food Marketing & Technology 1/2021

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

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1/21<br />

Vol. 35 • 31377<br />

ISSN 0932-2744<br />

Cover: Steam Peeling<br />

Solutions<br />

Covid Intensifies<br />

Well-Being Interest<br />

Food Extruder in<br />

Hybrid Design<br />

Sustainable Barrier<br />












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ANDRITZ solutions for<br />

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DRYING<br />


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Targeted at international trade shows<br />

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in October<br />

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Editorial<br />

A New Start in <strong>2021</strong><br />

Some people find it difficult to see<br />

anything positive coming out of the<br />

year 2020. Others see it as healthy to<br />

take stock of one’s personal situation<br />

and make appropriate changes in things<br />

like <strong>food</strong> consumption. Many people<br />

have ordered groceries on-line – and<br />

this is a trend we can expect to continue.<br />

Equally so is the ‘dining-in experience’.<br />

We tried it at home over the holiday<br />

period. We ordered <strong>food</strong> from our local<br />

restaurant, and created an atmosphere<br />

at home, with table cloth, candles<br />

and background music which made<br />

the occasion special. It was a positive<br />

memory which will live beyond Covid-19<br />

and which we will be glad to repeat.<br />

One major trend we can expect to<br />

see continue this year is sustainability,<br />

which has many forms. It remains<br />

important to find long-term solutions<br />

to the <strong>food</strong> we harvest and process. This<br />

may mean alternatives in proteins from<br />

plants or insects, it may mean blending<br />

them to enhance benefits of different<br />

options. It will also mean tackling the<br />

problem of <strong>food</strong> waste. Climate control<br />

and meat replacement are often linked<br />

together under the sustainability<br />

umbrella. Some environmental benefits<br />

of less travel have already been seen<br />

and recorded.<br />

The number and quality of nonmeat<br />

burgers has grown. The plant<br />

based movement has created a lot of<br />

opportunities within the hydrocolloid<br />

world. Many <strong>food</strong>s-that-used-to-becalled-burgers<br />

use methylcellulose,<br />

starch and fibre. Some products will<br />

have bacon based on vital wheat gluten.<br />

Current commercial vegan cheeses<br />

rely on potato and tapioca starch,<br />

xanthan and konjac gum to achieve<br />

the meltability and texture consumers<br />

are expecting from cheese. Everything<br />

which is based on wheat and pea protein,<br />

makes organic and non-GMO sourcing<br />

of these proteins necessary for future<br />

differentiation from the competition.<br />

Personalised nutrition is another<br />

buzzword which sounds good, but is<br />

probably still looking for its definition.<br />

Recent data has underlined the<br />

continued growth in child obesity. The<br />

call is loud to the <strong>food</strong> industry to reduce<br />

20% of sugar and calories in everyday<br />

<strong>food</strong> consumed regularly by children.<br />

Ingredient manufacturers often select<br />

a colour for a new year which then<br />

becomes a trend of its own. It doesn’t<br />

really matter which one. For <strong>2021</strong> I<br />

am choosing white. For one thing it is<br />

a difficult colour to produce naturally<br />

Ian Healey<br />

Editor-in-Chief<br />

and sustainably. And my favourite<br />

soccer team plays in white, so that’s as<br />

good a reason as any.<br />

In the meantime the digital opportunities<br />

for this magazine are staying dynamic.<br />

Under www.<strong>food</strong>-mt.com you can find a<br />

digital copy of this issue as well as other<br />

news as it comes in, white papers, banners,<br />

and video slots. It is possible to receive<br />

the magazine electronically as soon as it<br />

is published. Please subscribe using the<br />

button on the website. Good for the<br />

readers and good for the environment!<br />

Our twice-monthly newsletter was<br />

launched last year and has proved very<br />

popular. Feel free to register for free.<br />

Sincerely,<br />

If you like it – subscribe!<br />

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


XIX International Trade Fair<br />

for Savoury Snacks & Nuts<br />

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

Hamburg, Germany<br />

Contents<br />

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

1 Editorial<br />

42 Impressum<br />

Move your<br />

business<br />

forward<br />

Ingredients<br />

9 Flavor, Color, & Texture Trends in <strong>2021</strong><br />

12 Bringing Cultivated Meat to Japan<br />

13 New Seaweed Powder Unveiled to Address Consumers’<br />

Appetites for Label-Friendly Ingredients<br />

14 Olive Leaf Extract Now Non-GMO Project Verified<br />

16 CCOVID-19 Intensifies Consumers’ Interest in Well-Being<br />

and Eco-Friendly Products<br />

at the worldwide fair<br />

for savoury snacks<br />

The only trade fair 100% focused<br />

on savoury snacks and nuts<br />

Processing<br />

6 Steam Peeling Solutions for Vegetables and Fruits<br />

18 Sweet Revolution<br />

20 Food Extruder in Hybrid Design: Ideal System for Product<br />

Development and Piloting<br />

21 Baker Perkins Equipment Industry 4.0 Ready<br />

22 Shaping the Puzzle for Quality Formed Products<br />

24 Grinding Innovations from well-proven <strong>Technology</strong><br />

Key No. 99601<br />

snackex.com<br />

+ Experience the hottest trends,<br />

tastes and technologies<br />

+ Develop your business with the<br />

industry’s leading suppliers<br />

+ Connect with the decisionmakers<br />

of the industry and<br />

find international trade<br />

partners, distributors<br />

+ Meet existing customers and<br />

new prospects from around<br />

the world<br />

+ Sell your products to an<br />

audience that is ready to buy<br />

The industry-defining fair for<br />

the savoury snacks sector<br />

Packaging<br />

26 The Plant-Based Boom - A New High-Capacity<br />

Manufacturing Solution to Keep up with Consumer<br />

Demand<br />

29 Interpack and Components <strong>2021</strong> Canceled due to<br />

Covid-19 Restrictions<br />

30 Successfully Filling the Gap: Cereals now in Paper<br />

Packaging<br />

32 Bespoke Solutions in Meat Packaging Support Danish<br />

Crown’s China Expansion<br />

34 Independent Cart <strong>Technology</strong> Underpins Integrated<br />

Packaging Concept<br />

36 Elopak Records One Billion Natural Brown Board Cartons<br />

37 Digitized Silo Fill Level Monitoring<br />

Departments<br />

38 <strong>Marketing</strong><br />

40 Events

Vol. 35 • 31377<br />

ISSN 0932-2744<br />

Cover: Steam Peeling<br />

Solutions<br />

Covid Intensifies<br />

Well-Being Interest<br />

Food Extruder in<br />

Hybrid Design<br />

1/21<br />

Sustainable Barrier<br />

Packaging<br />

Cover: TOMRA Food<br />

Some of the main benefits of<br />

steam peeling are high quality<br />

and process efficiency. The yield<br />

and quality are much higher than,<br />

