbayern. 

The location offered the ideal 

conditions for the construction of the 

energy center from a space standpoint 

as well. Since the company was able to 

sufficiently dimension the production 

halls, there is still enough space to 


7

Cover Story 

When the energy center was built, 

instruments were installed that had 

never been used in the plant before, 

such as vortex-based flowmeters and 

steam computers. Here Lexhaller once 

again placed his complete trust in the 

advice and instrumentation layout 

provided by the Endress+Hauser field 

engineer who has been responsible 

for Berchtesgadener Land Dairy for 

more than 10 years. After four years 

of operating the energy center, he 

summed up his experience with a wink 

of the eye and said: “The stuff simply 

works.” 

High degree of automation in the 

energy center 

To optimize the resource efficiency of 

the energy center, the automation 

technology in the plant plays an 

important role. The system can react 

quickly to changes in the operating 

conditions and automatically adapts its 

performance. Through connection of 

the systems, measurement values and 

key energy indicators are continuously 

analyzed and applied by the energy 

management system. One of the key 

components here is the heat computer 

from Endress+Hauser, which features 

a Modbus TCP/IP interface. Lexhaller 

emphasizes that “Endress+Hauser is 

one of the few providers that offer this 

type of transmission link, which allows 

us to send the energy values direct to a 

central SPS and analyze them without 

extensive cabling work. 

Summary: well-aligned system 

with a high degree of efficiency 

The energy center is an important 

building block in Berchtesgadener 

Land’s sustainability strategy. To 

ensure that the system runs stably and 

smoothly, and to be able to achieve 

an efficiency of more than 90 percent, 

the individual components must be 

intertwined and well-aligned to one 

another. The instrumentation from 

Endress+Hauser plays an important 

role in ensuring the quality of the 

dairy products and the reliability of the 

systems. 

With the installation of the gas 

turbine, the dairy is also taking on 

the role of trailblazer when it comes 

The EngyCal RS33 steam computer records the 

amount of steam and the energy flow. 

to decentralized energy provisioning. 

Given that the system can be operated 

efficiently and the availability ensured 

through a redundant design, these 

arguments will certainly lead many 

other companies to one day follow the 

example of the Berchtesgadener Land 

Dairies. 

fmt 

The Author 

Florian Kraftschik is MarCom Manager 

Media Relations, Endress+Hauser Germany 

8 


Ingredients 

Straddling the Equator for Reliable Raw 

Material Sourcing and Production 

With sustainability in mind, BENEO’s broad-based approach to raw material sourcing ensures a secure supply 

chain 

BENEO’s dietary fibers are in greater 

demand than ever before. As 

intestinal health becomes a key issue 

for consumers around the world, the 

industry is responding to the growing 

level of interest with new product 

developments. But when it comes to 

raw materials from Mother Nature, 

the company is playing it safe and 

ensuring, no matter what obstacles 

and weather conditions they face, that 

they can reliably deliver consistently 

high-quality dietary fibers. The 

solution? BENEO is cultivating its 

chicory root on both sides of the 

globe to guarantee a reliable supply 

chain … even in times of crisis. Food 

Marketing & Technology now takes a 

closer look at one of these state-ofthe-art 

facilities at Pemuco in Chile. 

Well positioned for a global 

market 

To address the ongoing requirements 

for the prebiotic dietary fibers inulin 

and oligofructose from chicory root, 

and to ensure raw material security 

for its customers, BENEO opened 

a production site in Chile some 15 

years ago to complement its plant 

in Belgium. Although chicory was 

previously hardly grown in the region, 

the company has since become 

an integral part of the Chilean 

agricultural sector and is setting new 

standards in terms of sustainability. 

For BENEO, the plant in Pemuco, Chile, 

offers a decisive strategic advantage. 

With two locations on different sides 

of the equator, security of supply 

for international customers has 

significantly increased. Just like sugar 

beet, chicory is a seasonal crop that is 

harvested in the fall. The move to the 

southern hemisphere was therefore 

crucial to ensure the availability of 

raw materials — even during extreme 

climatic conditions. As the harvest 

season in Chile usually runs from 

March until the end of June, BENEO 

can process chicory roots twice a year, 

allowing much greater flexibility 

to respond to changing customer 

requirements in a fast-moving market. 

But, production in Chile offers even 

more advantages; owing to the high 

intensity of sunlight, the on-site 

photosynthetic capacity is extremely 

high, which benefits both quality and 

yield. In addition, frosts are very rare 

and, even during the day, it does not 

get too hot. In fact, the cultivation 

conditions are very similar to Central 

Europe in terms of temperature 

extremes. 

In addition, as BENEO serves a global 

market with its natural dietary fibers, 

the distances from Central Europe to 

some customers — such as those in 

Southeast Asia or the West Coast of 

the U. S. — are correspondingly long. 

The Pemuco location facilitates more 

efficient transportation, thus reducing 

costs, distances and CO 2 

emissions. 

Last but not least, Chile is the country 

with the highest number of free 

trade agreements (FTAs) worldwide. 

There are 26 agreements in place 

with a total of 62 economies, which 

generate almost 90% of the world’s 

gross domestic product. Accordingly, 

the South American country offers 

highly interesting access to a variety 

of markets. 

Challenging soil 

Around 250 employees now work for 

BENEO in Pemuco, 200 in production 

and administration and about 50 

in agriculture. Depending on the 


9

Ingredients 

year, the company co-operates with 

120–180 farmers and positions itself 

as a local service provider for them. 

For example, 100% of the seeds are 

supplied by BENEO and the company 

machines around 60% of the total 

cultivated area before and after 

sowing on behalf of the farmers. 

This also applies to mechanical 

weed control. In fact, harvesting 

and transport are done entirely and 

exclusively by the organisation. 

One of the major challenges in Chile 

is the soil and its composition. On the 

one hand, it can be very stony, which 

requires a good separation processing 

— both in the field and the factory — 

and, on the other hand, heavy rainfall 

regularly puts the drainage capacity of 

the soils to the test. For the harvesting 

machines to be able to access the 

fields, even during extreme rainfall, 

the harvesting sequence needs to be 

well planned and organized. All the 

fields are therefore classified by BENEO 

according to their drainage capacity. 

For example, particularly sandy soils 

are only harvested at the end of the 

campaign. And, when awarding 

contracts for the coming year to the 

farmers, care is taken to ensure that 

the necessary area is available on soil 

that drains well. As a rule, BENEO 

relies on a four-year rotation cycle 

using crops such as corn, quinoa, chia 

and buckwheat to maintain soil health 

in the long-term. Existing fallow land 

is also used as flowering areas to 

promote biodiversity. 

Tablets in the field 

Owing to the generally good climatic 

conditions, however, Chile also suffers 

from prolific weed growth. To win the 

race between cultivated crops and 

wildflowers, sowing, gap closure and 

weed control must be timed accurately. 

Whether by satellite, airplane or drone, 

BENEO makes great efforts in Chile to 

obtain the most precise information 

possible about the condition of its 

fields. With crop care and protection 

top of mind, the primary aim is to 

be able to work as accurately as 

possible. With the aid of soil sensors, 

water use and nutrient requirements 

of the plants are recorded and can 

be analysed over time. Using an app, 

farmers can also be directed to those 

parts of a field where growth is below 

10 food Marketing & Technology • June 2021

Ingredients 

average. In the future, it should also 

be possible to digitally identify weeds, 

so that even more targeted control 

measures can be taken. 

Further investment into 

sustainability 

At its plant in Pemuco, BENEO 

not only produces inulin and 

oligofructose, it also processes certain 

solid and liquid co-products that are 

used as mineral fertilizers or as feed 

products. The energy required for all 

these processes comes from a biomass 

boiler, which was commissioned in 

2015. Because there is a lot of wood 

and pulp industry in the region, the 

use of biomass is particularly fitting; 

BENEO actually uses the residual 

wood from local sawmills as a source 

of energy for its own combined heatpower 

plant. 

“We have switched the site’s energy 

supply to non-fossil fuels as far as 

possible. Around 80% of our total 

annual energy need comes from 

renewable sources and we plan to 

expand this in the future to further 

reduce our carbon footprint,” 

comments Christoph Boettger, 

Member of the Executive Board of 

BENEO. “In order to ensure continously 

a reliable supply chain in future we are 

investing more than € 50 million in the 

expansion of our Chilean site. This will 

enable us to increase our production 

capacity by 20% worldwide by 2022, 

he went on to say.” 

Projekt2_Layout 1 05.03.2021 13:23 Seite 1 

COLOUR 

For extra boost! 

The state-of-the-art plant in Pemuco 

is an equally important location for 

BENEO. In recent years, the company 

has established itself as a good 

employer and social partner in the 

region. For example, BENEO has been 

holding a competition for business 

start-ups for some time. Every year, 

this competition supports several 

micro-enterprises with knowledge 

and financial contributions. BENEO 

also takes care of the next generation 

of farmers. A dual training program 

has been initiated with local schools, 

and the first class has recently 

graduated. As such, BENEO is making 

an important contribution to leading 

the agricultural sector in Chile into a 

successful future with bright minds. fmt 

food Marketing & Technology 

Key No. 99993

Ingredients 

“Next-Level” PGPR for 

Chocolate Launched 

Palsgaard has launched a new PGPR product which offers chocolate manufacturers the best ever levels of 

functionality and efficiency. 

PGPR (polyglycerol polyricinoleate) is 

used in chocolate production for mould 

optimization, flow control and viscosity 

reduction. Palsgaard’s existing product, 

Palsgaard ® PGPR 4150, is already the 

market leader, but the company’s latest 

offering takes PGPR performance to 

new levels. 

Developed exclusively for chocolate, 

Palsgaard ® PGPR 4190 is 15% more 

efficient at controlling viscosity than 

Palsgaard ® PGPR 4150, and can be used 

at a dose 30-40% lower than other 

PGPRs, making it highly cost-effective. 

Other benefits include easier flow, better 

coating of inclusions, and taste- and 

odour-neutrality. Palsgaard ® PGPR 4190 

will be subject to Palsgaard’s unique 

quality standards, with batch-to-batch 

checks guaranteeing uniform stability. 

Morten Hoffmann Kyed, Director of 

Product Management at Palsgaard, said: 

“We’ve led the market for many years, 

but this really is the next level for PGPR. 

Palsgaard ® PGPR 4190 is the result of 

years of research and innovation, and 

it will offer chocolate manufacturers 

unique, best-in-class functionality. 

Furthermore, because a tiny drop 

delivers a huge effect, its benefits also 

include very high cost-in-use savings.” 


Ingredients 

Palsgaard ® PGPR 4190 is designed 

for chocolate spreads and enrobed 

and moulded products. Although it 

works well with traditional chocolate 

emulsifier lecithin, it is an ideal partner 

for Palsgaard ® AMP 4455, an alternative 

to lecithin with better organoleptic 

properties. Both products were 

showcased at the World Confectionery 

Conference on 1st June. 

The result of intensive research at 

Palsgaard’s main R&D center in 

Denmark, Palsgaard ® PGPR 4190 

is manufactured in the company’s 

specialist facilities in the Netherlands, 

where all production is CO 2 

-neutral, 

and which have recently undergone 

extensive equipment upgrades. fmt 

Flavors Designed by Nature: 

Kombucha Nutrition Trend 

A family company, Aromatech was 

created in 1987 in France, in Grasse, 

the world capital of aromas and 

fragrances. At the origin of this 

creation, Jacques MARTEL, whose 

son Benoit MARTEL now heads 

the Group with Yvan GRATTAROLA 

and their teams. Its international 

expansion then took it from Africa to 

the Middle East, then to Asia, from 

Thailand to China, via the United 

States. 

It is this entrepreneurial spirit and the 

clever mix of all these flavors from 

elsewhere that have built the world 

of Aromatech: Flavors designed by 

nature. 

terpene and iced tea notes. It will 

bring a touch of delicacy to sweet 

applications such as syrups, yoghurts 

and drinks. Relish this flavor full of 

sweetness in an alcohol-free cocktail 

recipe made with 0.18% liquid 

Kombucha flavor. 

Aromatech develops aromas specially 

formulated for alcoholic or nonalcoholic 

drinks, available in liquids, 

emulsions, solvents, powders (for 

instant drinks) atomized or granulated 

depending on the applications and 

manufacturing constraints. 

fmt 

Kombucha is a slightly acidic fermented 

drink made from a culture 

of bacteria and yeast inserted into 

a sweet infusion made from black 

tea. The Kombucha flavor, created 

by Aromatech Thailand, responds 

to the growing trend of consuming 

probiotic-based products. 

Its organoleptic profile is mainly 

characterized by sweet, flowery, fruity, 


13

Ingredients 

New Mood Support Patent 

for Saffron Extract 

Affron earns the exclusive right in the United States to the formulation and use of its saffron extract in 

connection with low mood support 

Affron ® , Pharmactive Biotech Products, 

SL’s flagship saffron extract, has been 

awarded a US patent for its proven 

positive role in low mood support. This 

patent serves as an official recognition 

of the company’s unique process in the 

formulation of affron and its ability 

to assist individuals with low mood 

related issues. 

