food Marketing & Technology 1/2021

InternationalPublications

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

1/21

Vol. 35 • 31377

ISSN 0932-2744

Cover: Steam Peeling

Solutions

Covid Intensifies

Well-Being Interest

Food Extruder in

Hybrid Design

Sustainable Barrier

Packaging


SEPARATION

THE RIGHT INGREDIENTS

FOR YOUR SUCCESS

IN THE FOOD AND

BEVERAGES INDUSTRY

CUTTING-EDGE TECHNOLOGIES, INNOVATIVE

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operations: the technology, the

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solutions.

ANDRITZ AG / Stattegger Str. 18 / 8045 Graz / Austria / andritz.com/separation


Know-how, competence and

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Need to maximize yield from your raw materials? Or improve the purity and the taste

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PROFIT FROM OUR PROCESS KNOW-HOW

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LET’S BE BRILLIANT. TOGETHER!

Ever since our first food research and development test

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CENTRIFUGATION

FILTRATION

BATCH-TYPE

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CONTINUOUS DRYING

Separators

Horizontal

peeler

centrifuges

Vertical peeler

centrifuges

Filter presses

Helix dryers

Fluid bed

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Drum

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Paddle

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Decanters

Pusher

centrifuges

Dynamic

crossflow

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Drum filters

Belt dryers

Drum flakers

Plate dryers

ANDRITZ AG / Stattegger Str. 18 / 8045 Graz / Austria / andritz.com/separation


PROCESS TECHNOLOGY&COMPONENTS

© SEEPEX

The cross-sectoral media platform

for suppliers and users in two languages:

German and English

Exclusive information around the pump

and compressor industry as well as

systems and components

Developments and trends

First-hand future technology

Targeted at international trade shows

for 2020

Special issue for the Russian market

in October

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


Editorial

A New Start in 2021

Some people find it difficult to see

anything positive coming out of the

year 2020. Others see it as healthy to

take stock of one’s personal situation

and make appropriate changes in things

like food consumption. Many people

have ordered groceries on-line – and

this is a trend we can expect to continue.

Equally so is the ‘dining-in experience’.

We tried it at home over the holiday

period. We ordered food from our local

restaurant, and created an atmosphere

at home, with table cloth, candles

and background music which made

the occasion special. It was a positive

memory which will live beyond Covid-19

and which we will be glad to repeat.

One major trend we can expect to

see continue this year is sustainability,

which has many forms. It remains

important to find long-term solutions

to the food we harvest and process. This

may mean alternatives in proteins from

plants or insects, it may mean blending

them to enhance benefits of different

options. It will also mean tackling the

problem of food waste. Climate control

and meat replacement are often linked

together under the sustainability

umbrella. Some environmental benefits

of less travel have already been seen

and recorded.

The number and quality of nonmeat

burgers has grown. The plant

based movement has created a lot of

opportunities within the hydrocolloid

world. Many foods-that-used-to-becalled-burgers

use methylcellulose,

starch and fibre. Some products will

have bacon based on vital wheat gluten.

Current commercial vegan cheeses

rely on potato and tapioca starch,

xanthan and konjac gum to achieve

the meltability and texture consumers

are expecting from cheese. Everything

which is based on wheat and pea protein,

makes organic and non-GMO sourcing

of these proteins necessary for future

differentiation from the competition.

Personalised nutrition is another

buzzword which sounds good, but is

probably still looking for its definition.

Recent data has underlined the

continued growth in child obesity. The

call is loud to the food industry to reduce

20% of sugar and calories in everyday

food consumed regularly by children.

Ingredient manufacturers often select

a colour for a new year which then

becomes a trend of its own. It doesn’t

really matter which one. For 2021 I

am choosing white. For one thing it is

a difficult colour to produce naturally

Ian Healey

Editor-in-Chief

and sustainably. And my favourite

soccer team plays in white, so that’s as

good a reason as any.

In the meantime the digital opportunities

for this magazine are staying dynamic.

Under www.food-mt.com you can find a

digital copy of this issue as well as other

news as it comes in, white papers, banners,

and video slots. It is possible to receive

the magazine electronically as soon as it

is published. Please subscribe using the

button on the website. Good for the

readers and good for the environment!

Our twice-monthly newsletter was

launched last year and has proved very

popular. Feel free to register for free.

Sincerely,

If you like it – subscribe!

food Marketing & Technology • February 2021

3


XIX International Trade Fair

for Savoury Snacks & Nuts

16-17 June 2021

Hamburg, Germany

Contents

food Marketing & Technology February 2021

1 Editorial

42 Impressum

Move your

business

forward

Ingredients

9 Flavor, Color, & Texture Trends in 2021

12 Bringing Cultivated Meat to Japan

13 New Seaweed Powder Unveiled to Address Consumers’

Appetites for Label-Friendly Ingredients

14 Olive Leaf Extract Now Non-GMO Project Verified

16 CCOVID-19 Intensifies Consumers’ Interest in Well-Being

and Eco-Friendly Products

at the worldwide fair

for savoury snacks

The only trade fair 100% focused

on savoury snacks and nuts

Processing

6 Steam Peeling Solutions for Vegetables and Fruits

18 Sweet Revolution

20 Food Extruder in Hybrid Design: Ideal System for Product

Development and Piloting

21 Baker Perkins Equipment Industry 4.0 Ready

22 Shaping the Puzzle for Quality Formed Products

24 Grinding Innovations from well-proven Technology

Key No. 99601

snackex.com

+ Experience the hottest trends,

tastes and technologies

+ Develop your business with the

industry’s leading suppliers

+ Connect with the decisionmakers

of the industry and

find international trade

partners, distributors

+ Meet existing customers and

new prospects from around

the world

+ Sell your products to an

audience that is ready to buy

The industry-defining fair for

the savoury snacks sector

Packaging

26 The Plant-Based Boom - A New High-Capacity

Manufacturing Solution to Keep up with Consumer

Demand

29 Interpack and Components 2021 Canceled due to

Covid-19 Restrictions

30 Successfully Filling the Gap: Cereals now in Paper

Packaging

32 Bespoke Solutions in Meat Packaging Support Danish

Crown’s China Expansion

34 Independent Cart Technology Underpins Integrated

Packaging Concept

36 Elopak Records One Billion Natural Brown Board Cartons

37 Digitized Silo Fill Level Monitoring

Departments

38 Marketing

40 Events


Vol. 35 • 31377

ISSN 0932-2744

Cover: Steam Peeling

Solutions

Covid Intensifies

Well-Being Interest

Food Extruder in

Hybrid Design

1/21

Sustainable Barrier

Packaging

Cover: TOMRA Food

Some of the main benefits of

steam peeling are high quality

and process efficiency. The yield

and quality are much higher than,

for example, mechanical peeling

by 10-15%. The higher quality can

be realized through the increased

value of the product and lower

operation costs, including reduced

energy consumption.

Our Cover Story starts on page 6.

Key No. 99498

Ingredients: Covid and Well-being

Environmental concerns have been heightened as a result of

COVID-19. This is in part due to some consumers questioning

whether issues such as air pollution have increased respiratory

issues, making people more vulnerable to the disease. This

concern is being translated into altered buying patterns, with

60% of consumers now being more attentive to the impact that

their food and drink has on the environment. Find out more on

page 16

Processing: Food Extruder

Extrusion is one of the most interesting technologies and is

included in a new food development and piloting facility in

Finland. The ZSK extruder is being used for process and product

development and is also combined with other food production

and packaging technologies. This enables the creation of

commercially ready solutions in the food approved facility

together with customers all over the world. Check out the full

story on page. Check out the story on page 20

Packaging: Sustainable Barrier

As part of a sustainability strategy, a well-known cereal

manufacturer wanted to completely switch its packaging from

plastic to paper. The company produces organic products such

as flour, porridge oats, muesli and bread mixes and occupies

a niche role in the German market. The challenge was to find

efficient packaging processes based on high quality and above

all, environmentally-friendly packaging materials. See page 30

Key No. 97065

food Marketing & Technology • February 2016


Cover Story

Steam Peeling Solutions for Vegetables

and Fruits

Steam peeling of vegetables is a technology that has been around for almost 50 years. Recent developments

have served to underline the hygienic, quality and cost benefits. Ian Healey talked to Eamonn Cullen, steam

peeling expert with TOMRA Food, based at the R&D center in Dublin, Ireland. TOMRA Food was the first

company to introduce steam peeling to many potato and carrot processors.

Food production companies that have

invested in recent years in technology,

automation and capacity are now

leading the industry’s race to produce

higher quantities of food, to satisfy the

growing demand for online shopping

and eat-at-home foods. Vegetable

processing is a good example of how

technology can provide operational

flexibilities for commercial advantage.

Take technology and automation in

peeling and sorting processes: these

enable customers to process vegetables

like butternut in the morning and celery

in the afternoon, with very little change

to the processing line. And processors

could just as easily switch the line

between, say, sweet potato, beetroot,

carrots, or kohlrabi in varying quantities.

Switching from one product to another

is remarkably easy. By simply changing

settings using a touch panel, the food

processor can start the line for a new

product with the confidence that

quality and efficiency will be optimized

and minimal need for human

interaction.

Today TOMRA Food is an industry

leader and there are more than 530

TOMRA steam peelers installed around

the world. Before the arrival of steam

peeling in the 1970s, potato skins were

removed by lye-peeling. This was an

inefficient process that used chemicals,

requiring special care and handling,

and consumed high volumes of water

to treat the chemical waste from the

process. Major food processors were

crying out for a new solution and

steam peeling was the answer. This

uses steam that is already in use in

processing plants and enables the

more efficient production of high

volumes. This advancement has saved

many processors thousands of Euros

every day. Steam peeling is the most

efficient method of removing skin from

fruit and vegetables. Lines processing

between 1,000 kg/hr – 65,000 kg/hr can

benefit from TOMRA’s steam peeling

equipment, resulting in significant raw

material and energy savings.

Optical sorting technology is where

TOMRA is more well-known and indeed

this is always the first application when

harvesting products. Potatoes and

other vegetables are initially processed

to remove dirt, stones and other

foreign materials. After being ordered

as to size and quality, also depending

on the customer and final destination,

the product is further processed.

Steam peeling entails surrounding each

potato with high pressure and hightemperature

steam to directly heat the

water below the potato’s skin. When

the steam pressure is released, the

water volume below the skin rapidly

expands by more than 1,000 times,

creating the force to separate the peel

from the flesh. This process can be used

for peeling several different vegetables,

including potatoes, carrots, beets,

pumpkin, sweet potato, kohlrabi, and

root celery. It is also used to peel fruits

such as apples, which naturally have

high moisture.

Some of the main benefits of steam

peeling are high quality and process

efficiency. The yield and quality

are much higher than, for example,

mechanical peeling by 10-15%. The

higher quality can be realized through

the increased value of the product

and lower operation costs, including

reduced energy consumption. Less

waste also increases the final factory

output.

6

food Marketing & Technology • February 2021


Cover Story

An efficient steam peeling process will

remove 98% to 99% of each potato’s

skin and will equally treat the surface of

up to 3,000 potatoes every few seconds.

To achieve this, fast pressurization and

depressurization of the steam vessel is

essential. The key measurement of this is

the exhaust efficiency factor (EFF), which

is the ratio of the steam shaft crosssection

area (mm2) to the vessel volume

(liters). Product movement and mixing

inside the vessel are also important.

There must be a high rotation speed (up

to 28 rpm) and consistent movement

of each potato. The EEF of TOMRA’s

Eco peelers is two to three times higher

than that of other steam peelers with

the same volume.

Benefits of TOMRA’s steam peeling equipment:

Fastest peeling times for a wide range of vegetables, potatoes, carrots, beets,

sweet potato, pumpkins

Superior quality and peeling consistency

Automated real-time adjustment up to 25% faster than other steam peelers

Highest performance solutions on the market, increase by 5% - 10% above others

Reduced labor requirements

Reduced rejected product

Up to 25% lower energy usage

The TOMRA Steam Peeler’s key benefit

over a competitors’ machine is the

unique peeling vessel design. Multiple

product lifters move the potatoes

around. This results in significantly

superior peeling performance, as well as

peeling very quickly. If the potatoes are

mixed uniformly throughout the vessel,

they are treated uniformly. A second

key advantage is a patented dual-stage

steam exhaust system that ensures the

steam’s fast release, removing the skins

and speeding up the process as such.