for example, mechanical peeling<br />

by 10-15%. The higher quality can<br />

be realized through the increased<br />

value of the product and lower<br />

operation costs, including reduced<br />

energy consumption.<br />

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

Key No. 99498<br />

Ingredients: Covid and Well-being<br />

Environmental concerns have been heightened as a result of<br />

COVID-19. This is in part due to some consumers questioning<br />

whether issues such as air pollution have increased respiratory<br />

issues, making people more vulnerable to the disease. This<br />

concern is being translated into altered buying patterns, with<br />

60% of consumers now being more attentive to the impact that<br />

their <strong>food</strong> and drink has on the environment. Find out more on<br />

page 16<br />

Processing: Food Extruder<br />

Extrusion is one of the most interesting technologies and is<br />

included in a new <strong>food</strong> development and piloting facility in<br />

Finland. The ZSK extruder is being used for process and product<br />

development and is also combined with other <strong>food</strong> production<br />

and packaging technologies. This enables the creation of<br />

commercially ready solutions in the <strong>food</strong> approved facility<br />

together with customers all over the world. Check out the full<br />

story on page. Check out the story on page 20<br />

Packaging: Sustainable Barrier<br />

As part of a sustainability strategy, a well-known cereal<br />

manufacturer wanted to completely switch its packaging from<br />

plastic to paper. The company produces organic products such<br />

as flour, porridge oats, muesli and bread mixes and occupies<br />

a niche role in the German market. The challenge was to find<br />

efficient packaging processes based on high quality and above<br />

all, environmentally-friendly packaging materials. See page 30<br />

Key No. 97065<br />

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

Cover Story<br />

Steam Peeling Solutions for Vegetables<br />

and Fruits<br />

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

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

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

company to introduce steam peeling to many potato and carrot processors.<br />

Food production companies that have<br />

invested in recent years in technology,<br />

automation and capacity are now<br />

leading the industry’s race to produce<br />

higher quantities of <strong>food</strong>, to satisfy the<br />

growing demand for online shopping<br />

and eat-at-home <strong>food</strong>s. Vegetable<br />

processing is a good example of how<br />

technology can provide operational<br />

flexibilities for commercial advantage.<br />

Take technology and automation in<br />

peeling and sorting processes: these<br />

enable customers to process vegetables<br />

like butternut in the morning and celery<br />

in the afternoon, with very little change<br />

to the processing line. And processors<br />

could just as easily switch the line<br />

between, say, sweet potato, beetroot,<br />

carrots, or kohlrabi in varying quantities.<br />

Switching from one product to another<br />

is remarkably easy. By simply changing<br />

settings using a touch panel, the <strong>food</strong><br />

processor can start the line for a new<br />

product with the confidence that<br />

quality and efficiency will be optimized<br />

and minimal need for human<br />

interaction.<br />

Today TOMRA Food is an industry<br />

leader and there are more than 530<br />

TOMRA steam peelers installed around<br />

the world. Before the arrival of steam<br />

peeling in the 1970s, potato skins were<br />

removed by lye-peeling. This was an<br />

inefficient process that used chemicals,<br />

requiring special care and handling,<br />

and consumed high volumes of water<br />

to treat the chemical waste from the<br />

process. Major <strong>food</strong> processors were<br />

crying out for a new solution and<br />

steam peeling was the answer. This<br />

uses steam that is already in use in<br />

processing plants and enables the<br />

more efficient production of high<br />

volumes. This advancement has saved<br />

many processors thousands of Euros<br />

every day. Steam peeling is the most<br />

efficient method of removing skin from<br />

fruit and vegetables. Lines processing<br />

between 1,000 kg/hr – 65,000 kg/hr can<br />

benefit from TOMRA’s steam peeling<br />

equipment, resulting in significant raw<br />

material and energy savings.<br />

Optical sorting technology is where<br />

TOMRA is more well-known and indeed<br />

this is always the first application when<br />

harvesting products. Potatoes and<br />

other vegetables are initially processed<br />

to remove dirt, stones and other<br />

foreign materials. After being ordered<br />

as to size and quality, also depending<br />

on the customer and final destination,<br />

the product is further processed.<br />

Steam peeling entails surrounding each<br />

potato with high pressure and hightemperature<br />

steam to directly heat the<br />

water below the potato’s skin. When<br />

the steam pressure is released, the<br />

water volume below the skin rapidly<br />

expands by more than 1,000 times,<br />

creating the force to separate the peel<br />

from the flesh. This process can be used<br />

for peeling several different vegetables,<br />

including potatoes, carrots, beets,<br />

pumpkin, sweet potato, kohlrabi, and<br />

root celery. It is also used to peel fruits<br />

such as apples, which naturally have<br />

high moisture.<br />

Some of the main benefits of steam<br />

peeling are high quality and process<br />

efficiency. The yield and quality<br />

are much higher than, for example,<br />

mechanical peeling by 10-15%. The<br />

higher quality can be realized through<br />

the increased value of the product<br />

and lower operation costs, including<br />

reduced energy consumption. Less<br />

waste also increases the final factory<br />

output.<br />

6<br />

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

Cover Story<br />

An efficient steam peeling process will<br />

remove 98% to 99% of each potato’s<br />

skin and will equally treat the surface of<br />

up to 3,000 potatoes every few seconds.<br />

To achieve this, fast pressurization and<br />

depressurization of the steam vessel is<br />

essential. The key measurement of this is<br />

the exhaust efficiency factor (EFF), which<br />

is the ratio of the steam shaft crosssection<br />

area (mm2) to the vessel volume<br />

(liters). Product movement and mixing<br />

inside the vessel are also important.<br />

There must be a high rotation speed (up<br />

to 28 rpm) and consistent movement<br />

of each potato. The EEF of TOMRA’s<br />

Eco peelers is two to three times higher<br />

than that of other steam peelers with<br />

the same volume.<br />

Benefits of TOMRA’s steam peeling equipment:<br />

Fastest peeling times for a wide range of vegetables, potatoes, carrots, beets,<br />

sweet potato, pumpkins<br />

Superior quality and peeling consistency<br />

Automated real-time adjustment up to 25% faster than other steam peelers<br />

Highest performance solutions on the market, increase by 5% - 10% above others<br />