The new patent essentially protects the 

proprietary composition and dosages of 

affron that renders it uniquely effective 

as a natural mood-support agent. “This 

new accreditation marks a momentous 

milestone for affron as it positions it 

as a leading-edge formulation at the 

forefront of the US cognitive health 

category,” enthuses Marguerite 

Gerritsen, Managing Director for 

Pharmactive. 

Pharmactive’s saffron ingredient is 

based on an all-natural and lowenergy 

consumption extraction 

process of saffron (Crocus sativus L.). 

Affron is manufactured using a unique 

proprietary AFF ® ON Cool-Tech activessaver 

extraction procedure, which 

is specifically designed to optimize 

the preservation and concentration 

of the key active ingredients with 

minimal industrial processing, without 

chemicals, and minimal energy 

use. Pharmactive has scientifically 

demonstrated its formulation’s 

fast-acting capabilities and high 

bioavailability in a pharmacokinetics 

study. It has a proven the lowest dose 

threshold on the market at just 28mg 

per day. 

Affron is standardized to a high 

concentration of crocins and safranals 

— the carotenoid pigments responsible 

for saffron’s bioactivity, crimson color, 

and prized organoleptic qualities. This 

is verified by means of HPLC (highperformance 

liquid chromatography). 

While saffron has a centuries-old 

reputation for health benefits in 

traditional medicine, the high efficacy 

of Pharmactive’s extract is supported 

by half a dozen clinical studies 

demonstrating a positive effect on 

multiple aspects of mental well-being, 

earning it a solid reputation as an 

all-encompassing cognitive ingredient. 

The research has highlighted affron’s 

manifold potentials for, relieving stress, 

improving mood, inducing positive 

feelings, and enhancing sleep quality. It 

is also the first commercial extract that 

has clinically demonstrated capacity to 

raise teens’ spirits. 

“Affron’s mood-enhancement capabilities 

are owed largely to its role 

in the inhibition of the reuptake 

of mood-related neurotransmitters, 

according to the broader spectrum of 

scientific literature,” informs Alberto 

Espinel, Head of Strategic R&D in Active 

and Functional Natural Ingredients for 

Pharmactive. “Affron possesses a potent 

antioxidant and anti-inflammatory 

impact. This capacity not only balances 

levels of key neurotransmitters, such 

as serotonin and dopamine, but also 

fights the oxidative stress that stress 

produces in the brain.” 

Pharmactive’s patent request specifically 

delineated the effective dose 

and appropriate concentrations of 

safranal and crocin compounds in the 

final extract as a critical condition for 

exerting a positive effect on disorders 

related to mood. 

To overcome the common hurdles 

experienced by saffron formulators 

in extracting the best of the active 

substances from the stigmas of 

this highly revered and priceless 

botanical, Pharmactive introduced an 

improved step in separating the active 

substances. Their extraction technique 

is based solely on water resulting in an 

ingredient that is clean of any solvents 

or alcohols. 

The patent is paralleled with a new 

“Informed Ingredient” certification 

mark, and in recognition of the safety 

profile and high-quality credentials 

of affron. This is in addition to 

affron’s previously earned strongbox 

of quality and safety seals awarded 

by internationally accredited 

bodies, including EU Organic, DNA 

certification (True-ID) confirming 

the authenticity of its botanicals, 

Doping-free, Kosher, Halal, etc. 

Affron is manufactured in a GMPcertified 

installation, complying also 

with ISO22000 (for its food safety 

management), ISO9001 (for its quality 

management) and ISO 14001 (for its 

commitment to environmental values). 

Pharmactive is also the official adopter 

of saffron by the American Botanical 

Council’s Adopt-an-Herb botanical 

research and education program, as 

industry leaders in saffron extracts. 

“Pharmactive is able to provide 

nutraceutical and pharma industry 

players with a truly effective, wholly 

trustworthy botanical alternative for 

use in connection with low mood 

related issues,” concludes Gerritsen. “It 

also ensures our position as the ideal 

partner for the US market for natural, 

botanical mood help.” 

fmt 


Ingredients 

Fat and Oils: Targeting the Positive 

Nutrition Trend 

Consumers are taking a proactive approach to health maintenance and are actively looking to improve their 

diets. Whilst doing this, they are taking a broader approach to what constitutes healthy eating and drinking. 

Indeed, focus is no longer associated just on avoidance and moderation but instead, ensuring that they have 

ingredients in their diets that offer a health boost beyond basic nutrition. This is something that the fats and 

oils industry needs to respond to, educating consumers about how “good” fats are something that can help 

address issues such as heart health and immunity 

Over the last twelve months, consumers 

have become more conscious about 

their health. For instance, in 2020 a 

total of 57% of consumers said that 

they deemed themselves vulnerable to 

disease and illness – compared to 38% 

who said this a year before. At the 

same time, satisfaction with immune 

health declined from 54% to 49% over 

the same period. This is due to the 

impact of the pandemic. Originally, 

concerns about the virus was about 

vulnerability to it, especially when less 

was known about how deadly it was. 

However over the last twelve months, 

consumers have had chance to reevaluate 

and have taken a broader 

approach to health, recognizing that 

even if they were not necessarily 

vulnerable to problems arising from 

COVID-19, they were at risk of other 

long-term health problems. This is 

due to consumers recognizing that 

their dietary habits are not as healthy 

as they could be. As such, they are 

wanting to take a proactive approach 

to health maintenance – with 76% 

saying that they plan to eat and drink 

more healthily over the last twelve 

months. 

As consumers take a proactive 

approach to health maintenance, they 

are focusing more on the concept of 

positive nutrition. This means that 

consumers are not associating dieting 

with avoidance and moderation in 

order to lose weight but instead, 

believing that if they adopt a well 

balanced diet, they will be able to 

improve all aspects of their health. The 

focus on this means that ingredientled 

claims are becoming more 

influential on purchasing behavior, 

with consumers wanting to see active 

ingredient and claims on products 

that offer a health boost beyond basic 

nutrition. Although it is important 

to not over-estimate consumer 

awareness of fats, they do recognize 

that some in moderation and part of 

a balanced diet can have a positive 

impact on health. For instance, 42% of 

consumers associate monounsaturated 

fats with having a positive impact 

on health, whilst 39% say this for 

polyunsaturated fat. Meanwhile, 47% 

of consumers say that they are prone 

to looking for these ingredients on 

product packaging. Over the last 

couple of decades, sugar has replaced 

fat as the number one dietary evil in 

the eyes of the consumer, and this 

research shows that consumers believe 

that fats, in moderation, can have a 

positive impact on health. 

“Good” fats such as monounsaturated 

fats and polyunsaturated fats can have 

a variety of benefits, such as helping 

aid with weight loss, improving heart 

health and boosting overall immunity. 

These areas of health are important to 

consumers. For instance, FMCG Gurus 

research shows that in 2020, a total of 

70% of consumers say that they have 

looked to make changes to their diets 

and lifestyles to improve their immune 

health – compared to 53% who said 

this a year earlier. Meanwhile, 65% in 

the same year said that they wanted 

to improve their heart health. Finally, 

in 2021, a total of 34% of consumers 

said that they were on a diet to lose 

weight (around a ten percent increase 

compared to when the survey was 

run three years earlier). The focus on 

health maintenance reflects the extent 

that COVID-19 has had on consumer 

attitudes to health, as more focus is 

placed on disease maintenance than 

ever before. 

Given that many consumers believe 

that there will be future waves of 

the virus and one in five believe that 

it is something that will impact on 

daily lives for several years, increased 

concern about vulnerability to disease 

will remain for some time. At the 

same, it is important to recognize that 

even before the pandemic, consumers 

were not conscious about their health, 

and were focusing on trying to stay 

fit and active until as late in life as 

possible. This is something that the 

fat and oils industry needs to respond 

to, educating consumers about the 

benefits of products and highlighting 

the benefits these ingredients have 

when consumed in moderation and as 

part of a balanced diet. At the same 

time, it is important that brands are 

not seen to be making exaggerated 

or misleading claims around these 

benefits. 

fmt 


15

Ingredients 

No to Food Waste: Avoiding Economic 

and Ecological Damage by Saving Food 

● More than 1.6 billion tons of food are wasted annually 

● $660 billion in economic losses due to waste of food raw materials 

● $356 billion global market volume of raw materials for food production 

The statistics are bleak. Out of them 

came an inspiration to change 

something. LEROMA’s philosophy is 

to act in a sustainable and economical 

way, because everyone has to play 

their part in this process to make a 

positive contribution. 

LEROMA GmbH, from Düsseldorf, 

Germany have set themselves the goal 

of combating the problem of food 

waste and the lack of transparency 

in the market. They have developed 

a B2B portal for food raw materials 

because they have recognized that 

food industry players need efficient 

raw material sourcing. LEROMA’s 

unique selling point is the specific 

filters that can be set differently 

for each product. In addition, the 

appropriate certificates are available 

for each raw material, which provide 

information about the quality of the 

product. 

Raw material suppliers can advertise 

their raw materials on LEROMA. 

This way, a comprehensive raw 

material database is created, which is 

constantly expanded with each new 

partner. Food manufacturers benefit 

from the platform, where they can 

easily find the raw materials they 

need and their suppliers. 

In addition, the Surplus Exchange has 

been developed, where companies 

simply offer to the market residual 

items, surpluses and remaining stocks 

of raw materials that have been 

incorrectly purchased or can no longer 

be processed, instead of disposing of 

them. In this way, there is an active 

contribution to reducing food waste 

and a step forward to sustainability. 

Examples of projects and cooperation 

so far include tomatoes processed 

into sauce, since they were no longer 

physically attractive, rice being made 

into rice protein and extracts being 

won from dried plants. Generally 

speaking, vegetables and fruits can be 

made into powder to add a delicious 

aroma in specific meals. It is also 

possible to make oil from e.g. apple 

cores and omega-3 capsules from fish 

skins. 

Other options include processing 

surplus food to cosmetics, cleaning 

materials or even use as paint balls. 

The only limit is the imagination! fmt 


Ingredients 

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IN LOOK, TASTE AND NUTRITION. 

For meat analog and extender production, 

rely on the pioneer of the process for textured 

vegetable proteins by extrusion. Wenger began 

the worldwide initiative over 50 years ago, and 

continues to lead with ever expanding options 

today. 

High moisture meat analogs (HMMAs) produced on 

Wenger twin screw extruders mimic whole muscle 

meat, with similar characteristics for moisture, 

protein and fat contents, as well as a densely 

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After extrusion, HMMAs may be cut, sliced or 

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17

Processing 

Fast service from Gear Specialist 

Ensures Continued Roll Production at 

Fine Lady Bakeries 

When Fine Lady Bakeries, the Banbury based bakery producer, needed to replace a failed gear unit on an 

operationally vital winding drum that needed to put back into production as quickly as possible, they turned 

to the nearby located NORD DRIVESYSTEMS GROUP member – NORD GEAR LTD. In ultra-quick time, NORD 

was able to replace Fine Lady’s failed gear unit with one from its standard range fitted with a specially 

designed and manufactured shaft. 

For many years, Fine Lady has produced 

a wide range of baked goods at its 10 

hectare premises in Oxfordshire, UK. 

Together with a factory in Manchester, 

the company produces millions of 

loaves of bread every week. As well as 

this, it produces various types of rolls as 

well as biscuits and Good Friday “hot 

cross buns”. 

UK Sales Manager - Distribution & End 

Users, at NORD GEAR LTD. “We’re 

located just 30 minutes from the 

Fine Lady site at Banbury. One of our 

engineers immediately visited the 

site to identify the failed gear unit. It 

turned out to be a competitor gear 

unit that had been discontinued for a 

number of years.” 

“In selecting the gear unit we took into 

consideration the maximum output 

torque of the existing unit, which was 

25,000 Nm at 1 rpm output speed,” says 

Paul Martin. “We also had to consider 

that any gear unit we chose could 

withstand the thrust load from the 

carousel, which rested on the gear unit 

as part of the design configuration.” 

The Easter period resulted in a 

considerable production increase 

of “hot cross buns” at Fine Lady. So 

the request for an urgent gear unit 

replacement on its dough proofer 

meant NORD had to act fast. 

“Due to the urgency, it was decided that 

the gear unit failure would be repaired 

so that they could restart production, 

although a long-term solution was 

clearly required,” explains Paul Martin, 

The NORD engineer set about taking 

key dimensions, such as shaft size and 

length, along with how the gear unit 

was mounted to the dough proofer. 

In discussions with the engineering 

team at Fine Lady, it was made clear 

that although there was a degree 

of flexibility in the mounting design 

(as the mounting frame could be reengineered), 

however the shaft size and 

length had to be as per the original gear 

unit in order to suit the drive coupling. 

The MAXXDRIVE industrial gear units from NORD DRIVESYSTEMS offer very high output torques, 

quiet running and a long service life. They are available as helical or bevel gear units 

Image: NORD DRIVESYSTEMS 

Once the thrust load was calculated, 

NORD opted for a gear unit from its 

MAXXDRIVE industrial gear unit series. 

Specifically, a size 8 gear unit was 

chosen, which has a rated torque of 

31,000 Nm and a thrust load capacity of 

140,000 N. 