TOMRA PEELING MODULE

Combining the high-performance

TOMRA Eco Steam Peeler with the

TOMRA 5A whole product sorter results

in a highly effective TOMRA peeling

module that’s also famously reliable,

simple to maintain, and easy to operate.

This combination overcomes the main

challenge for processors: ensuring

that the peeling line is optimized

continuously when there are continuous

and unpredictable vegetable quality,

size, and shape variations. The module is

fully automated and for every individual

vegetable processed it reports on peel

remaining, quality, defects, color, size,

shape, and more. It is certainly no

coincidence that today 85% of the

world’s French Fries are processed using

TOMRA equipment.

Food safety

ever faced. In a crisis such as this, it is

important that a customer’s business,

as an essential part of society, keeps

its activities running smoothly. Food

companies are working tirelessly in

difficult circumstances to ensure that

supermarket shelves, fridges, and

freezers are full of interesting and

flavorsome products. Food producers

are an essential part of creating the

meal-time experience that brings and

keeps us together.

On the one hand, the foodservice

business stopped very quickly, forcing

many potato producers to reduce

volumes and shut down peeling lines.

Even now, a year later, this industry

sector is still operating at reduced

capacity, and many companies are

having to weather financial losses. On

the other hand, however, there has

been an increase in the consumption

of eat-at-home foods, particularly fresh

vegetables. Seeing this, some companies

have adapted by introducing prepared

meals for dine-in consumers.

Many of the challenges brought by

the pandemic in 2020 will continue

COVID-19 – Challenges for food

processors

The COVID-19 pandemic is arguably

the most significant challenge the

global food processing industry has

food Marketing & Technology • February 2021

7


Cover Story

through much or all of 2021. TOMRA

cannot alter the circumstances

influencing food demand, of course.

Still, they can and will continue to

help food processors meet their

operational challenges through

remote machine monitoring and

management and remote customer

support and training.

“COVID-19 has impacted TOMRA Food’s

business by making it more challenging

to visit customers’ sites or host customers

at our Demonstration Centers, “says

Eamonn Cullen. “But through our

technologies, we have found ways to

introduce innovative online tools to

connect with our customers and to

help support their business needs. For

example, TOMRA Insight, the cloudbased

monitoring platform for sorting

lines, enables data-based decision

making and process adjustments in

near-real-time. TOMRA Visual Assist,

our new augmented reality tool,

allows us to provide customers with

specialist support remotely, just as if

a field service engineer were standing

in front of the machine. And TOMRA’s

new Online Demonstration Centers

enable customers to see and interact

with machine demonstrations via video

rather than attending the center in

person.“

Photos: TOMRA Food

TOMRA has used increased automation

through the COVID-19 situation to

improve safety and quality even more.

Production facilities have become

more remotely controlled, using fewer

people, reducing the real and potential

introduction of foreign materials. Food

traceability is also easier and can be

guaranteed to the retailer. This kind of

augmented reality has brought TOMRA

closer to customers and individuals

and has been accelerated by the Covid

restrictions.

The future

TOMRA’s plans for the near future are

focussing on waste reduction. Higher

pressure steam can be used to peel more

product faster. This can increase 6-8%

yield saving, which benefits customers,

consumers, and the environment alike.

As family mealtimes have grown in

importance in the last few months, so

the expectations in the food which is on

the table are also getting higher. Quality,

safety and consistency are what TOMRA

Food has specialized in for years. fmt

"There is no doubt that, because of the

pandemic, over the next months, we face

challenging times. The world is adapting to

the new restrictions, but struggling to keep up

with demand. Rest assured, however, that food

supply is ably supported by the watchful eyes

of technology and automation to help make

home-dining pleasurable." Eamonn Cullen,

Market Manager Peeling, TOMRA Food

8

food Marketing & Technology • February 2021


Ingredients

Flavor, Color, & Texture Trends in 2021

When it comes to choosing which food and beverage products consumers like, there are 3 key aspects which

lead to trying products and continuously buying those brands. Flavor, color, and texture are 3 major areas in

why consumers continue to purchase a brand of choice. So how influential are these 3 aspects and what are

consumers seeking in 2021

Flavors

Over the past few years there has been

much attention on healthier alternatives

within the food and beverage market,

however consumers still prioritize taste

as a key driver to why they choose a

product. In 2021, FMCG Gurus shows

that consumers will be looking for new

and exotic flavors from brands within a

number of categories. This is highlighted

as 74% of global consumers state they

like food and drink products with new

and unusual flavors. Especially in the

case for chocolate as 77% of consumers

would like to see new unusual flavors in

this market.

Due to the current global situations

with many consumers stuck at home,

they are looking for new ways to escape

their reality through food and drink.

This is highlighted as 74% of consumers

stated they like new usually flavors from

around the world. Not only are consumers

seeking new exotic flavors, but also 68%

of global consumers would be willing to

pay a premium price for these products.

Therefore, there is an opportunity for

brands to target these consumers with

exotic flavors from around the world to

help as they look to food and beverages

for escapism purposes.

Consumers are also turning to traditional/

nostalgic flavors which reminds them of

simpler times. The COVID-19 pandemic

has left numerous consumers across the

globe in a state of worry and anxiousness

about the future. FMCG Gurus research

shows that 68% of global consumers

find traditional and nostalgic flavors

appealing within food, with over 70%

suggesting they like these flavors

because it offers them comfort.

As consumers look to adopt a holistic

health approach to life, looking to

improve all aspects of their health

including their diets, they are seeking

out healthier and more natural products.

Natural flavors can be very appealing

to consumers as they will be highly

associated with being better for them.

Consumers are most likely to look for

natural flavors in the following markets:

Coffee (82%), Yoghurt (82%), and Fruit

Drinks (83%). These are highly important

food Marketing & Technology • February 2021

9

Key No. 99420


Ingredients

as 64% of global consumers would agree

that they would pay a premium for

these natural flavors, as they are seen as

healthier options.

Colors

When it comes to color in food and

beverage products it is very important

that brands get this right. FMCG Gurus

highlights that 57% of global consumers

find color influential when purchasing

products. New and experimental colors

can also be appealing to consumers with

46% of global consumers agreeing with

this. This is due to consumers associating

these colors with more fun and exciting

products, something which is needed in

a time of worry. However, experimental

colors are also associated with being not

natural which is a key driver to why 30%

do not find these products appealing.

These colors can be associated with being

artificial, something in which consumers

are actively looking to avoid.

It takes a consumer a matter of seconds

to choose which product to buy therefore

color is a key element to food and

beverage products. Although 49%

of consumers state they would pay a

premium for products with experimental

colors, traditional colors which consumers

know and trust are a lot more

influential when purchasing food and

drink products. This highlights again that

consumers may not trust experimental

colors as they can be seen as artificial

and not good for their health. This is key,

in a time where consumers are actively

seeking to improve their health to be

less vulnerable to catching any disease or

illness.

When asked which colors were most

appealing within beverages such as juice

drinks a large number of consumers

prefer colors that resemble fruits. FMCG

Gurus research shows that Orange, Red,

and Yellow are three of the most popular

colors in regards to juice drinks. This can

be associated that they are more natural

which resembles the flavors they like

and know. Therefore, it is important for

brands to understand that natural colors

associated with healthier flavors such as

fruits are more appealing to consumers

in a time of uncertainty around health

and wellness.

Textures

Texture is also another key component to

why consumers would choose to go back

to certain foods and drinks. This is again

highlighted as 59% of global consumers

state that the texture of a product is

influential when purchasing products.

However, texture preferences vary

largely by category. When it comes to the

beverage market only 28% of consumers

would like to experiment with unusual

textures. One of the main reasons for

this is that consumers already associate a

product with a certain texture and do not

want their favorite brands to change this.

So, when deciding whether to use new

unusual textures or traditional textures

consumers are already aware of, it is

important to know that 88% of global

consumers state that traditional textures

they know and trust are more influential,

with only 7% preferring new textures.

Summary

Flavors, colors, and textures all play a

key role in why consumers like to choose

certain products. When addressing

flavors, brands and manufacturers can

target consumers who are looking for

escapism with nostalgic flavors or new

and exciting flavors which are specific to

certain areas in the world. This will be

a key trend driving forward in 2021 as

COVID-19 still impacts consumers daily

lives. Colors are also key, however due

to a health kick in 2021 with consumers

looking for natural products consumer

may look to avoid artificial and

unnatural colors. It is important that

brands and manufacturers offer exciting

new colors which are made from natural

ingredients with simpler messaging

for consumers. Finally, it is important

to understand that consumers do not

like change when indulging in their

favorite products as they have certain

associations with textures and the

products they like.

fmt

10

food Marketing & Technology • February 2021


Ingredients

Technology & Marketing

International Magazine June 2020 ISSN 2628-5851

International Magazine October 2019 ISSN 2628-5851

International Magazine April 2020 ISSN 2628-5851

2/20

Technology & Marketing

2/19

xxx

1/20

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

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

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

FREE trial issue at food@harnisch.com

The magazine PetFood PRO has grown out of a conviction

and wish to underline the high level of quality and care in the

manufacture of pet food, through the choice of ingredients,

choice of technology and choice of packaging materials. We

will endeavour to present this in an informative way, through a

reader-friendly style and with a marketing perspective.

food Marketing & Technology • February 2021

www.harnisch.com 11


Ingredients

Bringing Cultivated Meat to Japan

Collaboration to bring cultivated meat to Japan will help the country meet climate change and food security

goals

Aleph Farms, Ltd., and Mitsubishi

Corporation’s Food Industry Group

signed a Memorandum of Understanding

(MoU) to bring cultivated

meat to the Japanese table. Aleph

Farms will provide its proven, scalable

manufacturing platform (BioFarm)

for cultivation of whole-muscle steaks.

Mitsubishi Corporation will provide its

expertise in biotechnology processes,

branded food manufacturing, and local

distribution channels in Japan.

“The MoU with Mitsubishi Corporation’s

Food Industry Group marks an

important milestone for us, as we

methodically build the foundations of

our global go-to-market activities with

selected partners,” notes Didier Toubia,

Co-Founder and CEO of Aleph Farms.

Mitsubishi Corporation is a global

integrated business enterprise that

develops and operates a global

network of 1,700 group companies

in 90 countries. With yearly revenue

of US$140B, Mitsubishi Corporation

is comprised of 10 Business Groups

covering virtually every industry. The

Food Industry Group covers food

resources, fresh foods, consumer

products, and food ingredients, and is

active in every link of the food supply

chain, from the production and sourcing

of raw materials to the manufacturing

of finished food products.

2020, Aleph Farms committed to

eliminating emissions associated with

its meat production by 2025 and reach

the same net-zero emissions across its

entire supply chain by 2030. As the

demand for meat continues to rise with

evolving lifestyles, the cooperation

will also provide actionable solutions

to overcome the societal challenges to

the local population surrounding the

domestic meat supply. This includes

implementing stable food channels of

quality nutrition.

“This is part of a network of ‘BioFarm

to Fork’ strategic partnerships being

developed by Aleph Farms in APAC,

LATAM, and Europe, following the

successful 2019 Round-A strategic

investment by Cargill and the Migros

Group in Switzerland,” reports Gary

Brenner, VP of Market Development at

Aleph Farms.

Aleph Farms and Mitsubishi Corporation

are members of the “Cellular

“The cooperation demonstrates Aleph

Farms’ strategy of working together

with the food and meat industries

to ensure a successful integration of

cultivated meat within the ecosystem,

while maximizing the positive impact

we make,” adds Toubia. “We are

excited to bring cultivated meat

production closer to the Japanese

market.”

fmt

This cooperation takes a lead role in the

fight against climate change, especially

now that the Japanese government

stipulated a goal of achieving zero

greenhouse gas emissions. In April

12

food Marketing & Technology • February 2021


Ingredients

Agriculture Study Group”, a consortium

implementing policy proposals under

the Japanese Center for Rule-Making

Strategy. The consortium brings together

a range of experts on the definition and

construction of cellular agricultural foods.