Reduced labor requirements<br />

Reduced rejected product<br />

Up to 25% lower energy usage<br />

The TOMRA Steam Peeler’s key benefit<br />

over a competitors’ machine is the<br />

unique peeling vessel design. Multiple<br />

product lifters move the potatoes<br />

around. This results in significantly<br />

superior peeling performance, as well as<br />

peeling very quickly. If the potatoes are<br />

mixed uniformly throughout the vessel,<br />

they are treated uniformly. A second<br />

key advantage is a patented dual-stage<br />

steam exhaust system that ensures the<br />

steam’s fast release, removing the skins<br />

and speeding up the process as such.<br />


Combining the high-performance<br />

TOMRA Eco Steam Peeler with the<br />

TOMRA 5A whole product sorter results<br />

in a highly effective TOMRA peeling<br />

module that’s also famously reliable,<br />

simple to maintain, and easy to operate.<br />

This combination overcomes the main<br />

challenge for processors: ensuring<br />

that the peeling line is optimized<br />

continuously when there are continuous<br />

and unpredictable vegetable quality,<br />

size, and shape variations. The module is<br />

fully automated and for every individual<br />

vegetable processed it reports on peel<br />

remaining, quality, defects, color, size,<br />

shape, and more. It is certainly no<br />

coincidence that today 85% of the<br />

world’s French Fries are processed using<br />

TOMRA equipment.<br />

Food safety<br />

ever faced. In a crisis such as this, it is<br />

important that a customer’s business,<br />

as an essential part of society, keeps<br />

its activities running smoothly. Food<br />

companies are working tirelessly in<br />

difficult circumstances to ensure that<br />

supermarket shelves, fridges, and<br />

freezers are full of interesting and<br />

flavorsome products. Food producers<br />

are an essential part of creating the<br />

meal-time experience that brings and<br />

keeps us together.<br />

On the one hand, the <strong>food</strong>service<br />

business stopped very quickly, forcing<br />

many potato producers to reduce<br />

volumes and shut down peeling lines.<br />

Even now, a year later, this industry<br />

sector is still operating at reduced<br />

capacity, and many companies are<br />

having to weather financial losses. On<br />

the other hand, however, there has<br />

been an increase in the consumption<br />

of eat-at-home <strong>food</strong>s, particularly fresh<br />

vegetables. Seeing this, some companies<br />

have adapted by introducing prepared<br />

meals for dine-in consumers.<br />

Many of the challenges brought by<br />

the pandemic in 2020 will continue<br />

COVID-19 – Challenges for <strong>food</strong><br />

processors<br />

The COVID-19 pandemic is arguably<br />

the most significant challenge the<br />

global <strong>food</strong> processing industry has<br />

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


Cover Story<br />

through much or all of <strong>2021</strong>. TOMRA<br />

cannot alter the circumstances<br />

influencing <strong>food</strong> demand, of course.<br />

Still, they can and will continue to<br />

help <strong>food</strong> processors meet their<br />

operational challenges through<br />

remote machine monitoring and<br />

management and remote customer<br />

support and training.<br />

“COVID-19 has impacted TOMRA Food’s<br />

business by making it more challenging<br />

to visit customers’ sites or host customers<br />

at our Demonstration Centers, “says<br />

Eamonn Cullen. “But through our<br />

technologies, we have found ways to<br />

introduce innovative online tools to<br />

connect with our customers and to<br />

help support their business needs. For<br />

example, TOMRA Insight, the cloudbased<br />

monitoring platform for sorting<br />

lines, enables data-based decision<br />

making and process adjustments in<br />

near-real-time. TOMRA Visual Assist,<br />

our new augmented reality tool,<br />

allows us to provide customers with<br />

specialist support remotely, just as if<br />

a field service engineer were standing<br />

in front of the machine. And TOMRA’s<br />

new Online Demonstration Centers<br />

enable customers to see and interact<br />

with machine demonstrations via video<br />

rather than attending the center in<br />

person.“<br />

Photos: TOMRA Food<br />

TOMRA has used increased automation<br />

through the COVID-19 situation to<br />

improve safety and quality even more.<br />

Production facilities have become<br />

more remotely controlled, using fewer<br />

people, reducing the real and potential<br />

introduction of foreign materials. Food<br />

traceability is also easier and can be<br />

guaranteed to the retailer. This kind of<br />

augmented reality has brought TOMRA<br />

closer to customers and individuals<br />

and has been accelerated by the Covid<br />

restrictions.<br />

The future<br />

TOMRA’s plans for the near future are<br />

focussing on waste reduction. Higher<br />

pressure steam can be used to peel more<br />

product faster. This can increase 6-8%<br />

yield saving, which benefits customers,<br />

consumers, and the environment alike.<br />

As family mealtimes have grown in<br />

importance in the last few months, so<br />

the expectations in the <strong>food</strong> which is on<br />

the table are also getting higher. Quality,<br />

safety and consistency are what TOMRA<br />

Food has specialized in for years. fmt<br />

"There is no doubt that, because of the<br />

pandemic, over the next months, we face<br />

challenging times. The world is adapting to<br />

the new restrictions, but struggling to keep up<br />

with demand. Rest assured, however, that <strong>food</strong><br />

supply is ably supported by the watchful eyes<br />

of technology and automation to help make<br />

home-dining pleasurable." Eamonn Cullen,<br />

Market Manager Peeling, TOMRA Food<br />

8<br />

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

Ingredients<br />

Flavor, Color, & Texture Trends in <strong>2021</strong><br />

When it comes to choosing which <strong>food</strong> and beverage products consumers like, there are 3 key aspects which<br />