NORD MAXXDRIVE gear units are 

specially designed for heavy-duty 

applications such as mixers, offering 

high output torques from 15,000 to 

25,000 Nm, along with quiet running 

and long service life. These gear units 

are available as helical or bevel gear 

units, and are equipped with highquality, 

low-friction bearings, and a 

torsionally rigid, one-piece housing. 

“The problem was that for large 

customer specific gear units, delivery 

times can range from 4 weeks for a 

standard model, up to 16 weeks for a 

more complex unit,” states Martin. “In 

addition, the Fine Lady Bakeries’ gear 

unit required a special shaft, which 

had to be specified and designed at 

the NORD headquarters in Germany. 

However, our team pulled out all the 

stops. The design was completed within 

24 hours and a quote, along with 

drawing, was issued to the customer. 

For a unit with a special shaft the usual 

lead time is 12 weeks, but due to the 

urgent nature of the situation at Fine 


Processing 

Robust and powerful The MAXXDRIVE industrial gear units are specially designed for heavy-duty applications such as mixers 

Image: iStock – VladimirGerasimov 

Lady, we managed to reduce delivery 

to under 6 weeks.” 

Keith Holloway, Engineering Buyer at 

Fine Lady Bakeries Ltd, says: “Through 

past experience we knew that rapid 

assistance was needed due to the 

gear unit failure and its age. We 

contacted NORD, who were quick in 

reacting to our predicament. The unit 

was identified and measured within a 

short period, and an order was placed 

for two units, which has been fitted 

to the machine after some framework 

modifications. We’re very happy with 

the service provided and would not 

think twice about using NORD in the 

future.” 

Having made the necessary changes to 

the existing mounting framework, the 

drive is now in operation. The new gear 

unit from NORD not only gives Fine 

Lady the confidence that it can fully 

rely on the local service and support, 

but also that it can depend on a high 

level of productivity. 

fmt 

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Processing 

“Cherry Time!” for Smoking and Barbecue 

With summer fast approaching, 

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whilst offering the perfect smoke 

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fish and even vegetables. 

100% natural smoke of wild cherry 

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Smoking” means 100% natural 

smoke. RÄUCHERGOLD ® cherry is no 

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smoking, it exudes the unmistakable, 

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tree. 

Safety of the known premium product 

quality RÄUCHERGOLD ® proven engineering, 

guarantees smooth plant 

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in our purely mechanical and thermal 

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and no chemicals or artificial additives 

are ever present at any time in 

production. 

The fresh, untreated wood is processed 

without any loss of aroma and is perfectly 

fractionated to enable optimum smoke 

production, suitable for just-in-time, stateof-the-art 

smoking facilities. The HACCP 

certification of RÄUCHERGOLD ® smoking 

chips ensures full compliance with all 

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RÄUCHERGOLD ® cherry wood products 

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fmt 

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industries. You can register for the newsletter at: 

20 food Marketing & Technology • June 2021 

our newsletter free of charge. Receive current 

www.harnisch.com

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21

Processing 

Quality is a Nice Feeling 

Unilever Chooses Checkweighers 

The Unilever company is one of the world’s most important branded goods manufacturers. Each day, 2.5 

billion people use Unilever products. With 400 brands in over 14 categories, no other company touches the 

everyday lives of so many people in so many different ways. The 25 small symbols – tucked away in the 

logo – show the company’s numerous business areas. Production ranges from foodstuffs and cosmetics to 

body care, as well as household and fabric care, products. The company has 161,000 employees in over 100 

countries around the world. 

Its fundamental principles include 

beneficial relationships with suppliers 

and business partners. So it’s not 

without good reason that the company 

relies on multihead weighers from 

MULTIPOND for weighing a diverse 

range of products. A new type MP- 

36-400-400-C multihead weigher has 

recently been acquired for the site in 

Heilbronn, Germany. Gunter Löffler, 

Project Engineer, justified the decision: 

“The MULTIPOND brand stands for the 

highest level of quality worldwide. Our 

past experience has been all good, and 

so MULTIPOND was our first choice 

from the outset.” 

Thanks to its multi-flexible design, 

the multihead weigher is able to 

gently weigh a highly diverse range 

of products, from mushrooms and 

vegetables to powdered products such 

as instant soup ingredients or ready-touse 

products. 

The system operates based on the 

principle of combining partial 

portions. The product is supplied from 

the top level of a MULTIPOND cross 

head feeder, which in turn feeds the 

multihead weigher. Once at the top 

on the weigher, the product is first 

conveyed to the prefeed hoppers via 

the radially positioned feed trays and 

then to the weigh hoppers below. 

Using the partial portions, a computer 

determines the best combination to 

achieve or come closest to the targeted 

weight. The finished, precisely weighed 

portions are then discharged into the 

the timing hoppers via the two outlets 

and finally to the floor-mounted form 

fill seal machine. Maximum accuracy 

and availability are ensured by the 

calibration systems integrated into 

each proprietary load cell. MULTIPOND 

is the only manufacturer of multihead 

weighers anywhere in the world that 

offers this solution. The system works 

fully-automatically, continuously and 

without production interruption. 

The target weight is up to 70 g, the 

achieved mean value, the decisive 

criterion for the existing giveaway, 

actually corresponding to the target 

weight to be achieved. 

Due to the output potential of the 

downstream packaging machine, the 

weigher runs with an output of up 

to 220 weighings per minute. The 

28-head weigher originally offered by 

MULTIPOND would have been adequate. 

However, Unilever had already 

considered future plans in the machine 

design, hence the decision for a 36-head 

weigher. In the long-term, the packaging 

machine is also to be replaced to be able 

to utilize the full output potential of 240 

packs per minute. 

Because the product is changed several 

times a day, it is vital that all productcarrying 

parts can be removed quickly 

and easily without tools for cleaning and 

maintenance. 

The systems are controlled and operated 

using a convenient color touchscreen 

monitor. Easy-to-use controls make 

working with the systems uncomplicated. 

According to the employees, learning 

to operate the machines is quick and 

unproblematic - an important criterion 

for Unilever. 

Photos: Multipond 

Simple operation, precise weigher 

results and faster speeds create an ideal 

platform for further optimizing the 

company’s processes. The weigher was 

designed to allow special dust enclosures 

to be retrofitted at anytime. During the 

weighing process, products such as soup 

ingredients, powder or granulates in 

particular whirl up a huge amount of 

dust, and this collects on the units. 

According to Gunter Löffler, Project 

Engineer, the cooperation between 


Packaging 

Unilever and MULTIPOND is incredibly 

smooth: “Having solutions that are 

tailored exactly to the conditions 

and requirements of our production 

facility is extremely important to 

us. That’s how we know we are in 

the right hands with MULTIPOND. 

Ultimately, the conditions differ 

from product to product. In case of 

problems, we contact the specialists 

at MULTIPOND and get the perfect 

solution within the shortest possible 

response time.” 

MULTIPOND has been an ownermanaged 

German company since the 

very beginning. Drawing on more 

than 70 years’ experience in industrial 

weighing technology, we are a pioneer 

in this sector. Our success 

is based on the high quality and 

excellent technical standard of our 

weighing systems. We consciously 

commit to a high level of vertical 

integration, as well as production 

focus has become our corporate 

maxim. A team of more than 300 

employees commits worldwide to 

offer our customers from the food 

and non-food sectors optimized, 

unique solutions tailored exactly 

to their requirements at all times. 

Sales, project planning and service 

are handled by the headquarters in 

Germany, by the four subsidiaries in 

France, the Netherlands, England and 

the USA, and by a worldwide network 

of agents. 

exclusively in Germany. Customer fmt 

STARCH IS LIKE 

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food Marketing & Technology • June 2021 23 

zeppelin-systems.com

Processing 

Bulk Bag Discharger Ups Efficiency of 

Cocoa Powder line 

From locally grown cocoa 

beans, Singapore-listed JB Cocoa 

manufactures and markets cocoa 

butter, cocoa powder and cocoa 

mass. Located 30 km from the port 

of Surabaya in the province of East 

Java, Indonesia, JB Cocoa’s facility can 

process 50,000 tonnes of cocoa beans 

annually. 

The beans are cleaned, roasted and 

winnowed to separate the cocoa nibs, 

which are treated to enhance flavor 

and color. The nibs are then ground 

into cocoa liquor, which is squeezed 

by a “butter press” to yield cocoa 

butter used in making chocolate, and 

crumbled cocoa “presscake” that is 

pulverized into cocoa powder. 

A portion of the presscake is shipped 

directly to customers in 1 tonne bulk 

bags, but most is processed into cocoa 

powder and packaged in handheld 

sacks. 

Rapid discharging from bulk bags 

dust-free 

To increase efficiency of the cocoa 

powder line, the plant installed a 

installed a Flexicon BULK-OUT ® BFC- 

C-X bulk bag discharger to handle 

loose cocoa presscake being put in 

storage before being reduced to 

powder and packaged for customers 

The discharger is configured with an 

electric hoist and trolley that ride on 

a cantilevered I-beam, allowing bulk 

bags to be loaded into the frame 

without the need for a forklift. 

To connect a bag, the operator slips 

the bag straps into four Z-Clip strap 

holders of a bag lifting frame, and 

Photos: Flexicon 


Processing 

uses a pendant to hoist the bag into 

the discharger frame. A Tele-Tube 

telescoping tube pneumatically raises 

a Spout-Lock clamp ring, allowing 

an operator to make a high-integrity 

sealed connection between the clean 

side of the bag spout and the clean 

side of the equipment. 

With the bag spout secured, the 

operator pulls its drawstring, allowing 

presscake to discharge into the surge 

hopper. 

Releasing the telescoping tube’s air 

pressure allows the clamp ring to 

maintain constant downward tension 

by gravity as the bag empties and 

elongates to promote material flow. 

Additional flow promotion is provided 

by Flow-Flexer bag activators that 

raise and lower opposite sides of the 

bag bottom to promote complete 

discharge through the bag spout. 

The 226 l capacity surge hopper with 

top-mounted enclosure is vented to a 

side-mounted Bag-Vac dust collector 

that creates negative pressure within 

the sealed system to prevent displaced 

air and dust from escaping into the 

plant environment. 

The enclosure also serves to contain 

spillage that might otherwise escape 

through seams in the bag and folds 

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25

Processing 

in the spout, and is equipped with a 

hinged access door and folding bag 

shelf, allowing manual dumping of 

under-filled sacks. 

A rotary valve at the hopper outlet 

metres the presscake into a pneumatic 

conveying line that moves it to a 

storage silo. From there, it is mixed 

and milled into six different recipes of 

cocoa powder and packed into 25 kg 

bags. 

Achieving plant hygiene and 

efficiency 

Constructed of stainless steel finished 

to sanitary standards, the discharger 

is certified for operation in foodgrade 

environments. “The use of the 

Flexicon bulk bag discharger provides 

a safe and hygienic way to unload 

cocoa cake from bulk bags.” said JB 

Cocoa’s Redi Koerniawan. “It ensures 

efficient unloading with little to no 

dust released into the processing 

environment.” 

fmt 

Continuously Operating 

Ploughshare Mixer 

Lödige Process Technology developed a process engineering solution for the production of monocalcium 

phosphate (MCP). The powder, which is an essential component of feed and phosphate fertilizers, can thus 

be produced economically in an “all-in-one” process. 

Monocalcium phosphate (MCP) 

is formed by the reaction of pure 

phosphoric acid and calcium carbonate. 

Powerful process technology is just 

as important to the production of 

high-quality MCP as the quality of 

the raw materials used. Lödige offers 

a solution that is specially designed 

for this application, based on a type 

KM Ploughshare Mixer for continuous 

operation. 

Ploughshare Mixer with 

application-specific design 

The Ploughshare Mixer for continuous 

operation uses the mechanically 

generated fluid bed system that was 

introduced to mixing technology by 

Lödige: Ploughshare shovels in their 

basic shape patented by Lödige in 1949 

rotate close to the walls of a horizontal, 

cylindrical drum. The circumference 

speed and geometric shape of these 

plough-like mixing tools are designed 

so that they pick up the raw materials 

for the mixture completely and throw 

them into the free mixing compartment. 

During this process, the material is lifted 

off the drum wall against the centrifugal 

force. This generates a mechanical 

fluid bed, in which the entire product 

mixture is constantly gripped, resulting 

in extremely thorough mixing, even 

with high mixture throughput and short 

retention times. The mixing elements 

are shaped to ensure product transport. 

Additional choppers in the mixing drum 

break up agglomerated material and 

permit systematic granulation during 

the mixing process. 

The result is a continuous “all-in-one” 

process. This means all process phases 

of MCP production can be performed 

in a single machine. Other units and 

process steps are no longer necessary. 

Moreover, the mixer offers great 

stability and minimized cleaning 

intervals. A special wear protection 

shields mixing tools and shovel arms 

against the high mechanical and 

corrosive stress caused by contact with 

the mixture. 

Production process 

The MCP production process has 

three phases: mixing – reaction – 


Lödige offers a solution for the production of MCP, based on a type KM Ploughshare Mixer 

for continuous operation. (Source: Lödige) 

granulation. In the first step, the two 

base materials, phosphoric acid and 

calcium carbonate, are mixed to form 

a highly homogeneous substance. 