It also adds clarification of conditions for

Japanese products and technologies to

have international competitiveness and

establishes mechanisms for coexistence

and division of roles with existing

industries.

fmt

New Seaweed Powder Unveiled to

Address Consumers’ Appetites for

Label-Friendly Ingredients

New WavePure® series brings indulgence from only natural seaweed components

Food manufacturers can now achieve

the rich eating experience consumers

desire with Cargill’s new label-friendly

WavePure® seaweed powder. Produced

from native seaweed and obtained

without chemical modification, Cargill is

the first to make large, commercial-scale

quantities of this familiar and versatile

ingredient available to its European

customers.

“Seaweed powder appeals to a trifecta

of consumer demands, allowing

product developers to create foods

and drinks with indulgent sensory

experiences, using a single ingredient

that consumers perceive as a positive

addition to ingredient labels,” said

Xavier Martin, Global Product Manager

Seaweed Extracts at Cargill. “By

bringing this ingredient innovation

to our customers, we’re giving them

the tools they need to create products

that truly stand out in a competitive

marketplace.”

The company’s first offering in the line,

the WavePure ADG series, is sourced

from Gracilaria red seaweed, which is

considered a traditional food ingredient

in the European Union. As a result, there

are various options for labeling with a

reference to the seaweed source.

From a formulation perspective, the ADG

series is well-suited for dairy desserts,

serving as a recognizable alternative to

less familiar ingredients. With WavePure

ADG, smooth and creamy textures bring

an optimal organoleptic experience,

while also offering excellent gelling and

thickening properties.

The ADG series debut ingredient,

WavePure ADG 8250, is a proven

solution for dairy desserts and the

company expects to extend the range

to other applications. In addition,

Cargill is exploring opportunities to

provide customers with a full line of

seaweed powder solutions that tap

into the rich diversity of other seaweed

species.

Cargill continues to work to enhance

the sustainability of all its seaweed

ingredients, including WavePure.

Ultimately, the company’s goal is to

make WavePure ingredients a part of

its Red Seaweed Promise program,

which embraces sustainable seaweed

production practices, enhances

producer livelihoods and supports

local communities.

fmt

In addition to its consumer-friendly

designation, Cargill’s seaweed powder is

produced without chemicals, a processing

approach that keeps all the natural

seaweed components intact.

“Seaweed has been a staple food source

in many cultures for centuries,” said Judd

Hofmann, Cargill’s Segment Director

Texturizers and Specialty Europe. “That

tradition continues today, as consumers

view seaweed as wholesome, healthful

and nutritious. Our innovative WavePure

seaweed powder range leverages that

heritage, enabling simple ingredient

labels that reference the familiar

seaweed source.”

food Marketing & Technology • February 2021

13


Ingredients

Olive Leaf Extract Now Non-GMO Project

Verified

Heart health supporting olive leaf extract is also available in Organic grade

IFF has received Non-GMO Project

Verified certification for its Benolea®

(EFLA® 943), an olive leaf extract,

clinically shown to support cardiovascular

health. In addition, the company recently

received recognition by the Council of

Ecological Agriculture of the Region of

Murcia (CAIRM) for an organic grade of

Benolea available to its customers. These

new certifications endorse the ingredient

as a trusted and transparently sourced

all-natural product.

The olive leaves used for IFF’s unique

formulation are nurtured and harvested

in Spain as a side stream of the olive

oil industry. The extract is processed

locally, at the company’s Murcia facility,

to reduce the environmental footprint.

IFF’s team of experts work closely with

the olive growers, ensuring pure, clean,

high quality olive leaf extract, with a

healthy amount of powerful polyphenol

antioxidants. They test it through every

step of production, from raw materials,

over intermediates, to the final products

giving them full control of the supply

chain from farm to fork.

“We have focused significant

R&D activities on researching the

cardioprotective mechanisms of the

botanical ingredient and optimizing

the formula to promote cardiovascular

support at the highest purity, quality,

and sustainability standards,” says

Laetitia Petrussa, PhD, Product Manager

for IFF Health unit.

The traditional use of olive extracts,

including bark and fruits, goes back

to the biblical era. In ancient Greece,

it was valued as a remedy with

multifunctional properties, including

purported abilities to alleviate high

blood pressure, prevent cardiovascular

disease, relieve gout and fever, and to

promote the body’s natural elimination

functions. Recent empirical evidence

has substantiated some of these

traditionally ascribed benefits. Today,

olives and olive oil play a central role in

the Mediterranean Diet which has been

universally recognized as a leading

nutritional heart protector.

Benolea olive extract is standardized

to a potent concentration of

14

food Marketing & Technology • February 2021


Ingredients

polyphenols (30%), with 16-24%

oleuropein — the most prevalent

phenolic component of olives and

extolled as a strong antioxidant that

actively contributes to the protection

of blood lipids from oxidative

stress. The ingredient undergoes IFF

Health’s proprietary EFLA HyperPure

technology to guarantee the absence

of contaminants as well ensure a

consistently concentrated and stable

source of polyphenols.

Benolea’s heart-protective potential

has been confirmed by a range of

studies in animal models and three

human clinical studies. In one trial

involving 20 monozygotic adult

twin volunteers, Benolea intake was

associated with dose-dependent

decreases in blood pressure. This

study also showed a significant

reduction of LDL-cholesterol and

demonstrated positive effects on

blood lipid profiles.

A secondary metabolite of oleuropein,

hydroxytyrosol, is responsible for the

potent antioxidant potential of olive

leaves, and carries an impressive

Oxygen Radical Absorbance Capacity

(ORAC) value that surpasses other

acclaimed natural antioxidants on the

market, such as coenzyme Q10 and

green tea. One daily 500mg dose of

Benolea contains the equivalent of 20

tablespoons of extra virgin olive oilsourced

polyphenols.

“Our dedicated team of expert

formulators worked intensively to

achieve an ideal combination of olive

leaf bioactives and maximize their full

potential,” enthuses Petrussa. “Our

studies have demonstrated Benolea’s

ability to exert coronary and vascular

protection.”

The Non-GMO Project Verified seal

gives consumers the assurance

that a product has completed a

comprehensive third-party verification

for compliance, ensuring the

claim is unbiased, rigorous, and

transparent. Benolea is fully watersoluble

and can be integrated into

multiple applications, such as softgels,

powders, and capsules. It also is

certified kosher and halal.

fmt

Want modern

shapes?

USE OUR TECHNOLOGIES

TO CREATE DEMAND!

SCHAAF TECHNOLOGIE GMBH

www.foodextrusion.de

Key No. 99030

food Marketing & Technology • February 2021

15


Ingredients

COVID-19 Intensifies Consumers’

Interest in Well-Being and Eco-Friendly

Products

Healthy ingredients and label transparency

are more important to

consumers than ever before following

the COVID-19 pandemic, concludes a

new global survey commissioned by the

market research company FMCG Gurus

on behalf of BENEO.

The results show that across the

globe consumers are becoming more

conscious about their well-being -

particularly immunity - as they question

their vulnerability to disease and illness.

They are also concerned about the

environment and whether the virus’

impact has been intensified because

of increased levels of environmental

damage. As a result of these attitudinal

shifts, consumers are looking to

purchase food and drink products that

increasingly promote well-being and

sustain their energy in challenging

times, whilst minimizing impact on the

environment.

Good for you and the environment

Environmental concerns have been

heightened as a result of COVID-19.

This is in part due to some consumers

questioning whether issues such as air

pollution have increased respiratory

issues, making people more vulnerable

to the disease. This concern is being

translated into altered buying patterns,

with 60% of consumers now being

more attentive to the impact that their

food and drink has on the environment.

Increased focus on food and drink

products that provide health benefits

Furthermore, the widespread effect of

COVID-19 has also resulted in 64% of

consumers saying that they are now

more conscious about their immune

health. Even consumers who previously

deemed themselves to have a good

immune system are now questioning

their vulnerability to disease and

illness. This is having a direct impact on

purchasing behavior, with two-thirds

(64%) of consumers more interested in

ingredients, or food and drink products,

that provide protective or preventative

health benefits. This trend is likely to

continue being prevalent in the market

for the foreseeable future.

Consumers want natural,

sustained energy boosts

In these challenging times, consumers

are also looking for ways to fight

feelings of fatigue more naturally. In

“As concern for the environment continues to

gather pace, it is important that we all play our

part in promoting sustainable business practices.

At BENEO, we actively support sustainable

farming, to encourage biodiversity and reduce

water pollution and soil erosion. We valorize

100% of our raw material to minimize waste.”

line with this, 34% of consumers say

that they are now more likely to seek

out food and drink products that boost

energy in a sustained and balanced

way. Also, not surprisingly, consumers

are looking to improve their mental

well-being, with more than half (55%)

saying they are likely to opt for food

and drink to boost their mood. However,

formulation is key, as consumers

look to avoid ingredients deemed

detrimental to their long-term health

in pursuit of a short-term energy boost.

One opportunity arising from this is the

appeal of slow-release, low-glycaemic

carbohydrates such as Palatinose

(isomaltulose), with 45% of consumers

believing such carbohydrates are better

for their health.

Myriam Snaet

Michael Hughes, Director of Insights at

FMCG Gurus, comments: “The results of

our latest consumer survey clearly show

that beneficial ingredients and label

transparency are now more important

16

food Marketing & Technology • February 2021


31377

Ingredients

than ever before to consumers across

the globe, as a result of the pandemic.

People are exploring topics such as inner

defence, staying fit and healthy, blood

glucose control, as well as sustained

energy and wanting to buy products with

proven health benefits. BENEO is well

equipped to help manufacturers tap into

these key growth areas. The company’s

prebiotic chicory root fibers and slowrelease

carbohydrate offer a range of

scientifically proven health benefits that

help support long-term health and can

be communicated on pack.”

Myriam Snaet, Head of Market

Intelligence and Consumer Insights at

BENEO, explains: “As concern for the

environment continues to gather pace, it

is important that we all play our part in

promoting sustainable business practices.

At BENEO, we actively support sustainable

farming, to encourage biodiversity and

reduce water pollution and soil erosion.

We valorize 100% of our raw material

to minimize waste and have reduced our

specific energy consumption by 50% over

the past 30 years. Looking to the future,

we aim to achieve carbon neutrality by

2050, thanks to our recent investments

into upgrading and expanding our

facilities.”

fmt

1/21

Vol. 35 •

ISSN 0932-2744

Come and see for yourself:

www.harnisch.com

Cover: Steam Peeling

Solutions

Covid Intensifies

Well-Being Interest

Food Extruder in

Hybrid Design

Sustainable Barrier

Packaging

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 -

food Marketing & Technology • February 2021

17


Processing

Sweet Revolution

In a globally unique project, called

CONNECT, nine well-known companies

of the confectionery industry have come

together and developed an industrial

production process for real 3D jellies.

Now it is possible to design gummy

bears and jelly babies with a beautiful

backside. That’s revolutionary!

We know fruit gums and jellies in many

different shapes. But they all have at

least one flat side or an unpleasant

“dosing dot”. With this worldwide

new process of CONNECT, real threedimensional

figures can be produced.

Real three-dimensional figures that

always show their best side, no matter

how you turn them.

The CONNECT-Team has developed an

innovative product concept, researched

the necessary raw material properties,

worked out recipes, designed shapes,

and built the right production facilities.

Always scientifically accompanied in

order to achieve well-founded market

relevance for the confectionery industry.

The unique strength of the CONNECT-

Team lies in the bundling of the

technical competence of nine

companies in order to support the

confectionery manufacturers as best as

possible with expertise and passion. The

CONNECT developments focus on new

types of confectionery with enjoyment,

surprise and fun for consumers.