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

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

consumers seeking in <strong>2021</strong><br />

Flavors<br />

Over the past few years there has been<br />

much attention on healthier alternatives<br />

within the <strong>food</strong> and beverage market,<br />

however consumers still prioritize taste<br />

as a key driver to why they choose a<br />

product. In <strong>2021</strong>, FMCG Gurus shows<br />

that consumers will be looking for new<br />

and exotic flavors from brands within a<br />

number of categories. This is highlighted<br />

as 74% of global consumers state they<br />

like <strong>food</strong> and drink products with new<br />

and unusual flavors. Especially in the<br />

case for chocolate as 77% of consumers<br />

would like to see new unusual flavors in<br />

this market.<br />

Due to the current global situations<br />

with many consumers stuck at home,<br />

they are looking for new ways to escape<br />

their reality through <strong>food</strong> and drink.<br />

This is highlighted as 74% of consumers<br />

stated they like new usually flavors from<br />

around the world. Not only are consumers<br />

seeking new exotic flavors, but also 68%<br />

of global consumers would be willing to<br />

pay a premium price for these products.<br />

Therefore, there is an opportunity for<br />

brands to target these consumers with<br />

exotic flavors from around the world to<br />

help as they look to <strong>food</strong> and beverages<br />

for escapism purposes.<br />

Consumers are also turning to traditional/<br />

nostalgic flavors which reminds them of<br />

simpler times. The COVID-19 pandemic<br />

has left numerous consumers across the<br />

globe in a state of worry and anxiousness<br />

about the future. FMCG Gurus research<br />

shows that 68% of global consumers<br />

find traditional and nostalgic flavors<br />

appealing within <strong>food</strong>, with over 70%<br />

suggesting they like these flavors<br />

because it offers them comfort.<br />

As consumers look to adopt a holistic<br />

health approach to life, looking to<br />

improve all aspects of their health<br />

including their diets, they are seeking<br />

out healthier and more natural products.<br />

Natural flavors can be very appealing<br />

to consumers as they will be highly<br />

associated with being better for them.<br />

Consumers are most likely to look for<br />

natural flavors in the following markets:<br />

Coffee (82%), Yoghurt (82%), and Fruit<br />

Drinks (83%). These are highly important<br />

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

9<br />

Key No. 99420

Ingredients<br />

as 64% of global consumers would agree<br />

that they would pay a premium for<br />

these natural flavors, as they are seen as<br />

healthier options.<br />

Colors<br />

When it comes to color in <strong>food</strong> and<br />

beverage products it is very important<br />

that brands get this right. FMCG Gurus<br />

highlights that 57% of global consumers<br />

find color influential when purchasing<br />

products. New and experimental colors<br />

can also be appealing to consumers with<br />

46% of global consumers agreeing with<br />

this. This is due to consumers associating<br />

these colors with more fun and exciting<br />

products, something which is needed in<br />

a time of worry. However, experimental<br />

colors are also associated with being not<br />

natural which is a key driver to why 30%<br />

do not find these products appealing.<br />

These colors can be associated with being<br />

artificial, something in which consumers<br />

are actively looking to avoid.<br />

It takes a consumer a matter of seconds<br />

to choose which product to buy therefore<br />

color is a key element to <strong>food</strong> and<br />

beverage products. Although 49%<br />

of consumers state they would pay a<br />

premium for products with experimental<br />

colors, traditional colors which consumers<br />

know and trust are a lot more<br />

influential when purchasing <strong>food</strong> and<br />

drink products. This highlights again that<br />

consumers may not trust experimental<br />

colors as they can be seen as artificial<br />

and not good for their health. This is key,<br />

in a time where consumers are actively<br />

seeking to improve their health to be<br />

less vulnerable to catching any disease or<br />

illness.<br />

When asked which colors were most<br />

appealing within beverages such as juice<br />

drinks a large number of consumers<br />

prefer colors that resemble fruits. FMCG<br />

Gurus research shows that Orange, Red,<br />

and Yellow are three of the most popular<br />

colors in regards to juice drinks. This can<br />

be associated that they are more natural<br />

which resembles the flavors they like<br />

and know. Therefore, it is important for<br />

brands to understand that natural colors<br />

associated with healthier flavors such as<br />

fruits are more appealing to consumers<br />

in a time of uncertainty around health<br />

and wellness.<br />

Textures<br />

Texture is also another key component to<br />

why consumers would choose to go back<br />

to certain <strong>food</strong>s and drinks. This is again<br />

highlighted as 59% of global consumers<br />

state that the texture of a product is<br />

influential when purchasing products.<br />

However, texture preferences vary<br />

largely by category. When it comes to the<br />

beverage market only 28% of consumers<br />

would like to experiment with unusual<br />

textures. One of the main reasons for<br />

this is that consumers already associate a<br />

product with a certain texture and do not<br />

want their favorite brands to change this.<br />

So, when deciding whether to use new<br />

unusual textures or traditional textures<br />

consumers are already aware of, it is<br />

important to know that 88% of global<br />

consumers state that traditional textures<br />

they know and trust are more influential,<br />

with only 7% preferring new textures.<br />

Summary<br />

Flavors, colors, and textures all play a<br />

key role in why consumers like to choose<br />

certain products. When addressing<br />

flavors, brands and manufacturers can<br />

target consumers who are looking for<br />

escapism with nostalgic flavors or new<br />

and exciting flavors which are specific to<br />

certain areas in the world. This will be<br />

a key trend driving forward in <strong>2021</strong> as<br />

COVID-19 still impacts consumers daily<br />

lives. Colors are also key, however due<br />

to a health kick in <strong>2021</strong> with consumers<br />

looking for natural products consumer<br />

may look to avoid artificial and<br />

unnatural colors. It is important that<br />

brands and manufacturers offer exciting<br />

new colors which are made from natural<br />

ingredients with simpler messaging<br />

for consumers. Finally, it is important<br />

to understand that consumers do not<br />

like change when indulging in their<br />

favorite products as they have certain<br />

associations with textures and the<br />

products they like.<br />

fmt<br />

10<br />

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

Ingredients<br />

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

International Magazine June 2020 ISSN 2628-5851<br />

International Magazine October 2019 ISSN 2628-5851<br />

International Magazine April 2020 ISSN 2628-5851<br />

2/20<br />

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

2/19<br />

xxx<br />

1/20<br />

Ingredients: Hydrocolloids in Pet Food, Acacia Gum's Versatility, Antioxidants<br />

Processing: Optical Sorting, Gentle Cooling, Removing Risks in Food Safety<br />

Packaging: Pouches and Printing, Sustainability, Choosing the Right Bags<br />

<strong>Marketing</strong>: Ask the Vet, Company News, Updates From the Fairs<br />