In the second phase of the process, 

an exothermic reaction is produced 

under defined conditions, resulting 

in a conversion of the base materials 

into monocalcium phosphate. This 

is followed by granulation in phase 

3. The granulate properties can be 

adapted specifically to the customer’s 

requirements. The final process 

step, granulation, offers a variety of 

advantages over ungranulated MCP: 

It improves the pourability of the 

substance and makes transport and 

storage easier. It allows the product 

to be packaged dust-free and permits 

perfect dosing. 

A variety of different machine sizes 

is available for throughput rates in a 

range from 1t/h to 50t/h. 

fmt 

The Right Dough 

Temperature Every Time 

For an optimal and more importantly, a reproducible baking result, 

the basic conditions must remain constant. The temperature of the 

dough, which is particularly influenced by the raw materials (flour and 

water), plays an important role in this respect. For this purpose, the 

Pneumotherm batch process for flour cooling offers economical use. 

by Andreas Hofmann 

Industrial bakeries produce a wide range 

of baked goods made from different 

types of dough. To ensure that the 

baked goods are always of consistent 

quality, doughs should have a certain 

target temperature after kneading. This 

is best achieved if the flour and liquids 

are tempered evenly before processing. 

Especially when different types of 

flour are stored in outdoor silos, they 

must first be brought to the correct 

temperature before processing. 

water temperature + flour temperature 

+ thermal geating from kneading = dough temperature 

2 


Key No. 100286

Processing 

Determining the optimum dough 

temperature 

For wheat-based doughs, such as those 

produced with a dough yield of TA165, 

an optimum dough temperature of 

approx. 24-26°C is needed. The water 

temperature normally used for this 

purpose (tap water temperature) is 

10-12°C and the flour being used is at 

20°C. With standard intensive kneaders, 

a high amount of energy is introduced 

into the dough, so that a large part of 

the mechanical energy is converted into 

thermal energy, resulting in a heating 

of the dough by 8-10°C. Many bakers 

use a very simple formula to quickly 

calculate the dough temperature: 

12˚C + 20˚C 

2 

The temperature determined in this 

way is approx. 26 °C and is in the range 

of the optimum dough temperature for 

wheat-based doughs. 

Unfortunately, the flour temperature is 

often not at the optimal temperature 

of 20°C mentioned here. Frequently, 

especially in the summer months in 

Central Europe or in Mediterranean 

countries in general, this temperature 

is greatly exceeded and can even 

reach 40°C in some cases. This effect 

results from the fact that the ambient 

temperature is very warm and the flour 

is transported long distances in tankers 

to the bakery. Moreover, the flour 

heats up during storage in uninsulated 

silos, which are directly exposed to the 

sun. In such cases, not even the use 

of ice water at 2°C is sufficient, which 

the above-mentioned baker’s formula 

demonstrates when converted to the 

temperature values. 

2˚C + 40˚C 

2 

+ 10˚C=26˚C 

+ 10˚C=31˚C 

The dough temperature of 31°C 

calculated here is much too high for 

wheat-based dough. The dough, and 

consequently the baked goods would 

not meet the desired quality criteria 

and would have to be discarded. For this 

reason, many customers warmer regions 

of the world use the Pneumotherm 

batch process for flour cooling, which 

allows the flour temperature to be 

cooled down quickly and easily. For use 

with special doughs, such as doughnuts, 

Flour cooling function diagram 

where the individual portions are deepfrozen 

after the fermentation time, 

the maximum dough temperature 

should not exceed 16°C. Here, the 

optimum dough temperature can only 

be achieved with the help of ice water 

(2°C) and a flour temperature of 8°C. 

In general it can be said that 

fluctuating and excessively high dough 

temperatures create a sticky dough 

that is difficult to process and can lead 

to undesired baking results. The dough 

does not rise evenly and the product will 

vary in size. The different sizes may lead 

to breakage in the packaging plant. 

Cooling process for flours 

The most popular cooling methods 

include lowering the dough 

temperature with ice, liquid nitrogen 

or cold laminar air flows. The process 

using ice shavings or flaked ice has 

hygienic disadvantages; it is also 

difficult to regulate. Also, very often 

the flour is cooled with liquid carbon 

dioxide before entering the kneading 

machine. However, the process is 

considered relatively cost-intensive. 

This is why Zeppelin developed the 

Pneumotherm batch process, which has 

now proven itself in many applications 

worldwide. For many years, it was 

mainly used in warmer regions, such as 

the Middle East, Asia, Southeast Asia or 

South America, as well as Italy or Spain. 

Increasingly, however, there are also 

plants in Germany. Due to fluctuating 

temperatures in the external storage 

silos during the transition from day 

to night, differences of more than 10 

degrees can arise. Also, in plants with 

external silos, temperatures of more 

than 30 degrees can easily be reached in 

the summer, dropping sharply at night. 

How does it work? 

In the Pneumotherm batch process, a 

certain amount of flour is cooled from 

an inlet temperature to the desired end 

temperature (usually 15°C) in a defined 

time (e.g. 10 minutes). This is done with 

the aid of a built-in fluidized bed. The 

flour is weighed in a pre-container and 

transferred from there to the tempering 

container. Cold air is then blown in from 

below through the mixer to create a 

fluidized bed. This leads to an optimal 

mixing of flour particles and cold 

fluidizing air. This air is compressed by 

a fan, cooled in a heat exchanger and 

returned to the tempering tank. The 

fluidizing air is circulated until the 

desired final temperature of the flour 

is reached. The process used minimizes 

dust pollution of the surroundings 

and the process is independent of 

fluctuating ambient conditions. After 

tempering, the flour is either directly 

pneumatically conveyed into the target 

container or discharged into a secondary 


Performance examples depending on the desired inlet and outlet temperature 

container so that a temporal decoupling 

of the downstream systems can be 

achieved. A new batch is requested via 

the secondary container in automatic 

mode as soon as there is enough space 

for a new batch. For systems that 

require a low flour temperature down 

to 5°C, Zeppelin offers special versions 

featuring a cooling circuit with dual 

heat exchangers. 

Fast, hygienic and flexible process 

Thanks to our years of experience 

with these fluidized bed vessels, we 

can guarantee exact software-based 

design, providing reliable operation. 

The advantages are precise temperature 

control, low operating costs, a proven 

process and a long service life. The 

ongoing operating costs and the 

environmental impact are low in contrast 

to CO 2 

cooling, as only electricity and 

cooling water are required. 

At the same time the fluidized bed process 

is very hygienic. There are no fittings, so 

the tank is very easy to clean. Furthermore, 

since the heat transfer occurs directly 

from the particle to the gas and not via 

cooling surfaces, there is no condensation 

inside the tempering vessel. 

A further advantage is that the 

Pneumotherm batch process adapts 

to sudden load changes by switching 

downstream lines on and off by 

interrupting the cooler refill and does 

not have to be started up and shut 

down as in continuously operating 

systems. This means that changing the 

type of flour is no problem - only one 

system is needed for different products, 

which are then transported to separate 

downstream containers or lines. This 

makes it possible to react flexibly to all 

eventualities in production. 

Conclusion 

The Pneumotherm batch process for 

cooling flours from approx. 30° to 

16° - 20°C has proven itself around the 

globe for decades. It is no longer used 

only in tropical countries, but is also of 

interest for plants in Europe. Along with 

reduced energy use and low operating 

costs, the process leads above all to 

a uniform baking result and thus to 

better baked goods. Zeppelin currently 

offers four modular sizes, allowing a 

precise response to a wide range of 

requirements from a few hundred kg up 

to 3 - 4 t/h cooling capacity at different 

inlet and outlet temperatures. fmt 

The Author 

Andreas Hofmann is General Manager Process 

Technology at Zeppelin Systems GmbH 

Flour cooling system for the capacity 

of 3.000 kg/h 

(inlet t = 35˚C; outlet t = 15˚C 


Key No. 100286 

29

Processing 

Firm, Chewy, and Bouncy: GEA Strikes 

the Right Balance for Perfect Noodles 

GEA offers turnkey solutions for the noodle processing industry 

The origin of noodles – now one of the 

best-loved traditional foods in Asia and 

elsewhere – dates back to ancient times. 

They are an extremely versatile product, 

which can be combined with a wide 

variety of ingredients and adapted to a 

variety of recipes and cooking methods 

to suit different eating habits: boiled 

in salted water, fried or stir-fried in a 

wok, and then served with meat, fish, 

or vegetables. 

Companies today are increasingly 

focused on healthier types of noodle, 

launching gluten-free, MSG-free, lowsalt 

and low-fat products, or noodles 

made using wheat, oats as well as 

healthier and fresher ingredients, 

with the inclusion of more vegetables 

or ground meat. GEA designs and 

installs turnkey process lines tailored to 

customers’ specific needs. Its expertise 

enables the company to optimize each 

production step, taking care of every 

detail and aspect of noodle production. 

The processing technologies developed 

focus on the noodles’ unique taste and 

texture. As a result, GEA’s technology 

experts have encapsulated an eating 

tradition going back thousands 

of years in a high-quality and fully 

versatile product that is suitable for any 

preparation method or recipe. 

“We pay great attention to hygiene and 

safety aspects. All of our lines are CE, 

ATEX, and MOCA certified. In addition, 

our process lines are designed to last 

and require minimal intervention. Built 

using durable materials, the machines 

are designed to simplify maintenance 

and prevent product deposits. Thanks 

to their high degree of automation, 

GEA machines maximize efficiency 

and ensure consistent quality,” explain 

Davide di Nunno, R&D Director and 

Nico Scattola, Sales Area Manager. 

The right mix 

GEA supplies a wide range of machinery 

from standalone components to fully 

integrated solution lines. Everything 

starts with the right mix of components. 

GEA’s high-capacity continuous dough 

mixers can be equipped with various 

optional devices, including gravimetric 

dosing units as well as multiple liquid 

ingredients/additives dosing, fast premixing, 

semi-automatic washing, and 

CIP systems. 

The perfect shape: sheeted or 

extruded 

Noodles can be produced in the form of 

round nests, square cakes, or in multiplelayer 

bundles. They are made either by 

passing the dough through sheeting 

rollers and then cutting the flattened 

dough using slitting rollers. Alternatively, 

they are extruded using a special 

continuous press where the dough passes 

through an extrusion die, allowing the 

formation of all kinds of noodles. 

Photos: GEA 

Multiple lamination units with automatic 

gauging control systems laminate 

the dough to obtain sheets of the right 

thickness. Four to five lamination rolls 

are then arranged in a row to thin the 

dough step by step. 

The GEA xTru Cooker is the best choice 

for producing all-cereal gelatinized 


Processing 

noodles through a continuous, 

automatic, and reliable process with 

little operator intervention required. 

This model is a six stages single screw 

low shear cooking-extruder. Instead of 

applying traditional pressurized batch 

cookers, there is the option of using 

native raw flours and cooking in a 

continuous extrusion cooker. This will 

drastically reduce raw material costs and 

ensure precise control of all parameters, 

resulting in an excellent and consistent 

product. This specific application is 

the result of GEA’s experience in the 

production of continuous cooking 

extruders, achieved through more 

than four decades at the forefront of 

cooking extrusion processes. 

Creating a noodle nest 

Located at the end of the extruder, 

the nesting machine is one of the 

most distinctive parts of the noodle 

production line. The well-designed 

headpiece of the GEA xTru extruder 

regulates the flow pressure, ensuring 

the extruded product flows evenly 

over the entire die surface. The dough 

is then equally distributed when 

inserted into the die. This guarantees 

that a homogeneous product with 

precise shape and weight enters the 

nesting machine. The nesting machine 

is composed of two cutting units – an 

upper and a lower unit – equipped with 

rotary blades and fixed counter blades 

that continuously cut the extruded 

product and precisely define its length 

thanks to the adjustment system. Once 

cut, the product is conveyed into the 

forming tubes where a powerful jet 

of compressed air controlled by the 

pneumatic system gives the nest its 

final shape. 

After that, the nest is unloaded 

onto the forming cups, which are 

then conveyed on a belt to the heat 

treatment area. Attention to hygiene 

and cleanliness is a prominent feature 

of all of the machinery that makes 

up GEA production lines. The nesting 

machine is no exception: Made of 

stainless steel, it is equipped with a 

waste recovery system that optimizes 

production while at the same time 

ensuring ease of cleaning. 

Thermal treatment 

Further thermal treatments include 

high-performance steaming units as 

well as fast or super-fast, medium, or 

high temperature continuous dryers. 

These were developed based on our 

experience with dry pasta and are 

suitable for the production of lowfat 

noodles. Drying is an important, 

smooth, and stable process, with gentle 

variations depending on the product 

and ambient conditions. Generating 

the right specific microclimate is 

the key to guaranteeing the most 

efficient drying profile with the lowest 

energy consumption, thus reducing 

the machine’s energy footprint. The 

keywords for GEA’s thermal treatments 

are: hygienic execution and easy 

maintenance, proper insulation, active 

thermal control (ventilation flow, 

correct temperature profile), full 

parameter control, cleaning, energy 

efficiency, and low TCO. 

fmt 


31

Processing 

Chicory Root Cutter CRC200 

With the chicory root cutter CRC200, KRONEN GmbH offers a new type of solution specially developed for 

processing chicory. The cutting machine removes the root and separates it from the product in just one 

processing step and with a capacity of up to 80 pieces per minute. 