The innovative CONNECT 3D jellies were

presented globally in four live launch

events at the end of October. Around 750

interested people from the international

confectionery industry followed. The

focus was on the manufacturing process

and the integration of the process

into confectionery production. The

response is enormous, there are already

numerous project inquiries from Japan

to Mexico.

The successful launch event took place

on October 28, 2020. A recording is

available for all fans of real 3D jellies.

For everyone who missed the launch

event: at request@connect-sweets.

com you can request the link to

the recording or an individual Q&A

session with the CONNECT experts,

who are known by insiders as “The

Jellylovers”.

fmt

18

food Marketing & Technology • February 2021


Processing

SIMULATE WHOLE MUSCLE MEATS

IN LOOK, TASTE AND NUTRITION.

For meat analog and extender production,

rely on the pioneer of the process for textured

vegetable proteins by extrusion. Wenger began

the worldwide initiative over 50 years ago, and

continues to lead with ever expanding options

today.

High moisture meat analogs (HMMAs) produced on

Wenger twin screw extruders mimic whole muscle

meat, with similar characteristics for moisture,

protein and fat contents, as well as a densely

layered, somewhat fibrous structure.

After extrusion, HMMAs may be cut, sliced or

shredded – and then further processed or frozen.

In addition to soy proteins or wheat gluten

ingredients, alternative protein sources can be used

for texture, mouthfeel and appearance objectives.

Discover the latest in cutting edge extrusion

processing and product development assistance.

Email info@wenger.com now.

Key No. 99382

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

USA | BELGIUM | TAIWAN | BRASIL | CHINA

food Marketing & Technology • February 2021 19


Processing

Food Extruder in Hybrid Design:

Ideal System for Product Development

and Piloting

Research and development company

Foodwest Ltd., located in Seinäjoki,

Finland, has expanded its food

development center with a ZSK 27

Food Extruder in Hybrid Design. Thanks

to the Coperion extrusion system’s

modular construction, Texturized

Vegetable Protein (TVP), High Moisture

Meat Analogues (HMMA), and

numerous other extrudates such as

snacks and cereals can be manufactured

on the same machine. The extruder is

particularly well suited for research

and development with throughputs of

up to 80 kg/h, and thanks to constant

process parameters within the entire

ZSK extruder series, ensures reliable

scale up to higher throughput ranges.

Along with the extruder, the Coperion

system encompasses a highly accurate

Coperion K-Tron K-ML-D5-KT20

gravimetric twin screw feeder for dry

powders, a ZGF Centric Food Pelletizer

from Coperion Pelletizing Technology,

and a cooling nozzle.

Foodwest has been a successful

development provider for innovative

food products for over 25 years, and

with this new ZSK 27 Food Extruder,

expands its product tests, research, and

development efforts to a much broader

spectrum of applications.

ZSK Food Extruder in Hybrid

Design for Maximum Flexibility

Foodwest will be able to manufacture

both TVP and HMMA on the ZSK Food

Extruder in Hybrid Design with only a

minimum of retrofitting. The feeding

and process section for both applications

are nearly identical, while the discharge

units differ significantly. While the ZGF

Centric Pelletizer is attached to the

process section for manufacturing TVP

in order to cut the product directly at

the nozzle plate, HMMA is discharged

using a specialized cooling nozzle

which produces a product strand that

exhibits a texture closely resembling

that of genuine meat. Using an adapter

solution developed by Coperion, the

ZSK Food Extruder’s discharge can now

be switched from a ZGF to a cooling

nozzle in no time. The same principle

functions just as quickly in reverse when

switching from an HMMA process to

TVP.

The extruder twin screws’ combination

of self-wiping and modular construction

will allow Foodwest to

develop and test numerous other

products on the ZSK system alongside

meat substitutes, including snacks and

cereals; for production of the latter,

Foodwest individually configures the

extruder as well as the extensive array

of peripheral equipment available.

As a result, the company profits from

the extruder’s very high hygiene

standards, intensive dispersion

performance, and gentle product

handling.

Harri Latva-Mäenpää, PhD, Innovation

Director at Foodwest says: “Extrusion

is one of the most interesting technologies

and we wanted to include

it in our new food development

and piloting facility in Finland. The

versatile package and expertise

offered by Coperion convinced us to

make this investment. We can use the

ZSK extruder for process and product

development and also combine it with

other food production and packaging

technologies. This enables us to create

commercially ready solutions in our

food approved facility together with

our customers all over the world.”

Stefan Gebhardt, General Manager of

the Food & Pharma Business Unit at

Coperion, adds: “We’re very pleased

to equip such a renowned company

as Foodwest with a ZSK Food Extruder

in Hybrid Design. We are convinced

that the ZSK extruder, with its high

configuration flexibility and reliable

scale up to larger extruder sizes, is

the optimal technology for a large

bandwidth of product tests, research,

and development. Moreover, we are

very pleased to announce that, moving

forward, Coperion customers will have

a testing area for production of meat

analogues and other products at their

disposal at the Foodwest test center in

Finland.“

fmt

20

food Marketing & Technology • February 2021


Baker Perkins Equipment

Industry 4.0 Ready

Uncompromising hygiene

with NETZSCH pumps

Technology ensuring equipment is

Industry 4.0 Ready is being fitted as

standard to all new Baker Perkins

machinery.

Industry 4.0 harnesses data from all the

machines, devices and sensors in any

manufacturing operation and enables

them to communicate with each other

via the Internet to make informed and

timely decisions.

Baker Perkins’ policy is to provide all

machines ‘Industry 4.0 Ready’ to a level

that allows interconnection with other

systems via the Internet. The key unit

is an eWON Flexy Gateway - a modular

router and data gateway allowing

linkage to remote devices with

benefits based around data acquisition,

handling and transmission.

All systems will now sample and upload

all data from the process equipment

to a secure cloud or server, where it

will be available to facilitate improved

decision making. The major advantage

with simpler control systems is that

analysis is being carried out on the

process as a whole, rather than discrete

sections. Real time OEE (Overall

Equipment Effectiveness), trending and

basic maintenance are all included.

Innovative features include a unique

Baker Perkins machine center-lining

system allowing operating parameters

to be compared with previous settings,

and alerting supervisors to potential

problems caused either by operator

changes or impending equipment failure.

The next step in the development of

Industry 4.0 will allow Baker Perkins

to predict when key components need

replacement. Intelligent analysis of

process performance and machine

condition will enable timely advice to be

provided on potential machine problems

or service and parts requirements,

before they cause costly downtime.

Performance optimization based on

comparisons with similar machines will

also be possible.

The eWON Flexy modular router and

data gateway has been used for some

time by Baker Perkins to dial into

customer’s control systems anywhere

in the world when they call for remote

support. It has also been used in the

remote commissioning from the UK of

a new extruder in India.

Industry 4.0 is a fast developing

technology that manufacturers can

tailor to suit their own unique situations.

With equipment and systems Industry

4.0 Ready, Baker Perkins is ideally

positioned to help customers, whatever

the level of complexity required. fmt

Gentle conveyance of sanitary

and aseptic products

Flow rates up to 140 m³/h

Pressures up to 24 bar

Pumps designed, manufactured and

tested according to EHEDG, QHD, 3A

and GOST-R standards

FDA-certified elastomers

High corrosion-resistant, crevice-free,

wear-free and maintenance-free

flexible rod

Product and cleaning temperature up

to 150° C

Explosion protection according to ATEX

CIP and SIP capable

Decades of expertise in uncompromising

hygiene

NEMO® aseptic pump

food Marketing & Technology • February 2021

NETZSCH Pumpen & Systeme GmbH

Business Field Food & Pharmaceutical

Tel.: +49 8638 63-1030

info.nps@netzsch.com

www.netzsch.com

Key No. 98838


Processing

Shaping the Puzzle for

Quality Formed Products

Formed meat products are big

business. Burgers and chicken nuggets

dominate the market, but tastes are

changing. One of the challenges for

food manufacturers is the increased

consumer demand for a variety of

clean label products, as well as fish and

vegetarian options, and all at prices

that consumers consider to be good

value.

Ensuring the highest possible quality

products within budget limitations,

whilst continually innovating to meet

consumer demand, can be made more

challenging by the fact that creating

perfectly formed food products is a

very precise technical process. Rather

like a jigsaw puzzle, every part of the

process must be perfectly aligned

and in place in order to complete the

picture successfully.

With over half a century’s worth of

experience when it comes to forming,

leading supplier of food processing

equipment GEA has developed a

package of information based on

six key elements, with the aim of

demystifying this multi-faceted process

and highlighting the support GEA can

provide to manufacturers.

Application know-how

GEA’s vast experience in formed

product processing has enabled the

company to develop creative ways of

overcoming the technical challenges

that can occur. For example, to ensure

the best possible yields, the required

level of moisture must be retained

within formed products. Water also

acts as a carrier for salts and other

additives which extend shelf life and

enhance flavor, texture, color and

binding properties. However, binding

water into chicken mass is often the

one aspect of forming that can prove

the most difficult. To overcome this,

GEA has developed technology which

mixes the ingredients in near vacuum

conditions. This helps to open up the

meat cells thereby improving the water

retention of chicken.

Equipment and Innovation

Now into its ninth generation of

forming equipment, GEA offers

two primary production methods

for formed products. Plate forming

for low-medium production levels,

for example using its MultiFormer

machine, and rotary forming for

high speed production of long-run

standard products, such as with the

GEA MaxiFormer. Versatility, capacity,

yield, hygiene, sustainability and,

above all, product quality have been

the key drivers in the development of

GEA’s equipment, innovating designs

over the years in a continual quest to

streamline processes using the latest

technology, meeting and exceeding

customer expectations.

It’s all in the mix

The importance of getting all factors

well controlled early on in the process

cannot be underestimated. Regardless

of the forming technology used, it

is often the upstream process of

preparing the raw mix that has the

biggest impact upon the success of

operations further down the line. The

mixture must be carefully prepared

upstream with the right balance of

ingredients at the right temperature

and viscosity, to feed efficiently into

the forming equipment. Manufacturers

sometimes make the mistake of trying

to mix all the ingredients together in

one go. However, some ingredients,

such as starches, are only effective

during cooking and can inhibit the

absorption of water if added too

early. GEA has developed a range of

equipment for accurate and effective

mixing including the GEA CutMaster,

GEA PowerGrind and GEA ProMix.

Test before you invest

Naturally, before any decisions are

made, food manufacturers need

reassurance that any equipment

purchased will prove to be a profitable

investment. Feasibility studies, process

improvements and R&D tests all need

to continue, even during the current

COVID crisis. Tests are carried out at the

GEA Technology Center in Bakel, The

Netherlands, which remains fully up

and running. Customers are welcome

to visit the center for tests, but if this

isn’t possible due to travel restrictions

or company rules, GEA experts can

carry out tests at a distance, after

which results are collected and a

test report including videos, pictures

and, if possible, samples are shipped.

Alternatively, ‘live’ interactive testing

can also be arranged.

Passion for Excellence

Rather than simply supplying equipment,

GEA prides itself on its passionate

22

food Marketing & Technology • February 2021


Processing

approach and knowledgeable staff,

and has developed long term working

relationships with food manufacturers

around the globe, supporting them in

providing excellence at every stage of

production

Service

Any investment made in GEA’s

equipment is supported by a longterm

relationship, and a network of

service engineers and stocks of spare

parts are available around the world.

Denmark-based producer of cooked

chicken products Danpo installed a fully

automated chicken nugget line from

GEA, expanding its ‘Your Chicken’ brand.

Product Technical Manager Per Ulrik

Jørgensen commented: “I like working

with GEA, I can speak to people and they

understand what I am talking about.

They provide a round-the-clock service

with fast, easy solutions to improve the

line capacity or performance.”

A new digital channel which allows

customers to access a range of services

for their equipment, GEA Advance is

now also being piloted. This new digital

solution will allow GEA to modernize

the way service colleagues interact with

customers, allowing for rapid ordering

of spare parts and real-time access to

technical documentation.

fmt

Key No. 99050

food Marketing & Technology • February 2021 23


Processing

Grinding Innovations from well-proven

Technology

The grinding of products, whose

dusts are potentially explosive, places

particularly high demands on the

technology used and the design of a

grinding plant with regard to safety,

for both machines and their operators.