Ingredients Blueberries, Fiber, Sea<strong>food</strong>, Microencapsulation<br />

Processing Extrusion, Pumping and Dosing, Pellet Production<br />

Packaging Flexible Wet Packaging and Sleeving, Pouches for Treats<br />

<strong>Marketing</strong><br />

Showcase India, Interzoo 2020 Preview<br />

Ingredients Indispensable Fatty Acids, Dietary Fiber for Pets, Yeast<br />

Processing HPP <strong>Technology</strong>, Extruding Fish Feed, Encapsulation<br />

Packaging Canning, Recyclable Bags, Cartons<br />

<strong>Marketing</strong> The Vet's Corner, News from Fairs and Firms<br />

FREE trial issue at <strong>food</strong>@harnisch.com<br />

The magazine PetFood PRO has grown out of a conviction<br />

and wish to underline the high level of quality and care in the<br />

manufacture of pet <strong>food</strong>, through the choice of ingredients,<br />

choice of technology and choice of packaging materials. We<br />

will endeavour to present this in an informative way, through a<br />

reader-friendly style and with a marketing perspective.<br />

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

www.harnisch.com 11

Ingredients<br />

Bringing Cultivated Meat to Japan<br />

Collaboration to bring cultivated meat to Japan will help the country meet climate change and <strong>food</strong> security<br />

goals<br />

Aleph Farms, Ltd., and Mitsubishi<br />

Corporation’s Food Industry Group<br />

signed a Memorandum of Understanding<br />

(MoU) to bring cultivated<br />

meat to the Japanese table. Aleph<br />

Farms will provide its proven, scalable<br />

manufacturing platform (BioFarm)<br />

for cultivation of whole-muscle steaks.<br />

Mitsubishi Corporation will provide its<br />

expertise in biotechnology processes,<br />

branded <strong>food</strong> manufacturing, and local<br />

distribution channels in Japan.<br />

“The MoU with Mitsubishi Corporation’s<br />

Food Industry Group marks an<br />

important milestone for us, as we<br />

methodically build the foundations of<br />

our global go-to-market activities with<br />

selected partners,” notes Didier Toubia,<br />

Co-Founder and CEO of Aleph Farms.<br />

Mitsubishi Corporation is a global<br />

integrated business enterprise that<br />

develops and operates a global<br />

network of 1,700 group companies<br />

in 90 countries. With yearly revenue<br />

of US$140B, Mitsubishi Corporation<br />

is comprised of 10 Business Groups<br />

covering virtually every industry. The<br />

Food Industry Group covers <strong>food</strong><br />

resources, fresh <strong>food</strong>s, consumer<br />

products, and <strong>food</strong> ingredients, and is<br />

active in every link of the <strong>food</strong> supply<br />

chain, from the production and sourcing<br />

of raw materials to the manufacturing<br />

of finished <strong>food</strong> products.<br />

2020, Aleph Farms committed to<br />

eliminating emissions associated with<br />

its meat production by 2025 and reach<br />

the same net-zero emissions across its<br />

entire supply chain by 2030. As the<br />

demand for meat continues to rise with<br />

evolving lifestyles, the cooperation<br />

will also provide actionable solutions<br />

to overcome the societal challenges to<br />

the local population surrounding the<br />

domestic meat supply. This includes<br />

implementing stable <strong>food</strong> channels of<br />

quality nutrition.<br />

“This is part of a network of ‘BioFarm<br />

to Fork’ strategic partnerships being<br />

developed by Aleph Farms in APAC,<br />

LATAM, and Europe, following the<br />

successful 2019 Round-A strategic<br />

investment by Cargill and the Migros<br />

Group in Switzerland,” reports Gary<br />

Brenner, VP of Market Development at<br />

Aleph Farms.<br />

Aleph Farms and Mitsubishi Corporation<br />

are members of the “Cellular<br />

“The cooperation demonstrates Aleph<br />

Farms’ strategy of working together<br />

with the <strong>food</strong> and meat industries<br />

to ensure a successful integration of<br />

cultivated meat within the ecosystem,<br />

while maximizing the positive impact<br />

we make,” adds Toubia. “We are<br />

excited to bring cultivated meat<br />

production closer to the Japanese<br />

market.”<br />

fmt<br />

This cooperation takes a lead role in the<br />

fight against climate change, especially<br />

now that the Japanese government<br />

stipulated a goal of achieving zero<br />

greenhouse gas emissions. In April<br />

12<br />

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

Ingredients<br />

Agriculture Study Group”, a consortium<br />

implementing policy proposals under<br />

the Japanese Center for Rule-Making<br />

Strategy. The consortium brings together<br />

a range of experts on the definition and<br />

construction of cellular agricultural <strong>food</strong>s.<br />

It also adds clarification of conditions for<br />

Japanese products and technologies to<br />

have international competitiveness and<br />

establishes mechanisms for coexistence<br />

and division of roles with existing<br />

industries.<br />

fmt<br />

New Seaweed Powder Unveiled to<br />

Address Consumers’ Appetites for<br />

Label-Friendly Ingredients<br />

New WavePure® series brings indulgence from only natural seaweed components<br />