The specific construction adapted 

to the shape of the chicory enables 

efficient, automated processing with 

a clean cutting result. The design of 

the cutting machine aims at a high 

level of work safety and ergonomic 

operation. The interior of the CRC200 

is accessible via a large hood, so 

that easy cleaning and hygiene are 

ensured. 

Operation of the chicory root 

cutter CRC200 

The chicory is manually inserted 

into the product holders on the 

entry chain and then automatically 

transported, while remaining in the 

optimal position, to the subsequent 

cutting process. After the cut, the 

separated root falls directly into the 

waste chute and the chicory as a good 

product is carried out of the machine 

on the discharge belt. 

The speed of the product entry is 

adjustable and enables adaptation to 

different production requirements with 

a capacity for processing between 40 to 

80 chicories per minute. The CRC200 

processes chicory with a maximum 

length of the good product of 200 mm. 

Optionally, the CRC200 can be 

equipped with nozzles for automatic 

cleaning of the discharge belt, the 

entry chain and the knife. The nozzles 

spray the inside of the machine during 

the production process. The cutting 

The CRC200 is specially adapted to the processing of chicory and removes the roots in an 

automated cutting process 

The chicory is placed in the product 

holders of the entry chain and fixed. The 

chain transports the product to the knife 

machine can be supplemented with a 

waste belt to transport the cut roots. 

Benefits of CRC200: 

• High processing capacity: The CRC200 

processes up to 4,800 chicories per 

hour. In just one work step, the 

root is cut off from the product and 

discharged separately so that the 

chicory can then be packaged. 

• Optimal cut quality: The product 

holders on the entry chain ensure 

that the chicory is transported to 

the knife in its fixed position, thus 

enabling a clean cut. 

• Ergonomics and work safety: When 

designing the machine, the focus was 

not only on optimal cutting results 

and hygiene, but also on ergonomic 

and safe operation. 

fmt 


Packaging 

Meat Packaging Equipment 

but the wrong choice for another firm 

with different requirements. To make a 

proper match one must first understand 

the differences between the two types of 

equipment, then one can decide which 

equipment best satisfies the firm’s needs. 

Ronnie P. Cons is CEO of C&C Packing Inc., leading 

Canadian meat and poultry distributor 

Buying the right or wrong meat packaging 

equipment can spell the difference 

between an efficient and profitable 

meat packaging firm and a non-efficient 

one that has varied production, and 

efficiency issues. The right equipment 

for a given firm will be determined by 

many varied elements including; the size 

of the food processing and packaging 

company, its needs, their budget, the 

performance output needed, future 

growth expectations and type of product 

to be packaged. All these factors and 

more must be taken into consideration 

in order to make the right decision. A 

wrong decision can be very costly, thus 

an informed decision is essential. I should 

add that the number and variety of 

equipment on the market makes the 

decision making process a complex one, 

thus guidance is very important. For 

example, a meat packaging firm must 

decide whether to purchase FFS or Tray 

sealing packaging equipment. 

FFS stands for Form, Fill, Seal packaging 

and uses rolls of film that are Formed 

with the use of heat into pouches or 

containers. The pouch is then Filled with 

the food item and then heat is used to 

cover and Seal film to the top of the 

pouch. Tray sealing instead uses already 

bought trays that are filled with the food 

item. Film with the use of heat is then 

used to cover and seal the container. 

Which system is better? 

As mentioned above, the right 

equipment for any firm depends on the 

company and its requirements. Thus FFS 

may be the right choice for one company 

FFS or Form, Fill and Seal packaging 

provides the following advantages over 

Tray seal packaging: 

• More flexibility in package size and 

package shape. 

• FFS allows for the rapid programming 

of various package shapes including 

packaging for bulky products. 

• Higher packaging output due to 

the fact that the production process 

includes the package production in 

the same line. 

• Lower package costs partly due the 

reason just explained in #2 above. 

While Tray seal packaging has the 

advantage of usually offering higher 

product protection due to the sturdier 

seal. Some will argue that they are also 

more leak proof. 

Both allow for MAP (modified atmosphere 

packaging); gas flushing and 

many other features that are shared by 

both systems. Different manufacturers 

of these packaging machines may have a 

different focus. For instance one firm may 

produce a FFS machine that offers higher 

leak proof abilities over its competitors, 

but less efficient MAP abilities. 

It is recommended that the person 

in charge of buying the packaging 

equipment follow the complex decision 

making process below: 

• Analyze and quantify the firms 

objectives. 

• Give a weighted value to each of the 

respective criteria. 

• Invite the chosen vendors to present 

and explain their products. 

• Choose the product that is best suited. 

In summary, a well thought out complex 

decision making protocol as described 

above will result in the purchase of the 

meat packaging equipment that is best 

suited for the firm, resulting in enhanced 

performance and profits. 

fmt 

WHAT 

IS YOUR 

MIXING TASK 

FOR US? 

Your Solution 

Provider for: 

• Mixing 

• Reacting 

• Granulating 

• Coating 

• Drying 

Lödige Process Technology 

Elsener Str. 7-9 

33102 Paderborn 

Germany 

www.loedige.de 

LÖDIGE – ALWAYS 

THE RIGHT MIX 

Key No. 99844 

food Marketing & Technology • June 2021 33

Packaging 

Case Study – P.E. Labellers & Sani 

Trasporti 

When a supplier knows how to solve a problem promptly and efficiently, he wins the customer over. 

When he knows how to anticipate needs and propose differentiated solutions, he becomes a partner to be 

kept close. With PE it was easy to notice this right away. 

P.E. Labellers and Sani Trasporti: the history of a partnership 

Sani Trasporti is inextricably linked 

to the Italian agri-food sector. It is 

a historical company established in 

1950 and that evolved in the various 

generational transitions. Since its 

inception, the company has been 

working alongside important producers 

of canned products, that have been 

responding to logistical needs for the 

distribution of products and, over time, 

also to packaging requirements. This is 

how Sani Trasporti met PE Labellers, a 

leader in the production of automatic 

labeling machines, which are essential 

elements in the packaging process. 

“As it often occurs, an opportunity 

arose from a need” says Ivo Sani, 

owner of the company together with 

the siblings Franco and Giampietro, 

and head of the Packaging section. 

“In 2016, a well-known company of 

preserves that had begun its rise in the 

international food market, expressed 

the need for the excellent labelling of 

its products. My thoughts went to PE 

and I was very satisfied with the choice 

made. First of all this was because 

they showed the ability to react 

and solve the problem immediately, 

thus responding with great timing 

and professionalism”. It was a first 

important test bed, which laid the 

foundations for a solid and lasting 

collaborative relationship. Following 

this experience, Sani purchased the first 

labelling machine from P.E. Labellers, 

one with hot glue technology and an 

optical, label centering system. This 

solution has enriched the packaging 

lines inside company plants. 

“2PE found the solution, immediately”, 

continues Ivo Sani “just as what you 

would like to always happen when 

you face a problem. The benefit was 

immediate for the end customer 

and us. Compared to other suppliers 

of automatic labelling machines 

interviewed, PE has demonstrated 

itself to be of a truly superior level 

of professionalism and knowledge. 

However, this is not just about technical 

skills: the feeling is that of complete 

trust, and of being listened to all the 

time with the same level of attention. 

This is a significant advantage”. 

Today Sani Trasporti is a company that 

attests to its growth in the market, one 

of those excellences in Italy. Since its 

inception, it has reached a fleet of 100 

units, seen employees increase to 150 

loyal people, and expanded its own 

Headquarters with two storage plants 

and two packaging lines. 

What weight do they have and 

what role do PE machines play in 

the company’s production lines? 

“They play a key role, I would say 

- continued Ivo Sani – one doubly 

connected to the final output of the 

packaging process and the yield of 

product packaging. I identify the main 

plus factors in both the high quality 

of the PE labelling machines that 

guarantee perfect labelling solutions, 

and in the business processes aimed at 

quickly solving the production needs to 

be met”. 

34 


Packaging 

Which labelling machines were 

chosen to meet the company’s 

production needs? 

Once again, the packaging needs 

expressed by customers have sealed 

the partnership between Sani 

Trasporti and P.E. Labellers. In 2019 

another important reality in the Dairy 

sector was the labelling of half-kilo tin 

containers, in large volumes and with 

record timing. Also in this case, P.E. 

was able to solve the problem with 

so much speed and skill during the 

first collaboration, that the company 

bought the machine after that. “This 

labeling solution - Ivo Sani explained - is 

an even more advanced machine than 

the previous one, and features three 

stations with adhesive technology 

and the innovative centering system 

of the label on the jar cap. We make it 

work in double shifts, practically with 

nonstop production. When our clients 

see it in operation and become aware 

of the results it brings, they fall in love 

with this PE machine and ask us to use 

it to “dress up” their products in the 

best possible way”. 

Past and current demands: what 

is behind the choice of a product? 

Since 2016 the expectations and goals 

of Healthy Transport have changed, in 

line with production requirements of 

many companies we serve daily. ”In 

short, what we need most today is 

“Flexibility” continues Ivo Sani. What 

really makes the difference is the 

ability to readily adapt to the needs 

of customers from different sectors 

of the Food market. We happen to 

have to respond to ever new requests 

from companies, which raise the bar 

day after day and call for ever higher 

standards of excellence. The beauty of 

P.E. is that it does not compromise, but 

instead provides qualitatively superior 

solutions”. 

The first P.E. machine purchased met 

the need for hot glue labeling (15,000 

BpH) and with adhesive technology 

(12,000 BpH). The second doubles 

the labeling stations, a hot glue and 

three adhesives, with a solution 

that enables superior performance 

reaching 26,000 BpH with hot labeling 

and 24,000 BpH in adhesive stations. 

In this way, the great advantage 

of “nonstop” processing is obtained 

with the application of a label and 

the simultaneous application of the 

guarantee seal. It is a powerful and 

efficient machine, with easy access 

to many format changes. It is as if 

you can say that it has “standardized 

efficiency.” The results are so satisfying 

that Sani is already nurturing the 

idea of having a third P.E. machine 

like this one, to offer its customers 

an increasingly advanced packaging 

service. 

The challenges to be faced and 

the working solution 

If timing is a key element in giving 

decisive answers to customers, it is 

clear how the installation process 

of the labeling machine on the 

production and packaging line should 

be as fluid as possible. How did it go 

with PE? “All the phases of selection, 

production of the machine, testing, 

trial run and installation did not 

have any hitches or slowdowns on 

the schedule we had set ourselves - 

continued Ivo Sani. Even today, just 

pick up the phone and you can be sure 

that the company is ready to respond 

with great efficiency. Expertise 

saves time and solves problems, and 

personally I find that enormously 

beneficial”. 

A changing market, the new 

goals to reach 

The new demands are imposed by a 

market that is increasingly competitive 

and requires today, for example, the 

mixed automated lines to label trays 

with various kinds of products. This 

requirement did not exist years ago 

and today represents a new frontier. 

Automating this process and making 

it available to companies, means 

providing high quality service and 

optimizing processes, as Sani does 

for its customers. And to do that, it 

needs the right suppliers, that is, really 

reliable and “super-flexible” partners. 

The next steps: how to get 

equipped and act in advance 

In 2021 the inauguration of the 

third packaging line in Sani Trasporti 

will probably be seen. It will be one 

more step that the company will take 

with the aim of serving its customers 

with ever-greater efficiency, in line 

with the continuous evolution of 

the food market itself, due to the 

fragmentation of the production 

companies that operate in the world 

of preserves, dairy products, pasta, 

sauces, pesto, food for fitness, etc. 

“It is also thanks to the work of 

companies like P.E. that we have 

come this far - Ivo Sani concludes. We 

are confident that the collaboration 

will continue to maintain the levels of 

professionalism and flexibility that PE 

has accustomed us to, since day one. 

The future will be full of opportunities 

that we are ready to seize”. 

fmt 


Packaging 

Digital Technology and Sustainable 

Solutions: That’s How You Reach 

Generation YZ 

As consumers and future employees, generations Y and Z are the target of marketing and recruiting 

initiatives by the packaging sector. But where and how do you reach out to this generation? 

Marketing experts and recruiters 

are eyeing the generation of young 

people born after 1995 with great 

interest. Known as generation Z or 

digital natives, they succeed the 

previous generation of millennials (or 

generation Y), who have now reached 

adulthood and are of interest to the 

packaging industry both as the next 

generation of leaders and as customers 

with money to spend. What both 

these generations have in common is 

that they have grown up with digital 

media and the internet. In their private 

and professional lives, generations 

Y and Z seek personal fulfilment, 

expect authenticity, and attach great 

importance to ecologically sustainable 

behaviour on the part of brands and 

potential employers alike. 

Their natural affinity with a wide 

range of media helps digital natives to 

exploit new research options, making 

online searches a natural part of 

their information-gathering process. 

Companies that want to engage 

with them therefore need to have a 

presence on various channels and be 

well-versed in their use. 