The pressure shock resistant design of

the complete grinding system up to an

explosion overpressure of 10 bar(g) is

the most frequently used version, which,

however, is associated with a high level

of equipment and corresponding space

requirements.

Thanks to the ATEX-compliant Condux®

Compact plant concept, the installation

of a high- performance grinding plant

for numerous products is now much

easier, since explosion protection

valves or explosion suppression devices,

explosion isolators, fans and even

conventional dust filter systems are

no longer required with the newly

developed plant concept.

The idea of a compact grinding system

is not new but existing solutions

show significant disadvantages

when it comes to cleaning efforts

and hygienic design. NETZSCH has

therefore improved the decisive points

of its Condux® Compact plant concept

once again: The footprint or space

requirement of the compact plant is

80 % less than that of comparable

standard grinding plants with the same

throughput capacities. This also has an

effect on the investment costs, which

are approximately 30 % lower. By using

the newly developed CycloFil cyclone

filter in the Condux® Compact system,

the integrated pre-separation of the

grinding stock and the recirculation

of the process gas allow a filter area

that is over 90 % smaller than that of

comparable mill sizes. With CycloFil, the

degree of separation can be adapted to

the operator’s requirements by means

of exchangeable immersion tubes.

These features of the new system result

in various advantages. For example,

24

food Marketing & Technology • February 2021


Processing

the grinding system can be easily integrated into existing

production systems thanks to the minimal space requirement,

and the necessary cleaning when changing products is

extremely quick thanks to easy access to the parts in contact

with the product.

The well-proven Impact Mill Condux® is the basis machine

of this grinding system. The products are ground within this

mill mainly by impact and shearing action. For use with a

wide variety of products and final finenesses, this machine is

available in various executions, as either a blast mill, pin-disc

mill or wing-beater mill.

In contrast to conventional grinding plants, the processing

gas in the Impact Mill Condux® Compact streams in a circular

motion. The product is fed directly to the mill via a pressureshock-resistant

rotary valve and discharged after the grinding

process via a separator with air lock. Parallel to this, the

additional rinsing air fed through the valves and mill bearing

is continuously discharged through the CycloFil to prevent

a build-up of pressure. A subsequent aspiration system

generates the vacuum needed to stabilise the system pressure.

Thanks to the innovative CycloFil cyclone filter, the supplied

energy is dissipated via the product and the system surface, so

that no additional cooling is required. The warmth produced

by the grinding process is mainly compensated along with the

product when it leaves the machine and to a smaller extent by

the system surface, and is therefore throughput dependent.

The expected temperature increase, for e.g. of ground

powdered sugar (d90 = 100 μm) is normally in the range of ∆T

= 10-25°C. For a large range of products the warming has no

influence on the quality or the downstream process. For the

grinding of particularly temperature-sensitive products, the

system can be additionally cooled with liquid nitrogen.

Especially the degree of innovation of the System was confirmed

recently by the Fi Europe Innovation Award jury, who awarded

the fine impact mill Condux® Compact as the winner of the

Food Tech Innovation Award for the most innovative technical

processing solution for food ingredients.

fmt

Highlights of the NETZSCH Condux® Compact:

• Compact design = Low space requirement

• Low investment costs

• Low feeding height

• ATEX conform

• Hygienic design

• Fast and easy cleaning

• Low maintenance costs

• Easy and clear operation

• Easy access

• Dust-free filling

• Universal operation

Firm, chewy and bouncy:

the right balance for

noodles

Enhance the taste of your noodles with

GEA technology: a stronger, chewier

texture with a pleasant bite-feel.

At GEA we have developed processing

technologies for noodles starting from their

unique taste.

We have focused on encapsulating a history

of consumption going back thousands

of years in a high-quality and completely

versatile product, suitable for every

preparation and recipe.

Discover

GEA’s noodles processing technology

gea.com/noodles

food Marketing & Technology • February 2021

Key No. 99510


Ingredients

The Plant-Based Boom - A New High-

Capacity Manufacturing Solution to Keep

up with Consumer Demand

The global food industry is facing

the enormous challenge of feeding

a population of 10 billion people, a

number we are expected to reach by

2050.

Our food supply chains are very complex,

comprising multiple steps, from the

farm to storage, transport, processing,

retail and ending eventually on the

consumer’s plate. The way we produce

out food takes its toll on the planet,

taking up 70% of the world’s available

freshwater for agriculture in addition

to a tremendous amount of energy,

and contributing to nearly a quarter

of global green-house gas emissions.

Despite all of this, one-third of all food

produced ultimately goes to waste.

With population growth comes an

expected change in demographics. A

shift towards more urban lifestyles,

with the majority of the world

eventually living in cities, suggests

an increase in purchasing power.

With the growing awareness among

consumers of balanced and proteinrich

diets, there is a tendency towards

putting as much protein on the plate

as possible. Looking at our existing

protein value chain, it is estimated that

with livestock farming, 45% of protein

produced worldwide is lost during the

conversion of plant protein to animal

protein. Beyond these inefficiencies,

the overproduction of animal-based

protein for human consumption has

been the leading cause of the most

recent pandemics, from COVID-19 and

SARS to swine flu and bird flu, among

many others.

Today, consumers are compelled to

reconsider their food choices and look

for alternative sources of proteins.

Moreover, they are exploring a wide

range of foods and expect more

choice in the products available on

the market. Researchers around the

world are therefore looking for novel

proteins sources which could be used

for human consumption. In this race,

plant-based proteins top the charts

as they are becoming increasingly

popular among consumers. Through

twin-screw extrusion technology, it is

possible to use plant-based protein

sources to create products that mimic

animal-based meat such as chicken

pieces, burgers, pulled pork, tuna,

etc. Pioneering food producers have

had huge success with recent plantbased

meat market launches and the

enthusiasm of consumers in buying

such products is in turn fueling the

plant-based revolution.

It is expected that, by 2040, the global

protein market share will be dominated

by alternative proteins, including

both plant- based and cultured meat,

26

food Marketing & Technology • February 2021


Processing

leading to a considerable reduction

in traditional meat products. This has

intrigued many companies from the

traditional meat and dairy industries,

encouraging them to diversify their

portfolios and cater to the needs of the

market. According to the 2019 ‘US State

of the Industry Report’ by the Good

Food Institute (GFI), between 2017

and 2019 there was a 31% increase in

the retail sales of plant-based meat,

compared to only 5% for animal-based

meat products. This explains the actions

of food giants like Nestlé, PepsiCo and

Kraft Heinz who are stepping into

plant- based meat sector. Additionally,

many traditional meat producers such

as Tyson and Hormel have launched

their own plant-based meat brands

such as ‘Raised & Rooted’ and ‘Happy

Little Plants’ respectively.

The role of technology in

mimicking meat:

Despite the existing concerns in the

food system, and especially in the

protein value chain, it is still a challenge

for consumers to fully shift to plantbased

diets. People love the sensory

experience involved in eating meat, not

only from the flavor but also from the

texture of the product. The bite and

chewiness that is provided by a meat

product is missing in traditional meat

alternatives such as tofu and tempeh.

Extrusion is the leading technological

solution used in the production of

plant-based meats, which enables

alternative sources of protein to be

transformed into meat-like products.

With the advent of high-moisture

extrusion in particular, it is now

possible to mimic meat products more

closely. Plant proteins in their raw state

are typically globular in structure. As

Key No. 98981

HYGIENE TECHNOLOGY MADE IN GERMANY

Kohlhoff food Marketing Hygienetechnik & Technology • February GmbH & 2021 Co. KG

27

Isaac-Newton-Straße 2 · 59423 Unna · Germany

Phone: +49(0)2303-98183-0 · E-Mail: info@kohlhoff-hygiene.de

www.kohlhoff-hygiene.de

For more information about our hygiene technology devices

for food processing companies please visit our web pages


Processing

they are processed inside the extruder,

the plant-proteins are denatured due

to shear loading and the increase in

temperature, which re-aligns them into

long fibers. The cooling die is a vital

attachment to the extruder. As the

restructured protein flows through the

cooling die, phase separation results in

a fibrous and layered structure, which

is then cooled to a solid product exiting

the cooling die. This meat substitute,

typically a rectangular slab due to

current cooling die designs, can then

be further processed to create diverse

products such as ground meat, pulled

pork, burger patties and chicken pieces.

The cooling die is also the main

bottleneck in the high-moisture

extrusion process. Until now, the

throughput has been limited to 500

kg/h, making it difficult for the industry

to keep up with consumer demand and

to compete with the high volumes

produced by the meat industry. To

address this, Bühler is excited to

announce the launch of a new high

performance cooling die, the PolyCool

1000, with a throughput of up to 1000

kg/h. This novel solution is unparalleled

in the industry and will revolutionize

the production of sustainable meat

alternatives and other protein products.

With the ability to double throughput

on one line, the cost per kilogram

of product becomes much cheaper,

allowing producers to reduce the

sales price and reach more consumer

markets.

Bühler, as a complete solution provider

for the meat substitute value chain, is

heavily engaged in innovation in this

area. Specializing in both dry and high

moisture extrusion, Bühler enables its

customers to find solutions with their

customized recipes in order to achieve

the desired layered and fibrous texture,

like that of meat. Bühler’s application

centers located in Minneapolis (USA),

Uzwil (Switzerland), Wuxi (China), and

soon in Singapore, enable customers to

carry out trials for recipe and process

optimization with the expert support

of Bühler’s technology team. In order

to cater to the growing demand, plantbased

meat producers need to increase

the throughput of their processes.

Bühler’s unique solution of a cooling

die with a throughput of 1000 kg/h

makes it the market leader among

state-of-the art technological solution

providers. In addition to extruder

systems and cooling dies, Bühler

provides solutions for pre-processing

of the material using pre- conditioners.

These pre-conditioners can provide an

additional retention time for the raw

ingredients which might be needed

to stimulate certain physicochemical

reactions, improving the functionality

of the recipe components. Bühler has

several partnerships with downstream

processors of the extruded product,

thereby supporting customers in

finding the full bean-to-burger solution.

Technological advancements in

the meat substitute segment have

prompted numerous start-ups to

launch in this market. According to

the GFI report quoted above, USD 457

million was invested in the plant-based

sector in 2019 alone. Hence, the growth

in this segment is an indicator of the

growing interest from consumers for

such products.

Popular and futuristic protein sources

for meat substitutes:

Current popular plant-based meats in

the market are produced from soy or

pea protein-based recipes. For highmoisture

extrusion for example, basic

products can be formulated by mixing

33% soy protein concentrate with 66%

water, or 45% pea protein isolate with

55% water in the recipe. The extrusion

conditions also differ depending on the

recipe. Typical temperatures need to

reach up to 145-150 °C when extruding

soy protein concentrate, while for pea

protein isolates, temperatures are in the

range of 130-145 °C. The configuration

of the screw elements are also adjusted

depending on the protein sources in

order to provide the necessary amount

of shear loading inside the extruder.

These process parameters are optimized

thanks to experience and scientific

understanding.

Other protein sources gaining

popularity more recently are chickpea,

lentil, potato, fava bean, and

mycoprotein, which all have great

nutritional properties and can be used

to produce meat-like structures. With

the advancement of fermentation

technology, single-celled proteins

such as algae, yeast, and bacteria will

become more important in the near

future.

In conclusion, scientists and industries

around the world are continuously

engaged in exploring the nutritional

and functional aspects of alternative

protein sources in order to make our

protein value chain more efficient. Meat

substitutes present an unparalleled

opportunity for sustainability in our

food systems. With the new PolyCool

1000, Bühler proves it is committed to

leading the way in developing the best

solutions for the alternative protein

industry.

fmt

28

food Marketing & Technology • February 2021


Processing

Interpack and Components 2021

Canceled due to Covid-19 Restrictions

In agreement with its association and

industry partners as well as the trade fair

advisory committee, Messe Düsseldorf

has decided to cancel both interpack and

components 2021, due to the restrictions

related to the COVID-19 pandemic. The

trade fairs were scheduled to take place

from February 25 – March 3, 2021 at the

fairgrounds in Düsseldorf, Germany.