Food manufacturers can now achieve<br />

the rich eating experience consumers<br />

desire with Cargill’s new label-friendly<br />

WavePure® seaweed powder. Produced<br />

from native seaweed and obtained<br />

without chemical modification, Cargill is<br />

the first to make large, commercial-scale<br />

quantities of this familiar and versatile<br />

ingredient available to its European<br />

customers.<br />

“Seaweed powder appeals to a trifecta<br />

of consumer demands, allowing<br />

product developers to create <strong>food</strong>s<br />

and drinks with indulgent sensory<br />

experiences, using a single ingredient<br />

that consumers perceive as a positive<br />

addition to ingredient labels,” said<br />

Xavier Martin, Global Product Manager<br />

Seaweed Extracts at Cargill. “By<br />

bringing this ingredient innovation<br />

to our customers, we’re giving them<br />

the tools they need to create products<br />

that truly stand out in a competitive<br />

marketplace.”<br />

The company’s first offering in the line,<br />

the WavePure ADG series, is sourced<br />

from Gracilaria red seaweed, which is<br />

considered a traditional <strong>food</strong> ingredient<br />

in the European Union. As a result, there<br />

are various options for labeling with a<br />

reference to the seaweed source.<br />

From a formulation perspective, the ADG<br />

series is well-suited for dairy desserts,<br />

serving as a recognizable alternative to<br />

less familiar ingredients. With WavePure<br />

ADG, smooth and creamy textures bring<br />

an optimal organoleptic experience,<br />

while also offering excellent gelling and<br />

thickening properties.<br />

The ADG series debut ingredient,<br />

WavePure ADG 8250, is a proven<br />

solution for dairy desserts and the<br />

company expects to extend the range<br />

to other applications. In addition,<br />

Cargill is exploring opportunities to<br />

provide customers with a full line of<br />

seaweed powder solutions that tap<br />

into the rich diversity of other seaweed<br />

species.<br />

Cargill continues to work to enhance<br />

the sustainability of all its seaweed<br />

ingredients, including WavePure.<br />

Ultimately, the company’s goal is to<br />

make WavePure ingredients a part of<br />

its Red Seaweed Promise program,<br />

which embraces sustainable seaweed<br />

production practices, enhances<br />

producer livelihoods and supports<br />

local communities.<br />

fmt<br />

In addition to its consumer-friendly<br />

designation, Cargill’s seaweed powder is<br />

produced without chemicals, a processing<br />

approach that keeps all the natural<br />

seaweed components intact.<br />

“Seaweed has been a staple <strong>food</strong> source<br />

in many cultures for centuries,” said Judd<br />

Hofmann, Cargill’s Segment Director<br />

Texturizers and Specialty Europe. “That<br />

tradition continues today, as consumers<br />

view seaweed as wholesome, healthful<br />

and nutritious. Our innovative WavePure<br />

seaweed powder range leverages that<br />

heritage, enabling simple ingredient<br />

labels that reference the familiar<br />

seaweed source.”<br />

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


Ingredients<br />

Olive Leaf Extract Now Non-GMO Project<br />

Verified<br />

Heart health supporting olive leaf extract is also available in Organic grade<br />