Discriminating consumers 

Generation Z and millennials are 

distinguished by their comprehensive 

understanding of technology and 

media. They seek information about 

products and companies primarily 

online and are inspired to make 

purchases on social media. New 

forms of advertising therefore need 

to be used to attract the attention of 

representatives of generation YZ. The 

marketing strategies that a company 

deploys should focus on social media 

platforms like YouTube or Instagram, 

which are an integral part of the lives 

of this generation. 

Young people decide within a matter 

of seconds whether content is relevant 

to them or not. This means that 

advertising needs to be memorable and 

convincing. However, this also means 

that packaging design can embrace 

36 


Packaging 

totally new approaches to interaction. 

Linking packaging with interactive 

features to online content has proven 

popular and allows companies to win 

over young consumers with stories 

about the product. Marketing experts 

call this storytelling. 

This can be done on packaging using 

a QR code, for example. Scanning this 

code with a mobile phone takes the 

consumer to a website, social media 

profile or video. Connecting real 

products with digital media makes 

packaging an important intermediary 

for appealing to young consumers. 

Of course, it is then also important to 

meet their demands for authenticity 

and transparency and to design the 

linked information accordingly. Some 

of the presentations by experts in the 

PACKBOX and TECHBOX forums at 

FACHPACK in September will explore 

how packaging can function as an 

interactive communicator. 

However, its affinity with digital media 

is not the only character trait typical 

of the younger generation. Packaging 

companies should be aware that 

the “Fridays for Future” movement 

originated in generation Z. And this 

is also reflected in their purchasing 

decisions. 

“Generation Z embraces a healthy 

lifestyle and cannot imagine a life 

without smartphones. These young 

people have high expectations, so 

products and services need to be fast, 

intuitive, entertaining and sustainable,” 

says Dr Christian Wulff, Leader Retail 

and Consumer at PwC Germany. PwC 

conducted a survey to take a closer 

look at generation Z and found that it 

tries to avoid plastic (37 percent) and 

buys products with as little packaging 

as possible (35 percent). In addition, 

52 percent are willing to pay more 

for organic products, while just under 

half (47 percent) would be prepared to 

spend more on sustainably packaged, 

eco-friendly food. 

But even 18-24-year-olds still like to 

shop in bricks and mortar stores. In fact, 

they visit traditional retailers more 

often than any other age group: 59 

percent of generation Z respondents 

stated that they shopped in physical 

stores at least once a week. 

Recruitment in the digital era 

Potential recruits apply the same 

standards to their choice of future 

employer as they do to their 

consumption. This means that their 

work doesn’t just have to be a way 

of earning a living, it also needs 

to be meaningful and sustainable. 

Generations Y and Z can only be 

enticed to a limited extent with 

promises of company cars and 

financial benefits alone. To find out 

whether their own aspirations are 

compatible with a company’s goals 

they head to the company’s website 

and look at its ratings on employer 

review platforms or social media. This 

means that recruiting departments 

need to be well positioned in the 

digital environment to attract notice 

and to be able to help shape the 

company’s image. Communications 

agency B+P Communications, which 

represents some major companies 

from the packaging sector, has written 

an article that also confirms that 

millennials and generation Z favour 

companies whose culture coincides 

with their own values and aspirations. 

According to B+P, millennials and 

generation Z have a strong need 

for authenticity in the workplace. 

Together with corporate culture, this 

aspect has become synonymous with a 

company’s employer brand. 

However, job advertisements, a 

website and Facebook profile alone 

are not enough to get visibility 

for an employer brand. As well as 

using traditional platforms like Xing 

or LinkedIn, therefore, recruiting 

consultants Vesterling are increasingly 

also having to conduct targeted 

searches on social networks and 

sourcing platforms like Talential, 

Talentwunder or Talentbin. 

The good news for companies in the 

packaging sector is that a successful 

recruitment of generation ZY means 

that your company is also gaining 

the right kind of talent capable of 

reaching out to customers from this 

generation. 

fmt 


Packaging 

A State of Readiness 

Laetitia Durafour, Marketing Director at Crown Food Europe, looks at the growing category of ready meals 

and how metal packaging delivers on quality, convenience, and sustainability 

According to Statista, the revenue 

generated for ready-to-eat meals in 

Europe is $83,849 million USD in 2020, 

with a per capita figure of $98.88 USD 

(up 27.4% y-o-y) . Busy lifestyles are 

driving demand for convenience, and 

with less time to spare, consumers’ 

willingness and opportunities to cook 

from scratch are diminishing. As an 

alternative, they are expecting to 

find high-quality, ready meal options. 

As a result, the market has already 

registered an increased demand for 

premium products that balance great 

ingredients, taste, convenience, and 

sustainability – all in one package. 

Metal packaging has continued to 

deliver on this balance as it has done 

since the first canned products were 

introduced by Nicolas Appert of 

France in 1809. Today, the timeless 

sterilization and sealing process 

continues to be successfully used 

around the world. Testament to this 

is Crown’s most recent media event 

hosted in Appert’s home country, 

France. The aim was to highlight 

the distinct benefits of this versatile 

packaging format for the current 

local ready meals market. 

Having partnered with longstanding 

customer William Saurin – renowned 

French producer of premium ready 

meals for over 100 years – and 2-star 

Michelin chef Olivier Bellin (owner of 

L’Auberge des Glazicks), the event 

spotlighted a new canned ready meal 

concept. Using the finest ingredients, 

the aim is to offer a gourmet 

experience to consumers looking 

for flavor and finesse in their meals, 

packaged in metal to provide a truly 

premium feel to the product. On the 

day of the event, Bellin demonstrated 

the recipes development process and 

guests – had the opportunity to take 

home a canned version of the meal 

they had enjoyed. 

Crucially, the research and 

development had already taken 

place in the William Saurin labs, with 

valuable input from the chef and 

Crown on the packaging side, to 

prove that this premium-level product 

could be scaled up to mass production 

by combining the best ingredients, 

recipe, process, and packaging. The 

metal can features a peelable lid that 

locks in freshness along with a cliptop 

lid, enabling consumers to control 

their own portion sizes and reseal the 

can for future. 

Health and Nutrition: Key 

Market Drivers 

In addition to convenience, a marked 

increase in awareness around health 

and wellness is feeding directly 

into the ready meals market, with 

manufacturers keen to deliver. While 

ready meals may have been associated 

with high fat, sugar, and salt content 

in the past, today the variety of 

healthy, balanced options continues 

to expand thanks to metal packaging. 

The canning process eliminates the 

need for artificial preservatives to 

keep contents fresh, allowing more 

38 


Packaging 

natural, clean products for healthconscious 

consumers. 

The two recipes created by chef Bellin 

– a Duck Pot au Feu and a Glazed 

Carrot dish -- got the seal of approval 

from dietician and nutritionist 

Ysabelle Levasseur, also present at the 

culinary event. Levasseur commented 

both on the nutritional balance of 

the delicious meals, each under 530 

calories. She also noted that enjoying 

canned meals on a regular basis can 

be part of a healthy, balanced diet, 

when consumers leverage the more 

natural products metal packaging 

supports. 

vegan meat alternatives will hit 

$7.5 billion globally by 2025 2 . Metal 

packaging not only makes these 

products available in any season but 

also helps to reduce food waste by 

preserving produce canned at the 

peak of freshness. 

Finally, there are also a wide range of 

canned appetizers and snacks that can 

be opened and served immediately. 

Anchovies in oil or vinegar paired 

with bread, for example, or a 

charcuterie board paired with nuts, 

olives and other finger foods can 

make for a visually appealing, tasty, 

and nutritious spread. 

Metal Packaging Presents 

Endless Meal Possibilities 

The sheer variety of canned ready 

meals available today will leave most 

consumers spoiled for choice—and as 

we have seen from the likes of Duck 

Pot au Feu, full meals can be canned 

and retain their quality. Cassoulet is a 

prime example of a classic French dish 

that has been canned for many years, 

while options such as chilli con carne, 

curries and a wide variety of regional 

casseroles and stews are also popular 

choices. 

Soup – a shelf-stable product that is 

synonymous with metal packaging— 

is also receiving an upgrade. Often 

seen as a seasonal option, soup is now 

becoming a year-round selection that 

caters to different cultural and dietary 

requirements. Vegetable soups are 

incredibly popular, while many 

manufacturers are also looking to the 

cuisines of the world for inspiration. 

Asian, Indian, Middle Eastern and 

Western varieties all rub shoulders 

together in the supermarket aisles, 

and year-on-year, countries such as 

Spain, the Netherlands and Germany 

have seen retail value rises. 

Canned ready-to-eat foods provide 

great flexibility and versatility for 

fast and nutritious meals, and also 

cater to all dietary requirements. 

The rise in popularity of plant-based, 

vegetarian, and flexitarian options, 

for example, has led brands to extend 

their ranges further than ever before. 

It is expected that the market for 

Sustainability: An Increasingly 

Important Factor 

Today’s well-informed consumers are 

not content to merely buy products 

based on ingredients and nutritional 

value alone; they are also conscious of 

making ethical and responsible choices 

around packaging. Here, metal has 

delivered from the outset. The format 

is not only 100%, infinitely recyclable 

without loss of properties but is also 

one of the most recycled materials 

globally. In fact, approximately 80% 

of metal ever produced is still in use 

today, making it a prime example of 

the circular economy at work. 

A great example of this commitment 

to make ongoing use of this precious 

resource can be seen in the Metal 

Recycles Forever campaign, launched 

in 2014 by members of Metal 

Packaging Europe. Its aim is to inform 

and enable consumers to better 

understand the role they have to play 

in keeping metal within the material 

loop and is an initiative that Crown 

and its customers have supported 

from day one. Products such as 

Branston Baked Beans from brand 

owner Princes proudly display the 

logo, which is applicable to all forms 

of metal packaging. 

As a Company, Crown is also 

committed to accelerating its 

own sustainability efforts. In 2016, 

Crown set its first company-wide 

sustainability goals, and as of January 

2020 has achieved its greenhouse gas 

emissions (GHG) reduction target and 

decreased absolute emissions - even 

while seeing significant increases in 

production. 

Sustainability is about protecting the 

environment, but it is also so much 

more. As a result, the rollout of what 

has been named the Twentyby30 

program will be one more exciting 

step in its journey. Twenty measurable 

goals have been implemented with 

the aim to achieve all by the year 

2030, and five pillars of action will 

create the framework to achieve this 

goal. 

They are: 

• Climate Action 

• Resource Efficiency 

• Optimum Circularity 

• Working Together 

• Never Compromise 

In the ready meals sector and beyond, 

through leveraging the precious 

resource that is metal, Crown can 

continue to provide nutrition and 

sustenance to the world in a packaging 

format that is as sustainable as it is 

effective. 

fmt 

1) https://www.statista.com/outlook/40080100/102/readyto-eat-meals/europe 

2) https://healthcareers.co/vegan-statistics/ 


Packaging 

325 years of paper “Made in Flensburg” 

The Mitsubishi HiTec Paper mill in Flensburg is marking its 325th anniversary this year. Founded by Hinrich 

Gultzau in 1696 at “Mühlenstrom” outside the city gates, it stands today for the production of high quality 

thermal, inkjet and barrier papers for flexible packaging. Coated speciality papers from Flensburg are in 

demand all over the world. 

325 years ago: A Papermaker 

comes to Flensburg 

In 1696, the Mecklenburg papermaker 

Hinrich Gultzau came to Flensburg. His 

ambitious plan was to build a paper mill. 

Back then, the city was still struggling to 

recover from the aftermath of the Thirty 

Years’ War. Papermaking also suffered 

severe setbacks during wartime, while 

demand continued to grow. This meant 

that towards the end of the 17th century 

paper was a scarce, valuable commodity. 

The most important condition for 

building a paper mill 325 years ago 

was a suitable watercourse with a 

corresponding natural gradient. At the 

gates of the city, on the “Mühlenstrom”, 

Gultzau found a suitable piece of land. 

After receiving official approval, he was 

allowed to set up a paper mill in front 

of the red gate in Hennings Lundt and 

to live there. The foundation stone for 

today’s paper mill in Flensburg was laid. 

The Flensburg paper mill today 

The Flensburg paper mill from 1830 to 1930 

Industrialization ... Specialization 

... Flexibility 

In the 19th century, industrial paper 

production took off at a rapid pace. 

In the first half of the 19th century, 

all processes, which had up to that 

point been carried out by hand, were 

mechanized. In the second half, new 

raw materials began to be produced 

in special pulp factories. In 1848, the 

first paper machine was installed at the 

current location in Flensburg. In 1954, 

a paper machine for the production of 

hygiene papers was put into operation 

and in 1970 the production of giroform ® 

carbonless papers began. In the early 

1990s, after the license agreement 

with Mitsubishi Paper Mills Ltd. for 

the production of thermal papers was 

signed, the production of thermoscript ® 

thermal papers started. The first 

application was paper for fax machines, 

which was the communication medium 

of choice at the time. 

In the 1990s and 2000s, investments 

were made in new high-tech coating 

processes for the finishing of speciality 

papers. Specialization and increased 

flexibility of the modernized production 

facilities opened the doors for new 

applications and new markets, for 

example, durable thermal paper with a 

topcoat for account statements, thermal 

paper with forgery-proof security 

features for admission tickets and lottery 

tickets, or special thermal paper for the 

ever-growing label sector. As a result 

of new technologies, a new product 

segment was created in Flensburg in 

1998 – high quality coated jetscript ® 

inkjet papers. 