“We have made every effort to do justice

to interpack’s tremendous importance

for the processing and packaging

industry, even during this pandemic

– above all because we have received

encouragement from the industry in

support of a face-to-face event and have

a tried and tested hygiene concept to

protect everyone involved. Ultimately,

however, feedback from our exhibitors

has shown that the uncertainty is too

great, and we are thus unable to host

an interpack event that would meet

the standards of a leading international

trade fair,” explained Wolfram N. Diener,

President & CEO of Messe Düsseldorf.

“On November 25, the Federal

Government and the German states

decided to implement stricter measures

in Germany, and to possibly even extend

these measures into the New Year. This,

unfortunately, does not give cause for

hope that the situation will improve

significantly over the course of the

coming months. This will affect all Messe

Düsseldorf events in the first quarter. We

are now focusing on the next edition of

interpack, which will take place in May

2023 according to plan, and which we

will supplement with extended online

offers,” added Diener.

“For the industry, in-person meetings

and live experiences are still extremely

important, especially when it comes to

complex technology. Both enable a direct

market comparison, new ideas, leads and

networks are created. Online formats

only partially achieve this. We are now

looking forward to a successful interpack

2023, where the industry can once again

come together at its leading global

trade fair in Düsseldorf,” added Richard

Clemens, Managing Director of the

VDMA Food Processing and Packaging

Machinery Association.

fmt

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+ Optimal accessibility

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product food handling Marketing at maximum & Technology throughput • February rates. For 2021 further information about Coperion‘s ZSK Mv PLUS please

29

visit our website at www.coperion.com/food-extruders

Key No. 99395


Packaging

Successfully Filling the Gap: Cereals now

in Paper Packaging

The use of resource-efficient materials is now a ‘must’ in the packaging industry. Numerous brand

manufacturers have identified this development and are already using environmentally friendly substrates,

however, the reluctance on the part of many food producers to switch from plastic-based solutions to paper

remains high. The innovation driver Sappi and the packaging machine manufacturer ROVEMA demonstrate

in a pilot project how this can work. A well-known cereal manufacturer successfully switched its fully

automated production of stand-up pouches to sealable barrier paper.

‘Sustainability’ challenge

As part of a company-wide sustainability

strategy, a well-known cereal

manufacturer wanted to completely

switch its packaging from plastic to

paper. The company that produces

organic products such as flour, porridge

oats, muesli and bread mixes still

occupies a niche role in the German

market. Only one Austrian competitor

has so far made strides in this direction

to the same extent. The company also

placed high demands on its partner

ROVEMA with regard to efficient

packaging processes based on highquality

and above all, environmentally

friendly packaging materials. In the

project to adopt paper with special

barrier properties as the material for

the stand-up pouches, that are used

for different product groups and in

different sizes, the packaging specialists

from Fernwald called on the innovation

leader Sappi to support them. The two

companies have been development

partners since 2018.

Sustainable materials demand

high expertise

For ROVEMA, it was clear that the

only way they could find a sustainable

substrate solution for the customer, to

ensure maximum performance, was

with the help of Sappi. “The smooth

production of stand-up pouches relies

not only on our special expertise

in machine configuration. Every

parameter in this process is important,

in order to ensure high, continuous

production,” says Gerhard Kuss, head

of application technology at ROVEMA

GmbH, explaining the challenge. “This

is because, unlike in the case of standup

pouches or flat pouches made from

composite materials, the resourceefficient,

paper-based alternatives

need to be handled much more

carefully during the packaging process

and during production of the pouches.

Paper tolerates only a small amount of

tension transfer here and tears more

easily. The perforation resistance of

the paper used also needs to be taken

into account much more during the

subsequent filling”.

This is precisely where Sappi’s extensive

expertise came into play. Once they

had carefully examined the customer’s

specific requirements, Sappi’s paper

specialists then selected the right

material for the packaging of sensitive

food products. As well as an efficient

grease and oil barrier function, the

paper-based alternative should also

have required optimum heat-seal

properties. The Sappi Guard product

line was therefore chosen, with its

30

food Marketing & Technology • February 2021


Packaging

and could be optimally configured to

the packaging process even in printed

form. Another key benefit is that it can

be recycled in the paper waste cycle.

innovative range of functional papers

specially developed for the flexible

packaging market. Thanks to their

integrated barriers, there is no need for

any additional application of coating

or lining to achieve the required

capabilities with these functional papers.

After a few weeks of testing, during

which Sappi and ROVEMA studied

the interaction of the packaging

material and the packaging machine

and coordinated them optimally to

one another, the perfect substrate

was found for the customer in the

form of Sappi Guard Nature MS in a

grammage of 80g/m². The material

not only offered the perfect mix of

formability and stability, but also a

high level of sealability. Guard Nature

MS also offered excellent print results

Development based on

partnership ensures a competitive

edge

The paper-based packaging material

demonstrated its capabilities in the

process that was perfectly coordinated

by Sappi and ROVEMA. The precise

coordination of packaging material and

machine played a major role in ensuring

the high quality of the packaging

process. In the automated shaping of

stand-up pouches in particular, folding,

seal times and seal temperature –

common sources of error in the process

– need to be perfectly synchronized in

order to ensure a reliable product.

In addition, due to the longer seal times,

switching to paper-based packaging

material can result in a drop in output

of up to 30 percent, however, in this

pilot project, performance loss was kept

to 10-15 percent. One of the reasons for

this was software specially developed

by ROVEMA, which is integrated into

the precise packaging process. This

enables parameter changes to be

directly synchronized virtually in real

time, so the process can be adapted

accordingly. Individually defined limit

values and plausibility calculations

prevent incorrect changes in the

process and thus keep the performance

stable. This is a level of precision that is

not yet common in relation to paperbased

packaging materials in particular.

The successful pilot project demonstrates

how Sappi’s expertise in

sustainable barrier packaging solutions

made from paper, together with the

technical expertise of the packaging

machine manufacturer Rovema, have

successfully filled a gap in the packaging

industry. Customers who are looking

to use resource-efficient packaging

materials can now benefit from the

combined knowledge and wealth of

experience of the two partners, get the

optimum packaging solution – tailormade

and customized – and thus gain

a clear competitive edge.

fmt

Gerhard Kuss

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Packaging

Bespoke Solutions in Meat Packaging

Support Danish Crown’s China Expansion

Ishida Europe has designed and

installed a series of bespoke packing

lines for specialist meat producer

Danish Crown’s new greenfield

factory in China.

Working in close partnership with the

customer, Ishida has supplied its own

and ancillary equipment for the four

lines, which are handling a variety

of products including minced and

diced pork, ribs and steaks, as well

as quality control for thermoformed

packs of pork. The factory is now in

operation and will have a capacity for

14,000 tonnes of meat to be processed

and packed each year when it is up to

full speed.

working relationship established

between our two teams and the

continuing dialogue between them

ensured that any issues or problems

could be discussed and quickly dealt

with to keep the project on time and

budget and enable us to meet our

performance targets.

“In addition, the company has an

office in China which ensures a fast

response in terms of service support

and spare parts.”

The Ishida models installed at the

factory include the company’s advanced

RV-214 multihead weigher,

QX-1100 Twin tray sealers, DACS-G

checkweighers, IX-GN x-ray inspection

systems and its weigh-price-labellers.

Additional equipment integrated

into the lines includes dicers, slicers,

batching tables, labellers and

cartoners. Ishida also gave factory

personnel comprehensive training

on all its machines and provided

a technician on-site permanently

Ishida’s ability to devise complete

solutions in line with customer

requirements and efficiency and

throughput targets, along with the

excellent performance and reliability

of its equipment, were key reasons

for the company’s selection by Danish

Crown.

“We felt that Ishida offered the most

relevant experience and the best

solutions,” explains Nicolai Linde,

Senior Manager Projects, Production

and Supply Chain. “Having a single

point of contact helped to speed up

the process. In particular, the close

32

food Marketing & Technology • February 2021


Packaging

during the first months

of operation to ensure a

trouble-free start up.

A key requirement of

the overall design was

to ensure maximum

flexibility in the lines’

ability to handle a wide

variety of products and

pack types. For example,

the multihead weigher is

able to discharge diced

meat directly into trays, or

transfer ribs to a batching

table for styling in the trays.

Similarly, the QX-1100 tray

sealers which currently seal

MAP trays are also able to

handle skin packs, which

will enable Danish Crown

to meet growing demand

in the Chinese market for

bone-in products.

“Although we were not

previously familiar with

Ishida’s tray sealers, they

have proved to be very

reliable and deliver

consistently high-quality

seals,” comments Nicolai

Linde.

As another example of the

excellent performance of

the Ishida machines, the

company’s IX-GN 4044 x-ray

inspection systems and DACS-G-015

checkweighers are also providing

quality control and weight checks on

two separate thermoforming lines.

Danish Crown is one of the world’s

largest exporters and one of Europe’s

largest producers of pork. The

new China factory in Shanghai was

established to meet growing consumer

demand in the Chinese market for

high quality meat products, supplied

via supermarkets and e-commerce.

“Our objective was to build the new

factory to Danish standards,” explains

Nicolai Linde. “For this reason, we

focused on sourcing the very best

European equipment throughout.” fmt

food Marketing & Technology • February 2021 33


Packaging

Independent Cart Technology Underpins

Integrated Packaging Concept

Advanced packaging solution integrates seamlessly into modern component fabrication line thanks to

innovative in-machine and between-machine transportation technology

Cama Group prides itself on the way

it designs, develops and deploys

new technologies, in order to bring

heightened integration, throughput,

accuracy and quality levels to the

packaging industry.

Its machines, which see action all

over the globe in a huge variety of

packaging applications, are designed

to offer the perfect blend of modular,

accessible and hygienic mechanical

frameworks, coupled to the very latest

technology the automation world has

to offer; including advanced and tightly

integrated in-house-developed robotic

pick-and-place solutions.

In a recent project, Cama’s high-tech

pedigree was really put to the test,

when it was tasked with designing and

integrating one of its Breakthrough

Generation (BTG) CL 175 cartoning

machines into an electrical component

fabrication line at one of the world’s

largest automation vendors, Rockwell

Automation.

In addition to proving the integration

capabilities of the control solution,

Cama had to demonstrate that its

machine would fit seamlessly into the

rest of the line, the majority of which

had been developed and built by US

company Calvary Robotics, a specialist

in the design and build of automated

assembly, test and material-handling

systems.

According to Giovanni Panzeri,

Automation Project Leader at

Cama: “The line with which we were

integrating is for the assembly of a

wide range of contactors, the model

type of which vary depending on the

contact configuration, the voltage and

the applicable local certifications, such

as CE and UL. The line is designed to

be as flexible as possible, so that small

batches of the various contactor models

can be fabricated – to order in a just-intime

fashion – as efficiently as possible,

with minimum re-engineering and

downtime. As a result, our packaging

solution had to deliver a commensurate

level of flexibility, to adapt and change

to the various product throughputs.”

Cama and Rockwell Automation had

already worked very closely before on a

number of industry-leading packaging

machines, so the relationship had a

significantly strong foundation. But it

was Cama’s experience with the global

automation supplier’s independent cart

technology (ICT) that helped seal the

deal… and provided the all-important

physical link into the rest of the line.

“Cama was one of the first companies

to deploy the iTRAK ICT in a customer

application,” Panzeri explains, “so

we already had a good grounding

in its operation and how it could be

leveraged to deliver the additional

flexibility many end users require. Using

iTRAK, with its near limitless motion

profiles, the individual product carriers

within our machine, controlled by the

central PLC, are pitched automatically

based on the width of the product or

product groups that require insertion

into the cartons. Thanks to this, the

cartoner can work intermittently or

Photos: CAMA Group.