IFF has received Non-GMO Project<br />

Verified certification for its Benolea®<br />

(EFLA® 943), an olive leaf extract,<br />

clinically shown to support cardiovascular<br />

health. In addition, the company recently<br />

received recognition by the Council of<br />

Ecological Agriculture of the Region of<br />

Murcia (CAIRM) for an organic grade of<br />

Benolea available to its customers. These<br />

new certifications endorse the ingredient<br />

as a trusted and transparently sourced<br />

all-natural product.<br />

The olive leaves used for IFF’s unique<br />

formulation are nurtured and harvested<br />

in Spain as a side stream of the olive<br />

oil industry. The extract is processed<br />

locally, at the company’s Murcia facility,<br />

to reduce the environmental footprint.<br />

IFF’s team of experts work closely with<br />

the olive growers, ensuring pure, clean,<br />

high quality olive leaf extract, with a<br />

healthy amount of powerful polyphenol<br />

antioxidants. They test it through every<br />

step of production, from raw materials,<br />

over intermediates, to the final products<br />

giving them full control of the supply<br />

chain from farm to fork.<br />

“We have focused significant<br />

R&D activities on researching the<br />

cardioprotective mechanisms of the<br />

botanical ingredient and optimizing<br />

the formula to promote cardiovascular<br />

support at the highest purity, quality,<br />

and sustainability standards,” says<br />

Laetitia Petrussa, PhD, Product Manager<br />

for IFF Health unit.<br />

The traditional use of olive extracts,<br />

including bark and fruits, goes back<br />

to the biblical era. In ancient Greece,<br />

it was valued as a remedy with<br />

multifunctional properties, including<br />

purported abilities to alleviate high<br />

blood pressure, prevent cardiovascular<br />

disease, relieve gout and fever, and to<br />

promote the body’s natural elimination<br />

functions. Recent empirical evidence<br />

has substantiated some of these<br />

traditionally ascribed benefits. Today,<br />

olives and olive oil play a central role in<br />

the Mediterranean Diet which has been<br />

universally recognized as a leading<br />

nutritional heart protector.<br />

Benolea olive extract is standardized<br />

to a potent concentration of<br />

14<br />

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

Ingredients<br />

polyphenols (30%), with 16-24%<br />

oleuropein — the most prevalent<br />

phenolic component of olives and<br />

extolled as a strong antioxidant that<br />

actively contributes to the protection<br />

of blood lipids from oxidative<br />

stress. The ingredient undergoes IFF<br />

Health’s proprietary EFLA HyperPure<br />

technology to guarantee the absence<br />

of contaminants as well ensure a<br />

consistently concentrated and stable<br />

source of polyphenols.<br />

Benolea’s heart-protective potential<br />

has been confirmed by a range of<br />

studies in animal models and three<br />

human clinical studies. In one trial<br />

involving 20 monozygotic adult<br />

twin volunteers, Benolea intake was<br />

associated with dose-dependent<br />

decreases in blood pressure. This<br />

study also showed a significant<br />

reduction of LDL-cholesterol and<br />

demonstrated positive effects on<br />

blood lipid profiles.<br />

A secondary metabolite of oleuropein,<br />

hydroxytyrosol, is responsible for the<br />

potent antioxidant potential of olive<br />

leaves, and carries an impressive<br />

Oxygen Radical Absorbance Capacity<br />

(ORAC) value that surpasses other<br />

acclaimed natural antioxidants on the<br />

market, such as coenzyme Q10 and<br />

green tea. One daily 500mg dose of<br />

Benolea contains the equivalent of 20<br />

tablespoons of extra virgin olive oilsourced<br />

polyphenols.<br />

“Our dedicated team of expert<br />

formulators worked intensively to<br />

achieve an ideal combination of olive<br />

leaf bioactives and maximize their full<br />

potential,” enthuses Petrussa. “Our<br />

studies have demonstrated Benolea’s<br />

ability to exert coronary and vascular<br />

protection.”<br />

The Non-GMO Project Verified seal<br />

gives consumers the assurance<br />

that a product has completed a<br />

comprehensive third-party verification<br />

for compliance, ensuring the<br />

claim is unbiased, rigorous, and<br />

transparent. Benolea is fully watersoluble<br />

and can be integrated into<br />

multiple applications, such as softgels,<br />

powders, and capsules. It also is<br />

certified kosher and halal.<br />

fmt<br />

Want modern<br />

shapes?<br />




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

Key No. 99030<br />

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


Ingredients<br />

COVID-19 Intensifies Consumers’<br />

Interest in Well-Being and Eco-Friendly<br />

Products<br />

Healthy ingredients and label transparency<br />

are more important to<br />

consumers than ever before following<br />

the COVID-19 pandemic, concludes a<br />

new global survey commissioned by the<br />

market research company FMCG Gurus<br />

on behalf of BENEO.<br />

The results show that across the<br />

globe consumers are becoming more<br />

conscious about their well-being -<br />

particularly immunity - as they question<br />

their vulnerability to disease and illness.<br />

They are also concerned about the<br />

environment and whether the virus’<br />

impact has been intensified because<br />

of increased levels of environmental<br />

damage. As a result of these attitudinal<br />

shifts, consumers are looking to<br />

purchase <strong>food</strong> and drink products that<br />

increasingly promote well-being and<br />

sustain their energy in challenging<br />

times, whilst minimizing impact on the<br />

environment.<br />

Good for you and the environment<br />

Environmental concerns have been<br />

heightened as a result of COVID-19.<br />

This is in part due to some consumers<br />

questioning whether issues such as air<br />

pollution have increased respiratory<br />

issues, making people more vulnerable<br />

to the disease. This concern is being<br />

translated into altered buying patterns,<br />

with 60% of consumers now being<br />

more attentive to the impact that their<br />

<strong>food</strong> and drink has on the environment.<br />

Increased focus on <strong>food</strong> and drink<br />

products that provide health benefits<br />

Furthermore, the widespread effect of<br />

COVID-19 has also resulted in 64% of<br />

consumers saying that they are now<br />

more conscious about their immune<br />

health. Even consumers who previously<br />

deemed themselves to have a good<br />

immune system are now questioning<br />

their vulnerability to disease and<br />

illness. This is having a direct impact on<br />

purchasing behavior, with two-thirds<br />

(64%) of consumers more interested in<br />

ingredients, or <strong>food</strong> and drink products,<br />

that provide protective or preventative<br />

health benefits. This trend is likely to<br />

continue being prevalent in the market<br />

for the foreseeable future.<br />

Consumers want natural,<br />

sustained energy boosts<br />

In these challenging times, consumers<br />

are also looking for ways to fight<br />

feelings of fatigue more naturally. In<br />

“As concern for the environment continues to<br />

gather pace, it is important that we all play our<br />

part in promoting sustainable business practices.<br />

At BENEO, we actively support sustainable<br />

farming, to encourage biodiversity and reduce<br />

water pollution and soil erosion. We valorize<br />

100% of our raw material to minimize waste.”<br />

line with this, 34% of consumers say<br />

that they are now more likely to seek<br />

out <strong>food</strong> and drink products that boost<br />

energy in a sustained and balanced<br />

way. Also, not surprisingly, consumers<br />

are looking to improve their mental<br />

well-being, with more than half (55%)<br />

saying they are likely to opt for <strong>food</strong><br />

and drink to boost their mood. However,<br />

formulation is key, as consumers<br />

look to avoid ingredients deemed<br />

detrimental to their long-term health<br />

in pursuit of a short-term energy boost.<br />

One opportunity arising from this is the<br />

appeal of slow-release, low-glycaemic<br />

carbohydrates such as Palatinose<br />

(isomaltulose), with 45% of consumers<br />

believing such carbohydrates are better<br />

for their health.<br />

Myriam Snaet<br />

Michael Hughes, Director of Insights at<br />

FMCG Gurus, comments: “The results of<br />

our latest consumer survey clearly show<br />

that beneficial ingredients and label<br />

transparency are now more important<br />

16<br />

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

31377<br />

Ingredients<br />

than ever before to consumers across<br />

the globe, as a result of the pandemic.<br />

People are exploring topics such as inner<br />

defence, staying fit and healthy, blood<br />

glucose control, as well as sustained<br />

energy and wanting to buy products with<br />

proven health benefits. BENEO is well<br />

equipped to help manufacturers tap into<br />

these key growth areas. The company’s<br />

prebiotic chicory root fibers and slowrelease<br />

carbohydrate offer a range of<br />

scientifically proven health benefits that<br />

help support long-term health and can<br />

be communicated on pack.”<br />

Myriam Snaet, Head of Market<br />

Intelligence and Consumer Insights at<br />

BENEO, explains: “As concern for the<br />