Today the Flensburg mill stands for high 

flexibility, experienced papermakers 

and modern coating technologies. 

Team spirit is particularly important. 

The highly motivated, experienced and 

very well trained workforce works every 

day to fulfil special customer requests 

from all over the world, even in small 

quantities: innovative, individual and 

sustainable. 

Coated Speciality Papers for the 

future 

For a number of years, in addition to the 

markets for thermal and inkjet papers, 

which are still expanding, the Flensburg 

mill has been concentrating on coated 

barrier papers for flexible food and nonfood 

packaging. Climate protection and 

sustainability are the great challenges 

of our time. In addition to reducing 

40 


31377 

Packaging 

packaging and avoiding waste, the focus 

is on topics such as the replacement of 

plastics, the use of sustainable materials, 

and circular economy and recycling. In 

2018 the first barricote ® barrier papers 

were produced in Flensburg. Important 

companies from the food and non-food 

industry, trade and packaging industry 

rely increasingly on the fully recyclable 

and particularly sustainable barrier 

papers made in Flensburg. 

Hinrich Gultzau suspected none of this 

when he brought paper production to 

Flensburg in 1696. He could not foresee 

the challenges and opportunities of 

industrialization, digitization or climate 

protection. But he would be very proud 

of his mill on the Mühlenstrom and 

of the Flensburg speciality paper mill 

of today. And so are we, and of our 

Flensburg team and 325 years of paper 

“made in Flensburg”! 

fmt 

Congratulations 

to the Flensburg mill on its 325 years of existence! 

A brief history of the paper mill in Flensburg: 

1696 Hinrich Gultzau builds the paper mill in Mühlenstromtal 1848 The first paper machine 

1929 Taken over by Feldmühle AG 

1954 New paper machine for sanitary paper 

1970 Production of carbonless papers begins 

1988 Licensed by Mitsubishi Paper Mills Ltd. to make thermal papers 

1990 Business taken over by STORA Group Thermal paper produced for first time 

1992 STORA Feldmühle Spezialpapiere GmbH founded 

1996 Mitsubishi Paper Mills Ltd. and Mitsubishi Corporation become shareholders 

1998 Inkjet paper produced for first time 

1999 Taken over by Mitsubishi Paper Mills Ltd. 

Company name changed to Mitsubishi HiTec Paper Flensburg GmbH 

2003 Coater 2 converted for production of multiple coats 

2004 Biological wastewater purification put into operation 

2007 Conversion of coater 1 

2008 Commissioning of the new power plant 

2010 Merger with the Bielefeld sister company 

New company name: Mitsubishi HiTec Paper Europe GmbH 

2018 Barrier paper produced for first time 

3/21 

Vol. 35 • 

ISSN 0932-2744 

Come and see for yourself: 





Production 





Perfectly positioned. 

The international specialist magazines from Dr. Harnisch Publications 

You can now explore our newly designed website, with a 

clear focus on responsive design and easily usable applications. 

Alongside the free-to-use digital magazine editions, you will 

find bonus news coverage, events, subscription and 

general information on all our magazines. Take a look at 

www.harnisch.com for all relevant content. 

Our publications include: 

- Technology & Marketing - 


Packaging 

How to Make Three out of Two – More 

Sustainable Packaging of Deli Products 

Achieving better climate protection through more sustainable use of resources is a global challenge, but food 

manufacturers have a special responsibility here. Packaging made of plastic protects the product against 

spoilage throughout its entire shelf life, as well as against damage during storage and transport, thus 

ensuring safer and longer- lasting food. The downside: according to the European Commission, citizens in 

Europe produce 25 million tonnes of plastic waste each year. The European Strategy for Plastics in a Circular 

Economy by the European Commission intends to lay the foundation for a new and sustainable plastics 

industry. One of the aims of this strategy is to change the way plastic packaging is handled within the 

European Union. However, there are a number of food applications for which there currently is no suitable 

alternative to plastic. Especially in the segment of delicacies, for example when packaging products such 

as salads, antipasti, seafood, cheese or meat, often only plastic packaging can provide the required product 

safety. The challenge for manufacturers lies in finding functional, yet at the same time more sustainable 

packaging systems that combine ecological and economic aspects. 

In case of deli products, trays with 

reclosable lids are a common sight. This 

packaging system allows for convenient 

handling, safe storage of opened packs 

and excellent protection of the product 

against premature deterioration. Such 

trays are often supplied with a snapon 

lid, in addition to the top film that 

provides the hermetic seal. “This third 

component, however, clearly contradicts 

with the general pursuit for plastic 

reduction”, as Marcel Veenstra, Marketing 

& Communications Manager at Sealpac 

International, explains. SEALPAC, a 

leading global supplier of traysealers 

and thermoformers, as well as innovator 

in packaging technologies, sees itself 

as a pioneer. “For some time now, our 

research and development activities have 

been focused on the optimization of 

conventional packaging systems towards 

more sustainable alternatives, leading to 

innovative solutions such as FlatSkin ® and 

eTray ® . Our developments always follow 

the same premise: they must be technically 

feasible, but also economically viable.” 

EasyLid ® – savings across the 

entire chain 

SEALPAC successfully introduced a whole 

new packaging system several years 

ago, which is now receiving increased 

attention due to the discussion about 

plastic waste: EasyLid ® . The concept, 

developed together with Naber Plastics, 

a well-known injection-moulding 

company in the Netherlands, is suitable 

for modified atmosphere packaging, 

making it ideal for delicacies. In short, 

EasyLid ® is a tray-sealing technology 

SEALPAC’s Easylid ® system 

Sealing and lidding in one single step. 

42 


Packaging 

that enables sealing and lidding in one 

single step, hence creating maximum 

efficiency in the packaging process. 

The system requires special, patented 

trays that, next to the common sealing 

edge, have an additional perforated 

ring. A peelable seal is applied to the 

regular sealing edge, whereas the 

additional ring is hermetically sealed 

in the same process. Upon opening the 

tray for the first time, the lid function is 

automatically activated. This allows the 

consumer to reclose the tray and keep 

its contents fresh during its entire shelf 

life. 

By eliminating the common snap-on 

lid, EasyLid ® is significantly more cost 

efficient and resource saving than 

comparable packaging. This stems 

from a series of benefits. For food 

manufacturers, the investment costs 

are reduced by not requiring a lidding 

system. Furthermore, the groundbreaking 

concept saves on time and 

space in their valuable production area, 

reduces the need for storage capacity 

and minimizes packaging waste. In other 

words, the EasyLid ® concept contributes 

to greater sustainability and efficiency in 

the packaging process: a true innovation 

from every perspective. Recognized 

for its impact on the environment, the 

EasyLid ® system has already been award 

with various international packaging 

prizes. 


Perfectly suitable for modified atmosphere 

packaging of various deli products. 

Improved recyclability, attractive looks 

To produce the EasyLid ® trays, Naber 

Plastics uses 100 percent polypropylene 

(PP). “In doing so, we are following 

the European guidelines on packaging 

materials for protein products, as well 

as the changing requirements of major 

retailers, who are demanding mono 

materials for improved recyclability“, 

as Marcel Veenstra explains. “However, 

a resource-saving use of materials 

and better recyclability of the plastic 

do not have to go at the expense of 

attractiveness.” 

EasyLid ® trays are perfectly suited 

for in-mould labelling (IML). In that 

case, as part of the manufacturing 

process of the tray, a label is included 

that enhances its design possibilities, 

but also provides a higher barrier. 

As the label is fully integrated into 

the polypropylene, it is resistant to 

moist. This is particularly beneficial 

to chilled deli foods, as the label will 

not detach from the tray and a highquality 

appearance is guaranteed. By 

using the same material for the lidding 

film, tray and in-mould label, in this 

case mono PP, easy recycling is made 

possible, as recommended by the 

various packaging guidelines in food 

production. 


In-mould labelling enhances product 

appearance and shelf life. 

The EasyLid ® solution runs on all 

of SEALPAC’s fully automated 

A-series traysealers. Depending on 

the application, outputs of up to 

160 packs per minute are achieved. 

“EasyLid ® is already celebrating 

success across Europe. With hundreds 

of millions of trays produced so far, it 

is an established concept that proved 

itself even before the industry made 

resource-saving production methods 

a priority. As a result of the latest 

market trends, it is now in even 

greater demand, which makes us very 

happy. Because nothing is as powerful 

as coming up with a clever innovation 

at the right time“, Marcel Veenstra 

concludes. 

fmt 


Packaging 

From Nice-to-Have to Must-Have: Ten 

years of PROVALIN ® 

Climate- and environmentally-friendly 

action and a conscious decision in 

favor of sustainable packaging are 

continuing to gain in importance 

as well as form decisive purchasing 

criteria. Environmentally-polluting 

manufacturing and disposal problems 

are to be minimized in the production 

of packaging materials and critical 

components which could migrate from 

them to food or other filled goods are 

to be eliminated. For decades now, 

Actega has been relying on sealant 

compounds which are free of PVC and 

plasticizers for beverage and food 

packaging: since the early 1980s for 

crown caps and aluminum seals, since 

2006 for metal composite seals, 2011 

for Twist-Off ® seals, and 2016 for 

P/T seals. In the form of PROVALIN ® 

and ACTGreen ® PROVALIN ® , the very 

first alternatives without PVC and 

phthalates for the last ones were 

launched onto the market which meet 

strongest EU guidelines and therefore 

guarantee a high degree of food 

safety. Today, PROVALIN ® can look 

back on 10 years of its brand which, 

although it has had to evolve step by 

step, is now definitely characterized by 

success. 

A Review: 

Even if there had long been a demand 

for PVC-free solutions for metal 

vacuum seals and plenty of experience 

had been acquired in-house with 

PVC-free material developments, the 

challenge was to find such a solution 

for Twist-Off ® seals. Unlike PVC-free 

crown corks or aluminum seals, new 

plants would have had to be designed 

especially for these PVC-free seals. The 

classic PVC plastisol machines were not 

suitable for the newly-developed PVCfree 

materials. Here at the latest, it 

was clear that the development would 

involve high investments on the part 

of closure manufacturers and many 

people advised against it at the time. 

This was one of the obstacles which not 

only concerned product development 

but also the environment if it was to 

be a commercial success at all. All the 

same, certainty prevailed that it was 

the solution of the future. Particularly 

for the area of canned food where 

metal vacuum seals are used, the use 

of sealing materials free of PVC and 

plasticizers was of major significance 

on account of the problems associated 

with migration by plasticizers into 

food. This was also reflected in the 

increasingly tight EU and Foodstuffs 

Ordinance. Accordingly, it was obvious 

that by simply tightening the migration 

limits, only systems free of plasticizers 

would be successful over the long term. 

It was imperative, therefore, to protect 

PROVALIN ® technology by registering 

it for patent and an application was 

submitted in 2007. 

44 


Packaging 

With an interested customer (Pano) 

and a purchaser (Dittmann), there was 

a perfect combination available as 

required for launching new products: 

expertise and the requisite plants for 

manufacturing the seals on the one 

hand and a manufacturer of branded 

goods on the other. These initiative 

partners provided the requisite 

technology boost and market pull for 

making such a lengthy and complex 

development a lasting and sustainable 

success. And a contribution was 

also made by the collaboration with 

Actega, Grevenbroich. After all, a 

Twist-Off ® seal not only comprises the 

metal cover and the sealant material 

but also adhesive inside varnishes 

and exterior lacquers. Many different 

raw materials had to be tested first in 

order to establish how the materials 

relate to each other. And the premise 

was also to develop BPA-free materials 

– another challenge, particularly with 

regard to resistance to acidic filling 

goods. These BPA-free adhesive 

varnishes are now available today. 

The material formulations developed 

need to be tested and examined 

extensively, including in terms of their 

processability and function. Initially, 

there was only one laboratory machine 

available which glued the compound 

(today: ring-liner technology) into 

empty shells which were then sent 

to Pano for rolling on before coming 

back to us. Development of a hand 

tool made it possible to shorten 

these lengthy development routes 

somewhat but it was still anything 

but optimal. Today, the Actega team 

can look forward to a new Sacmi 

plant which is to be available within 

2021, making it possible to react even 

faster, more effectively, and more 

targetedly to market requirements. 

What’s more, entire steam-vacuum 

sealing machines and pasteurization 

chambers are also available, enabling 

us to depict the entire closure 

manufacture about bottling, closing, 

heat treatment. Which means it will 

be possible to adapt the PVC-free seals 

to the respective legislation or market 

situation in the years and decades to 

come even faster. Major investments 

and the extensive expertise developed 

as a result, enabling the realization of 

innovative products and top customer 

service, are the keys for long-term 

success. 

The first area of application 

entailed oily products in the area of 

delicatessen products, e.g. pepperonis 

in oil. Practically a niche launch. This 

was soon joined by cold-filled products 

such as cheese cubes in oil which 

represented yet another challenge as 

it entailed filling under cold conditions. 