34

food Marketing & Technology • February 2021


Packaging

continuously depending on the product

and throughput required.

“The CL 175 comprises three main

operating stations,” he elaborates. “In

the first, carton boxes are picked from

a magazine and opened out as they

are placed into pockets on the iTRAK

carriages. Once placed, two pockets/

boxes at a time are presented to the

insertion station, where the contactors

are pushed into the boxes. Following

insertion, the boxes are closed and sealed

before passing to a printing station,

where the individual product-specific

information is printed and verified,

before the cartons leave on an exit

conveyor. After the products leave on the

conveyor, the iTRAK carriages recirculate

under the track ready for loading with

the next round of cartons. The cartoninsertion

system exploits a software

interpolator, which delivers coordinated

movement between the iTRAK and the

servo-controlled pushers. As well as

delivering far greater accuracy and axis

synergy compared to a more traditional

pneumatic systems, this approach also

reduces mechanical stresses.

“Advanced in-machine automation is

second nature to us, thanks to our broad

experience using robotics and linear/

rotary servo technologies,” Panzeri adds.

“But a vital element of this installation was

the way in which the CL 175 integrates

with the downstream assembly processes,

so as not to cause any bottlenecks. This,

as it turns out, was made possible using

another of Rockwell Automation’s ICT

technologies, MagneMotion Lite.”

Preceding the CL 175 cartoning machine,

the Calvary Robotics line comprises

three assembly machines, a productprinting

module and two testing

stations, arranged in a ‘U’ shape. All

of the assembly and testing steps are

interlinked using the MagneMotion ICT,

so the best possible solution would see

the MagneMotion technology extended

into the packaging operation.

delivers seamless interactions across all

elements of the line, as if it is one large

machine, so our packaging solution

was simply another step in a larger

process. Full EtherNet/IP connectivity

across the machines and larger devices

and I/O Link at the component level

means that full integration is possible,

as is the creation of fully transparent

data pathways, creating a true Industry

4.0 solution. This interconnected

architecture also means that all stations

along the line work in harmony with

each other. As each batch variation is

fed from the primary MES system, every

machine is geared up to undertake the

correct assembly, printing, testing and

packaging processes – with absolute

minimal human interaction.”

Rockwell Automation’s choice of Cama

for this application is testament to the

strength of their mutual relationship

and reinforces the capabilities of

modern integrated control solutions.

“We are often selected by Rockwell

Automation to act as product testers

for new hardware and the fruits of

this testing and evaluation are evident

in an application such as this,” Panzeri

adds. “This line is a graphic example

of three engineering teams working

together with a common goal, which

is underpinned by a very powerful

integration model.

“Indeed, this line is a great shop window

for all of our technology, teamwork and

capabilities and reflects the direction in

which the packaging industry is moving,”

Panzeri concludes. “ICT technology both

in machine and between machines is

creating the foundation for flexible

manufacturing and production, where

the idea of a production line will soon

become redundant. Smart-conveying

solutions are creating the basis for

production grids, or matrices, where

products only visit the stations they

need, but without creating mechanical

complexity, batch-adaptation hurdles or

transportation conflicts.”

fmt

“Thanks to the complete integration

and the holistic control environment,

having MagneMotion as the in-feed

supply solution was a straightforward

proposition,” Panzeri explains. “The

Allen-Bradley control architecture

food Marketing & Technology • February 2021 35


Packaging

Elopak Records One Billion Natural

Brown Board Cartons

The volume of Elopak’s Natural Brown

Board cartons will surpass one billion

units in February 2021. The milestone

is good news for the company’s

sustainability efforts, as the lower CO 2

footprint of these cartons means an

estimated 3,000 tons of greenhouse gas

emissions have been avoided as a result.

The reduction in CO 2

emissions resulting

from the use of Natural Brown Board is

equivalent to approximately 1,400 round

trip flights for one person London - New

York.

The news comes after Elopak recorded

a significant increase in its sale of

Natural Brown Board cartons in 2019,

with brands responding to increased

consumer interest in the environmental

credentials of their products by making

the transition to sustainable packaging

solutions. Today approximately 20% of

the Pure-Pak® milk cartons Elopak sells

in Western Europe are produced with

Natural Brown Board.

Speaking on the news, Elopak’s Director

Sustainability Marianne Groven stated,

“Beverage cartons already have strong

environmental credentials when

compared with alternatives such as plastic

bottles. It is encouraging to see that our

customers are embracing innovations

that offer a more sustainable solution,

such as the Natural Brown Board.

Together we can aim even higher and

help consumers make conscious choices.”

Launched in 2017, in partnership with

supplier Stora Enso, Elopak was the first

packaging company to provide gable

top cartons made with Natural Brown

Board. These Pure-Pak® cartons are

renewable and recyclable. They have a

lower CO 2

footprint owing to reduced

wood consumption and the elimination

of the bleaching process. Their rustic,

natural look effectively communicates

this commitment to sustainability and

instantly stands out on the shelves.

“This is an exciting milestone for us as

Elopak was the first company to offer

gable top cartons made with Natural

Brown Board. We were also the first in

our industry to announce that we are a

carbon neutral company offering carbon

neutral cartons, and the first to offer

fully renewable cartons made entirely

from wood,” Elopak’s Chief Marketing

Officer (CMO) Patrick Verhelst stated.

“Our customers are very responsive

to consumers’ desire to reduce their

environmental impact. A lot of them

offer organic, green or otherwise

sustainable products and they want

a packaging solution that reflects

this ethos and instantly signals their

commitment to the environment.

With its unbleached, natural look the

Pure-Pak® cartons with Natural Brown

Board effectively communicates that

inherent sustainability at first glance,” he

continued.

Several customers were quick to embrace

the Natural Brown Board with Arla

being the first major brand to adopt the

innovation for its line of organic EKO

products in Sweden. In June 2018, when

Arla launched its Arla Organic range of

milk and drinking yoghurts, the brand

opted again for one liter Pure-Pak®

cartons with Natural Brown Board, which

were rolled out across the Netherlands,

Denmark, Sweden, Germany and Finland.

Some customers have taken the concept

further and removed the renewable

plastic cap. Norwegian dairy, TINE,

transitioned from a white carton

with a cap to a Natural Brown Board

carton without a cap, resulting in a

carbon footprint reduction of around

40%. Sweden’s second-largest dairy

Skånemejerier has also removed the caps

on all their Hjordnära organic milk oneliter

cartons, launching its organic milk

in new Pure-Pak® cartons with an easy

opening funnel feature to replace the

plastic closure.

Since its launch, Elopak’s Natural Brown

Board has served as a platform for

further sustainability-focused innovations,

including the Pure-Pak® Imagine launched

in 2020. The carton is a modern version of

the company’s original Pure-Pak® carton,

containing 46% less plastic and designed

with a new easy open feature. It has no

plastic screw cap and is 100% forest-based

made with Natural Brown Board, making

it Elopak’s most environmentally friendly

carton to date.

fmt

36

food Marketing & Technology • February 2021


Packaging

Digitized Silo Fill Level Monitoring

Nanolike is pleased to introduce a new

digitized fill level monitoring solution

for food and beverage silos. The goal

is to simplify inventory and order

management processes in the food and

beverage industry. Another aim is to

help the manufacturers and suppliers

of raw materials and additives optimize

their silo replenishment processes. This

not only saves costs but also reduces

the environmental impact by enabling

route optimization. The new digitized

silo fill level monitoring solution stands

out through highly efficient sensor and

cloud connectivity technology using the

Sigfox 0G wireless network. It requires

zero maintenance for years and needs

neither an external power supply

nor a data line, which saves costs and

ensures that the digitization investment

is amortized very quickly. This makes

Nanolike technology highly disruptive,

as it can replace any alternative sensor

technology used exclusively to manage

replenishment management.

Users of Nanolike‘s digitized silo fill

level monitoring solution are found

in almost all sub-sectors of the food

industry, from soft drink and fruit juice

producers, dairy product manufacturers,

breweries and coffee roasters, to legume

processors and industrial bakeries as well

as jam, instant and convenience food

manufacturers – and that‘s by no means

an exhaustive list. Nanolike’s digitized

silo fill level monitoring solution isn’t just

for large silo operators; it also targets

silo manufacturers who aspire to include

this technology in their portfolios and,

above all, raw materials and additives

manufacturers aiming to offer their

customers automatic replenishment,

vendor-managed inventory (VMI)

or similar solutions as part of their

digitization strategies.

Quickly and easily mounted on the exterior

base of the silo, the Nanolike sensors

give users 24/7 access to information on

fill levels and demand forecasts in realtime.

This digital solution makes it much

easier to monitor the silo fill levels and

greatly reduces users’ workload, as they

no longer have to climb to the top of

silos at different locations to check the

fill levels. Instead, all required inventory

management tasks can be done in less

time from the safety of the office. An

integrated early warning system alerts

the silo operator to potential bottlenecks,

helping to prevent any shortages of raw

materials and additives.

Based on real-time data, the mobile

application also facilitates the

automation of purchase processes

as silo operators can chose to place

orders directly from their smartphones.

Such an integrated solution, which

can be implemented with just a few

clicks, greatly simplifies communication

between food manufacturers and

their suppliers. What is more, it makes

it possible to optimize the supply to

distributed silos at a higher level, leading

to overall savings in transport logistics,

which ultimately also improves the long

term CO 2

balance. The data from the

Nanolike sensors are consolidated in a

central cloud from where they can be

imported into existing software systems

and customer clouds, or retrieved via

smartphone app at any time.

The digitized fill level monitoring solution

from Nanolike is extremely simple to

implement, as it is self-calibrating, does

not require active calibration, and also

filters out undesirable environmental

influences. Before filling a silo, the user

sets the sensor to zero via the mobile

phone app and manually enters the fill

load once in the software. From thereon,

the changing fill level is calculated in

the cloud, based on a comparison of

sensor data recorded before and after

filling. The measurement corridor can

include just the one load, which doesn’t

have to be a full load, or it can map the

state between a completely empty and

completely full silo.

fmt

Food and beverage silos are easier to manage with Nanolike’s digitized fill level monitoring solution (© Teodororoianu | Dreamstime.com)

food Marketing & Technology • February 2021 37


Marketing

No More VOCs: Waterless Offset Printing

Japanese material technology expert Toray Industries, Inc. has developed the first printing system that is

completely VOC-free. Used in flexible packaging printing, it can keep workers safe without compromising

printing quality.

The demands placed on flexible

packaging manufacturers are

growing. Packaging should be more

environmentally friendly, more cost

efficient – and all that while delivering

superb printing quality and being

safe for consumers and workers alike.

On top of that, the food industry is

seeing a general trend towards a

diversification of products, resulting

in smaller printing runs. The use of the

right printing method plays a major

role in meeting these expectations.

But flexographic and gravure printing,

the established industry standards,

are increasingly reaching their limits

in accommodating some of these

aspects.

VOCs: Harmful to workers and

the environment

One such puzzle that has been

plaguing the industry for years is how

to avoid volatile organic compounds

(or VOCs) in the printing process. The

term encompasses a variety of gases

and small particles that are released

during the production, use, or even

storage of certain products, such

as cleaning liquids or paint – with

harmful consequences on both

the environment and the workers

Workers at printing plants come into contact

with VOCs at various touchpoints

interacting with VOCs. Long-term

exposure with VOCs can lead to

anything from eye and throat

irritation to loss of coordination,

chronic fatigue, or even cancer.

In flexible packaging printing, VOCs

occur mainly through the use of

solvents in inks and the cleaning liquid

used on the printing presses. In cases

where conventional offset printing is

used, the dampening water becomes

an additional contributor of VOC.

And while the environmental harm

of VOCs has largely been contained

through air filters in printing facilities,

the detrimental effects on workers’

health remain. Although significant

strides have been made in reducing

VOCs, it was not possible to avoid

them completely – until now.

One solution to rule them all

Toray Industries, Inc. has developed

the first ever printing system that is

100 percent VOC-free. What is more,

the solution makes no compromises in

printing quality or food safety.