A new compound had to be developed 

for this application – one which would 

stay tight yet be easy to open after 

storage in the refrigerator. The topic 

of sterilization was also broached at 

an early stage, e.g. as required for 

olives, classic sausages etc. This in 

turn shifted the focus to jar stacking. 

Answers were required concerning the 

sealing results on fast-moving plants 

as well as particularly soft materials 

requiring less steam yet sealing equally 

well. Other requirements arising from 

the market are implemented optimally 

following intensive examination. 

Accordingly, the existing portfolio 

has been steadily improved and will 

continue to be further optimized. 

What started as a niche product is now 

a firm component within the market. 

But this market is constantly in motion. 

New challenges can arise at any time, 

e.g. on the part of the filling industry, 

where the topic of sterilization has 

already been under discussion for 

some time now in terms of increasing 

the temperature to reduce the time 

for sterilization. Or on the part of 

the legislative bodies if, for example, 

materials such as additives in food 

contact are evaluated differently by 

the FDA or the EU or there is a shift in 

migration limits. Or the glass currently 

undergoing a renaissance will be 

replaced by containers made of PET 

or polycarbonate in the future. These 

are all key stimuli for innovations 

and new developments offering 

the filling company benefits such as 

improved handling, more extensive 

areas of application, the elimination 

of unknowns concerning regulations, 

and much more. 

The development has attracted 

a certain degree of attention in 

the market which has also led to 

PROVALIN ® receiving several awards. 

In 2011, PVC-free sealing systems 

in Actega’s Altana division won the 

annual Altana Innovation Award. This 

prize was awarded for PROVALIN ® 

and the corresponding varnish 

systems. Also in 2011, in the “Design 

and Processing” category, the “PVCfree 

cam screw cap Pano Blue Seal 

powered by PROVALIN ® ” received 

the German Packaging Award. The 

heart piece of this seal is formed 

by the PVC-free PROVALIN ® sealing 

compound. This was the first time 

a PVC-free seal was established in 

this market segment. Following a 

development phase extending over 

many years on the complex Press- 

On Twist Off ® seal project and an 

extremely time-intensive test and trial 

time, the SOPURE 51 seal by Pelliconi 

with the PVC-free PROVALIN ® sealing 

compound has been in commercial 

use since early 2018. It received the 

Canmaker Gold Award for the PVCfree 

Press-on Twist-off ® seal for baby 

food within the framework of the Can 

of the Year Award. Since 2020, this 

compound has been offered under 

the name of ACTGreen ® PROVALIN ® 

for better identification as a green 

sealing ring. Now with more than two 

billion twist-off seals per year on the 

European market, the PVC-free seal 

has meanwhile achieved a general 

market penetration. 

fmt 


Marketing 

Kerry Releases Webinar on Food Safety 

Challenges with Plant-based Meats 

Plant-based meats have food protection, preservation and safety challenges that are similar in scope to those 

of animal-based meats. In this webinar entitled The Business of Alt Protein: Unlocking Food Safety in Plantbased 

Meat, Kerry food protection and preservation experts outline the issues and challenges involved in 

protecting the freshness and taste of plant-based meat products through clean label solutions. 

Kerry, the world’s leading taste and 

nutrition company, has released and 

posted online an informative educational 

webinar—entitled The Business of 

Alt Protein: Unlocking Food Safety in 

Plant-based Meat—that delves into the 

exceptional changes being witnessed 

across the food and beverage landscape 

as plant proteins rise to the forefront. 

The webinar can be viewed here. 

Food protection and preservation is 

about protecting and perfecting the 

freshness, taste and safety of foods and 

beverages and this standard applies to 

plant-based meats as much as it does 

to traditional meat. In the webinar, 

attendees will hear food protection 

experts from Kerry Taste & 

Nutrition discuss food safety and 

preservation challenges 

specific to alternative proteins, 

and strategies on how to 

convert those challenges 

into actionable insights 

that maintain safety while 

also protecting taste and 

flavor during the product’s 

shelf life. No additive/ 

preservatives is a top growing 


Marketing 

position positioning for plant-based 

meats globally with the claim being 

featured in 16% of new product launches 

in 2020. Implementing clean label food 

preservation solutions in plant-based 

products that meet consumers’ desires 

for cleaner labels will be discussed in the 

webinar. 

Some of the challenges addressed in the 

webinar include: 

Why food protection in plant-based 

alternatives is important and why 

consumer-friendly ingredients are key. 

When to build food protection into your 

formulations and products to quickly and 

successfully go to market. 

How food protection works, to get your 

products out of the freezer and into the 

refrigerator, ensuring quality throughout 

their shelf life. 

The expert speakers from Kerry include 

Emma Cahill, Strategic Marketing, Food 

Protection & Preservation; Jennifer 

Wasieleski, RD&A Director, Food Protection 

& Preservation; and Renetta Cooper, 

Technical Business Development Director, 

Food Protection & Preservation. fmt 


International Magazine June 2020 ISSN 2628-5851 

2/20 

PetFood PRO magazine wants to 

emphasize the high level of quality 


1/20 

and care in the production of pet food 

through the choice of ingredients, the 

choice of technology and the choice 

Ingredients: Hydrocolloids in Pet Food, Acacia Gum's Versatility, Antioxidants 

Processing: Optical Sorting, Gentle Cooling, Removing Risks in Food Safety 

Packaging: Pouches and Printing, Sustainability, Choosing the Right Bags 

Marketing: Ask the Vet, Company News, Updates From the Fairs 

of packaging materials. 

Ingredients Indispensable Fatty Acids, Dietary Fiber for Pets, Yeast 

Processing HPP Technology, Extruding Fish Feed, Encapsulation 

Packaging Canning, Recyclable Bags, Cartons 

Marketing The Vet's Corner, News from Fairs and Firms 



47

Events 

FACHPACK 2021: Ready to Go! 

Hygiene concept enables safe trade fair attendance 

In its cabinet meeting on May 18, 2021, 

the Bavarian State Government decided 

on further easing of the Corona measures 

and named a clear opening perspective 

for the trade fair industry: if the infection 

situation continues to develop in a 

positive way, the resumption of trade 

fair operations is possible by September 

1, 2021 at the latest. For FACHPACK, 

European Trade Fair for Packaging, 

Technology and Processes, which will 

be held in Nuremberg from September 

28-30, 2021, this decision comes at the 

right time. Almost 800 exhibitors have 

registered and are currently preparing 

their exhibition stands in the nine 

booked exhibition halls. Trade visitors 

are cordially invited to attend FACHPACK 

on site in the exhibition center. A 

comprehensive hygiene concept will 

ensure a safe visit to the trade fair. 

“We welcome the decision of the Bavarian 

State Government, which is taking an 

important and correct step with its 

decision today! The possible restart on 

September 1 gives our customers more 

planning security and perspective for our 

exhibitions in the fall,” says Dr. Roland 

Fleck, CEO of the NürnbergMesse Group. 

And Peter Ottmann, NürnbergMesse 

CEO, adds: “Since the start of the 

Corona pandemic, we have been in 

constant communication with the health 

authorities. Together we have developed 

a comprehensive hygiene concept that 

makes safe exhibition operations possible 

Longing for a real trade show 

experience 

The demand for a meeting place for the 

packaging industry is great. For almost 

two years, the packaging industry has 

not had a trade show where it could 

present itself on site. “Finally meeting 

customers again, presenting innovations 

and exchanging ideas about trends in 

person - that’s what our exhibitors and 

all of us are longing for after the long 

period of deprivation. We are ready. The 

FACHPACK exhibition halls are planned; 

the supporting program is as good as 

ready,” says Heike Slotta, Executive 

Director at NürnbergMesse. 

Hygiene concept: personal 

networking possible 

To guarantee a safe visit to the exhibition, 

extensive protective measures and a 

detailed hygiene concept have been 

developed: Contactless payment, 

booking of online tickets, hand 

disinfection options, a state-of-the-art 

ventilation concept for exhibition halls 

and congress rooms, and traceability 

through digital contact recording via app 

at the exhibition stands are just a few 

examples. So-called community areas 

in the exhibition halls allow personal 

networking while maintaining distance 

regulations. For more information on 

the hygiene concept and protective 

measures in accordance with current 

specifications, visit: www.fachpack.de/ 

protective-measures 

myFACHPACK combines real and 

digital world 

A new feature this year is the digital tool 

myFACHPACK, which offers FACHPACK 

exhibitors the opportunity to extend their 

reach into the digital world. And visitors 

who don’t want to travel to Nuremberg 

can still take part in FACHPACK this way. 

myFACHPACK offers, for example, online 

matchmaking and networking even 

before the show starts, digital additions 

to the product displays on the exhibition 

stands, e.g. through videos, chats or 

virtual meeting rooms, as well as live 

streams of the three forums PACKBOX, 

TECHBOX and the new exhibitor forum 

INNOVATIONBOX. 

About FACHPACK 

FACHPACK (28.–30.9.2021, Nuremberg) 

is the European trade fair for 

packaging, technology, and processes, 

where exhibitors showcase their 

products for the packaging process 

chain for industrial and consumer 

goods. On display will be packaging 

materials, packaging and accessories, 

packaging and bottling machinery, 

labelling, marking and identification 

technology, machines and equipment 

for the packaging periphery, packaging 

printing and finishing systems, 

palletising technology, intralogistics 

and services. With its new slogan: “We 

create the future”, FACHPACK 2021 

will be devoted to the trending topic of 

“environmentally friendly packaging”. 

As the No. 1 gathering for the European 

packaging market, FACHPACK attracts 

trade visitors from all packagingintensive 

sectors like food/drinks, 

pharmaceuticals/medical technology, 

cosmetics, chemicals, automotive, and 

consumer and industrial goods. fmt 


Events 

Q3 2021 

18-21 July 

Chicago, IL, USA 

IFT Food Expo - first Let’s meet here 

Institute of Food Technologists 

252 W. Van Buren, 

Suite 1000, Chicago, IL 60607 

Tel.: +1-312-782-8424 

Fax: +1-312-782-8348 

www.ift.org 

22-25 September 

Tehran, Iran 


fairtrade Messe GmbH & Co. KG 

Kurfürsten Anlage 36, 

69115 Heidelberg, Germany 

Tel.: +49-6221/4565-0 

Fax: +49-6221/4565-25 

info@fairtrade-messe.de 



Las Vegas, NV 

Pack Expo International Let’s meet here 

1451 Dolley Madison Blvd., 

Ste 101 McLean, VA 22101 USA 

Tel.: +1 703 761 2600 

info@fpsa.org 


Nuremberg, Germany 

Fach Pack 

NürnbergMesse GmbH, 

Messezentrum, 

90471 Nuremberg 

Tel.: +49-911-8606-0 

Fax: +49-911-8606-8228 

www.fachpack.de 


Birmingham,UK 

PPMA Show 

New Progress House, 

34 Stafford Road, 

Wallington, Surrey SM6 9AA 

Tel.: +44(0)20 8773 8111 

scott.mckenna@ppma.co.uk 

Let’s meet here 


Q3/4 2021 

14-16 October 

Addis Ababa, Ethiopia 





Tel.: +49-6221/4565-0 

Fax: +49-6221/4565-25 



26-28 October 

Lagos, Nigeria 





Tel.: +49-6221/4565-0 

Fax: +49-6221/4565-25 



24-27 November 

Erbil, Irak 





Tel.: +49-6221/4565-0 

Fax: +49-6221/4565-25 



30 November-2 December 

Frankfurt, Germany 

Food ingredients Europe 

Informa Markets 


PO Box 12740, de Entree 73, 

Toren A, 1100 AS Amsterdam Zuid 

Oost, 

The Netherlands 

Tel.: +31-20-409 9544 

Fax: +31-20-363 2616 

www.ubm.com 

Q3/4 2021 

5-7 October 

Palexpo, Le Grand-Saconnex, Switzerland 

Vitafoods Europe 

Informa Exhibitions, 


5 Howick Place, 

London SW1P 1WG, 

Great Britain 

Tel.: +44 20 337 73111 

www.vitafoods.eu.com 


49

Last Page 

Advertiser’s Index • June 2021 

Key No. Page Company Location 

99864 25 Coperion GmbH Stuttgart, Germany 

96342 21 Endress+Hauser Group Services Reinach, Switzerland 

97065 5 fairtrade GmbH & Co. KG Heidelberg, Germany 

99844 33 Gebrüder Lödige Maschinenbau GmbH Paderborn, Germany 

100286 27, 29 J. Rettenmaier & Söhne GmbH Rosenberg, Germany 

99937 19 Jaudt Dosiertechnik Augsburg, Germany 

99993 11 Ringe + Kuhlmann GmbH & Co. Hamburg, Germany 

99411 Cover 4 URSCHEL Chesterton, IN, USA 

99334 17 WENGER Manufacturing, Inc. Sabetha, KS, USA 

99398 23 Zeppelin Systems GmbH Rödermark, Germany 

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

something should be not quite right. 

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Editorial Team: Bill Kaprelian, Silke Watkins, 

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PREVIEW • AUGUST 2021 

Back to the Fairs 

Bakery Ingredients 

Powder Processing 

Liquid Packaging 

… and lots more 


Vol. 35 • 31377 

ISSN 0932-2744 

3/21 





Production 


Issue 3/2021 



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