One key to achieving this is the

use of waterless offset printing

with Comexi’s CI8 printing press. In

offset printing, the inked image

is transferred – or offset – from a

printing plate to a blanket made

of rubber, which in turn transfers it

onto the printing surface. While this

printing technique has become an

established method in such fields as

newspaper printing, label printing,

plastic card printing and others, it

is still relatively unheard of in the

flexible packaging world.

Yet, offset printing comes with a

number of features ideally suited

for the present challenges in flexible

packaging printing: Offset printing

plates are a lot easier to produce than

the cylinders required for rotogravure

printing or photopolymer plates for

flexographic printing. This allows

more flexibility in terms of short-term

printing, facilitating smaller printing

jobs at a low cost point. Furthermore,

the use of waterless offset printing

can already reduce the amount VOCs

by up to 80 percent compared to

conventional offset printing.

However, conventional offset printing,

the most common offset printing

method, is fairly limited in the choice of

substrates that can be used. Moreover,

conventional offset printing requires

dampening water to repel the ink

in places that are not printed. The

stained dampening water becomes a

source of VOCs and also creates waste

water that subsequently needs to

be purified before further use. Thus,

while conventional offset printing

comes with a number of advantages

in terms of flexibility and economy,

it cannot fully eliminate VOCs in the

printing process.

Bringing waterless offset

printing to the flexible

packaging industry

To forego this issue, Toray is relying

on a technology that the company

has been successfully working on for

decades: waterless offset printing. In

38

food Marketing & Technology • February 2021


Marketing

on-site tests, the Comexi CI8 offset

printing press could easily be adapted

to this environmentally friendly

version of offset printing. Here, a

silicone polymer is used as an ink

repellant instead of a dampening

solution, eliminating one major

source of VOCs.

Inks and cleaners: Completing

the puzzle

The test also featured the second

central element of Toray’s new

printing solution: water-washable

EB inks. Reducing VOCs in inks has

been a goal of manufacturers for a

while, resulting most recently in the

introduction of water-based inks. The

concentration of organic solvents,

the main contributors to VOCs, is

between five and 30 percent in these

inks – compared to up to 80 percent

in regular oxidative inks. However, a

remnant of VOCs remain, not only in

the ink itself, but also in the liquids

used for cleaning the printing presses.

These require the use of organic

solvents in order to eliminate any

remaining ink, and they contain

relatively high levels of VOC. A waterbased

cleaning liquid could alleviate

this problem – but it can only be used

with the new kind of water-washable

EB ink developed by Toray.

The ink itself does not contain

any organic solvents, making it

completely VOC-free. At the same

time, the combination of special ink

formulation and waterless printing

achieves a particularly strong adhesion

to a wide variety of substrates. These

special inks are cured using an

electron beam (EB) instead of UV light

and therefore do not include any of

the photo-initiators limited by food

packaging regulations. Consequently,

there is no risk of any VOCs or

photo-initiators migrating into the

printing substrate. The new solution

is therefore particularly safe for food

packaging.

Finally, water-washable EB inks allow

the use of water-based ink cleaners.

As this cleaning process is mostly done

by hand, it is the most significant

factor where workers still come into

direct contact with VOCs. Eliminating

harmful particles here is therefore

especially important to maintaining

workers’ health. Together with waterwashable

EB inks and waterless offset

printing, these water-based cleaners

form the first completely VOC-free

printing system in the world.

The future of flexible packaging

printing is VOC-free

With the combination of waterless

offset printing, water-washable EB

inks, and water-based cleaning liquid,

Toray’s new printing system is the

first in the world to be completely

VOC-free. And it has already been

put to the test. A European converter

completed a series of tests to print

OPP, PA boil, and PET retort pouches

with Toray’s technology and a Comexi

CI8 press – with resounding success.

However, the Japanese material

technology specialist is not merely

hoping to offer flexible packaging

manfuacturers a more sustainable and

healthier alternative – the solution is

also meant to bring superior printing

quality.

This sentiment is expressed in the

brand name P4E, which in future will

include all VOC-free printing solutions.

The name stands for “Epoch-making,

Ecology, Excellence and Efficiency”

for the printing industry. An

ambitious goal that the company is

alread planning on expanding. “We

want to move towards contributing

to a circular economy in flexible

packaging printing and help achieve

the Sustainable Develeopment Goals

(SDGs) set by the United Nations”,

Toray Industries, declares.

In keeping with the company’s

own sustainability vision, Toray has

contunuously been seeking technical

developments that will help create a

greener future. Recycling has been

one dream in the flexible packaging

world for some time. In order to

make it a reality, Toray Industries’

film business segment is currently

working on applying mono-material

subtsrates to the process. At the

same time, the company is hoping

to extend VOC-free printing to other

printing segments, as well. Thus,

Retort packaging samples using Comexi CI8 press

and Toray’s novel printing system

Toray is working to provide the right

solutuon for the future of flexible

packaging – more sustainable, more

adaptable, and just as high-quality as

the currently leading solutions. fmt

The Author

Mr Takayuki Kamei is General Manager,

Electronic Information Materials Division,

Toray Industries, Tokyo, Japan

food Marketing & Technology • February 2021 39


Events

Fairtrade Launches Virtual for all Middle

East Africa 2021

Focus on Middle East Africa’s (MEA) agrofood & plastprintpack sector on 31 May to 02 June

After the success of the Virtual

agrofood & plastprintpack Africa in

November 2020, the German trade

show specialist fairtrade Messe is

launching another digital format

with the Virtual for all Middle

East Africa from 31 May to 2 June

2021. The organizers’ aim with this

event is to contribute to deepening

global relations with the Middle

East and Africa in the agrofood &

plastprintpack sector.

A brief review of November’s Virtual

for all Africa also gives an indication

of what participants at the new event

can expect. A total of 2,353 registered

participants from 87 countries

attended. 64 exhibitors from 17

countries received 8,783 visits to their

virtual stands and their products

were consulted 2,008 times. 3,540

visitors attended 67 panel discussions,

presentations and product demos

with a total of 98 speakers. These

facts, together with high satisfaction

scores on both the exhibitor and

visitor side, have made Virtual for all

Africa the most important agrofood &

plastprintpack online event with an

Africa focus.

“30 years of experience in organizing

international trade fairs in the Middle

East and 25 years in Africa enable

us to establish the new Virtual for

all Middle East Africa on a solid

footing. At the same time, we are

going down innovative digital paths

so that our exhibitors and attendees

can communicate and do business

in the best possible way,” explains

Martin März, fairtrade founder and

managing partner.

And fairtrade managing director

Paul März outlines: “Virtual for all

MEA 2021 will benefit from two

innovations: Firstly, in addition to

our proven partners in the Maghreb

and in West and East Africa, we are

setting further regional focuses. In

Africa with Egypt and South Africa

and in the Middle East with Saudi

Arabia, UAE, Iran, Iraq, Jordan, Oman,

Qatar, Kuwait and Bahrain.

And secondly we will complement

the award-winning event platform

we already used for Virtual for all

Africa 2020 by a mobile app that

will bring notifications regarding

appointments between exhibitors and

attendees directly to the smartphones,

helping to ensure that agreed B2B

appointments actually happen.”

Participation for visitors is

complimentary. Exhibitors can choose

between various exhibitor and

sponsorship packages.

In addition to the B2B meetings,

Virtual for all Middle East Africa 2021

will offer a large-scale conference

programme extending over the

entire three days addressing relevant

and currently highly debated topics.

For three days, the focus will be on

Middle East Africa and on agricultural

production, food and beverage

technology, food ingredients, food

trade, as well as plastic, printing and

packaging materials, raw materials

and technology.

• agro: To diversify Africa’s

economies and revive its rural

areas, the African Development

Bank (AfDB) has committed US$

24 billion towards agricultural

industrialization. According to the

German Engineering Federation

VDMA, MEA’s agricultural

machinery imports amount to well

over €2 billion annually.

food + bev tec: Imports of food

processing & packaging technology

account for €4.683 billion in 2019

(VDMA)

40

food Marketing & Technology • February 2021


Events

food ingredients: With 1.6 billion

inhabitants, MEA has long been

one of largest food markets in

the world. Expenditure in the F&B

sector is growing steadily, and F&B

production is by far the largest

segment of the MEA processing

industry.

food + hospitality: According to the

African Development Bank, MEA’s

annual food imports are estimated

to rise from US$ 85 billion to US$

170 billion by 2025.

• plast: Since the Middle East is a

huge exporter of plastics in primary

forms, and Africa only produces

39% of its required plastic raw

materials itself but imports 61%,

the Middle East & Africa fit very

well together to outbalance their

needs. African Imports of plastics

raw materials, for instance, grew

by 5.9% annually between 2011

and 2017, from 4,220 kt to 5,939

kt, +41%. And the Middle East’s

exports of such material grew

from 16,607 kt in 2011 to 25,280

kt in 2017, an annual increase of

7.25%. (EUROMAP) MEA’s imports

of plastics technology made up for

€1,779 billion in 2019. (VDMA)

• print: MEA’s imports of printing

& paper processing technology

represent €1,368 billion in 2018, up

7.8 per cent to 2017. (VDMA)

• pack: MEA’s imports of packaging

technology make up for €2.291

billion in 2019, +3.2% compared

with 2018. (VDMA)

fmt

Q2 2021

31 May-2 June

Middle East Africa agrofood

fairtrade Messe GmbH & Co. KG

Kurfürsten Anlage 36,

69115 Heidelberg, Germany

Tel.: +49-6221/4565-0

Fax: +49-6221/4565-25

info@fairtrade-messe.de

www.virtual-africa.com

www.fairtrade-messe.de

16-17 June 2021

Hamburg, Germany

Snackex

European Snacks Association

Rue des Deux Eglises, 26

1000 Brussels, Belgium

Tel: +32-2 538 20 39

Email: esa@esasnacks.eu

www.snackex.com

18-21 July

Chicago, IL, USA

IFT Food Expo

Institute of Food Technologists

252 W. Van Buren,

Suite 1000, Chicago, IL 60607

Tel.: +1-312-782-8424

Fax: +1-312-782-8348

www.ift.org

Virtual

Let’s meet here

Let’s meet here

Let’s meet here

Q3/4 2021

1 September

Palexpo, Le Grand-Saconnex, Switzerland

Vitafoods Europe

Informa Exhibitions,

5 Howick Place,

London SW1P 1WG,

Let’s meet here

Great Britain

Tel.: +44 20 337 73111

www.vitafoods.eu.com

4-8 October

Munich, Germany

drinktec

Messe München GmbH

Messegelände

81823 München, Germany

Tel: +49-89-949-11318

Fax: +49-89-949-11319

www.drinktec.com

Let’s meet here

30 November-2 December

Frankfurt, Germany

Food ingredients South America

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 Let’s meet here

www.ubm.com

food Marketing & Technology • February 2021 41


Last Page

Advertiser’s Index • February 2021

Key No. Page Company Location

94441 Digital ANDRITZ AG Leuven, Belgium

99050 23 Bühler AG Uzwil, Switzerland

99395 29 Coperion GmbH Stuttgart, Germany

99601 4 European Snack Association Brussels, Belgium

97065 5 fairtrade GmbH & Co. KG Heidelberg, Germany

99420 9 J. Rettenmaier & Söhne GmbH Rosenberg, Germany

98981 27 Kohlhoff Hygienetechnik GmbH & Unna, Germany

98838 21 NETZSCH Pumpen & Systeme G Waldkraiburg, Germany

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

99030 15 Schaaf Technologie GmbH Bad Camberg, Germany

99498 Cover TOMRA Sorting NV Leuven, Belgium

99411 Cover 4 URSCHEL Chesterton, IN, USA

99382 19 WENGER Manufacturing, Inc. Sabetha, KS, USA

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

something should be not quite right.

IMPRESSUM FMT

ISSN 0932-2744

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PREVIEW • APRIL 2021

Flow Packaging

Texture

Color Sorting

Health & Wellness

… and lots more

42

food Marketing & Technology • February 2021

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