environment continues to gather pace, it<br />

is important that we all play our part in<br />

promoting sustainable business practices.<br />

At BENEO, we actively support sustainable<br />

farming, to encourage biodiversity and<br />

reduce water pollution and soil erosion.<br />

We valorize 100% of our raw material<br />

to minimize waste and have reduced our<br />

specific energy consumption by 50% over<br />

the past 30 years. Looking to the future,<br />

we aim to achieve carbon neutrality by<br />

2050, thanks to our recent investments<br />

into upgrading and expanding our<br />

facilities.”<br />

fmt<br />

1/21<br />

Vol. 35 •<br />

ISSN 0932-2744<br />

Come and see for yourself:<br />

www.harnisch.com<br />

Cover: Steam Peeling<br />

Solutions<br />

Covid Intensifies<br />

Well-Being Interest<br />

Food Extruder in<br />

Hybrid Design<br />

Sustainable Barrier<br />

Packaging<br />

Perfectly positioned.<br />

The international specialist magazines from Dr. Harnisch Publications<br />

You can now explore our newly designed website, with a<br />

clear focus on responsive design and easily usable applications.<br />

Alongside the free-to-use digital magazine editions, you will<br />

find bonus news coverage, events, subscription and<br />

general information on all our magazines. Take a look at<br />

www.harnisch.com for all relevant content.<br />

Our publications include:<br />

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

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


Processing<br />

Sweet Revolution<br />

In a globally unique project, called<br />

CONNECT, nine well-known companies<br />

of the confectionery industry have come<br />

together and developed an industrial<br />

production process for real 3D jellies.<br />

Now it is possible to design gummy<br />

bears and jelly babies with a beautiful<br />

backside. That’s revolutionary!<br />

We know fruit gums and jellies in many<br />

different shapes. But they all have at<br />

least one flat side or an unpleasant<br />

“dosing dot”. With this worldwide<br />

new process of CONNECT, real threedimensional<br />

figures can be produced.<br />

Real three-dimensional figures that<br />

always show their best side, no matter<br />

how you turn them.<br />

The CONNECT-Team has developed an<br />

innovative product concept, researched<br />

the necessary raw material properties,<br />

worked out recipes, designed shapes,<br />

and built the right production facilities.<br />

Always scientifically accompanied in<br />

order to achieve well-founded market<br />

relevance for the confectionery industry.<br />

The unique strength of the CONNECT-<br />

Team lies in the bundling of the<br />

technical competence of nine<br />

companies in order to support the<br />

confectionery manufacturers as best as<br />

possible with expertise and passion. The<br />

CONNECT developments focus on new<br />

types of confectionery with enjoyment,<br />

surprise and fun for consumers.<br />

The innovative CONNECT 3D jellies were<br />

presented globally in four live launch<br />

events at the end of October. Around 750<br />

interested people from the international<br />

confectionery industry followed. The<br />

focus was on the manufacturing process<br />

and the integration of the process<br />

into confectionery production. The<br />

response is enormous, there are already<br />

numerous project inquiries from Japan<br />

to Mexico.<br />

The successful launch event took place<br />

on October 28, 2020. A recording is<br />

available for all fans of real 3D jellies.<br />

For everyone who missed the launch<br />

event: at request@connect-sweets.<br />

com you can request the link to<br />

the recording or an individual Q&A<br />

session with the CONNECT experts,<br />

who are known by insiders as “The<br />

Jellylovers”.<br />

fmt<br />

18<br />

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

Processing<br />



For meat analog and extender production,<br />

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

vegetable proteins by extrusion. Wenger began<br />

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

continues to lead with ever expanding options<br />

today.<br />

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

Wenger twin screw extruders mimic whole muscle<br />

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

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

layered, somewhat fibrous structure.<br />

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

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

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

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

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

Discover the latest in cutting edge extrusion<br />

processing and product development assistance.<br />

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

Key No. 99382<br />



<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • February <strong>2021</strong> 19

Processing<br />

Food Extruder in Hybrid Design:<br />

Ideal System for Product Development<br />

and Piloting<br />

Research and development company<br />

Foodwest Ltd., located in Seinäjoki,<br />

Finland, has expanded its <strong>food</strong><br />

development center with a ZSK 27<br />

Food Extruder in Hybrid Design. Thanks<br />

to the Coperion extrusion system’s<br />

modular construction, Texturized<br />

Vegetable Protein (TVP), High Moisture<br />

Meat Analogues (HMMA), and<br />

numerous other extrudates such as<br />

snacks and cereals can be manufactured<br />

on the same machine. The extruder is<br />

particularly well suited for research<br />

and development with throughputs of<br />

up to 80 kg/h, and thanks to constant<br />

process parameters within the entire<br />

ZSK extruder series, ensures reliable<br />

scale up to higher throughput ranges.<br />

Along with the extruder, the Coperion<br />

system encompasses a highly accurate<br />

Coperion K-Tron K-ML-D5-KT20<br />

gravimetric twin screw feeder for dry<br />

powders, a ZGF Centric Food Pelletizer<br />

from Coperion Pelletizing <strong>Technology</strong>,<br />

and a cooling nozzle.<br />

Foodwest has been a successful<br />

development provider for innovative<br />

<strong>food</strong> products for over 25 years, and<br />

with this new ZSK 27 Food Extruder,<br />

expands its product tests, research, and<br />

development efforts to a much broader<br />

spectrum of applications.<br />

ZSK Food Extruder in Hybrid<br />

Design for Maximum Flexibility<br />

Foodwest will be able to manufacture<br />

both TVP and HMMA on the ZSK Food<br />

Extruder in Hybrid Design with only a<br />

minimum of retrofitting. The feeding<br />

and process section for both applications<br />

are nearly identical, while the discharge<br />

units differ significantly. While the ZGF<br />

Centric Pelletizer is attached to the<br />

process section for manufacturing TVP<br />

in order to cut the product directly at<br />

the nozzle plate, HMMA is discharged<br />

using a specialized cooling nozzle<br />

which produces a product strand that<br />

exhibits a texture closely resembling<br />

that of genuine meat. Using an adapter<br />

solution developed by Coperion, the<br />

ZSK Food Extruder’s discharge can now<br />

be switched from a ZGF to a cooling<br />

nozzle in no time. The same principle<br />

functions just as quickly in reverse when<br />

switching from an HMMA process to<br />

TVP.<br />

The extruder twin screws’ combination<br />

of self-wiping and modular construction<br />

will allow Foodwest to<br />

develop and test numerous other<br />

products on the ZSK system alongside<br />

meat substitutes, including snacks and<br />

cereals; for production of the latter,<br />

Foodwest individually configures the<br />

extruder as well as the extensive array<br />

of peripheral equipment available.<br />

As a result, the company profits from<br />

the extruder’s very high hygiene<br />

standards, intensive dispersion<br />

performance, and gentle product<br />

handling.<br />

Harri Latva-Mäenpää, PhD, Innovation<br />

Director at Foodwest says: “Extrusion<br />

is one of the most interesting technologies<br />

and we wanted to include<br />

it in our new <strong>food</strong> development<br />

and piloting facility in Finland. The<br />

versatile package and expertise<br />

offered by Coperion convinced us to<br />

make this investment. We can use the<br />

ZSK extruder for process and product<br />

development and also combine it with<br />

other <strong>food</strong> production and packaging<br />

technologies. This enables us to create<br />

commercially ready solutions in our<br />

<strong>food</strong> approved facility together with<br />

our customers all over the world.”<br />

Stefan Gebhardt, General Manager of<br />

the Food & Pharma Business Unit at<br />

Coperion, adds: “We’re very pleased<br />

to equip such a renowned company<br />

as Foodwest with a ZSK Food Extruder<br />

in Hybrid Design. We are convinced<br />

that the ZSK extruder, with its high<br />

configuration flexibility and reliable<br />

scale up to larger extruder sizes, is<br />

the optimal technology for a large<br />

bandwidth of product tests, research,<br />

and development. Moreover, we are<br />

very pleased to announce that, moving<br />

forward, Coperion customers will have<br />

a testing area for production of meat<br />

analogues and other products at their<br />

disposal at the Foodwest test center in<br />

Finland.“<br />

fmt<br />

20<br />

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

Baker Perkins Equipment<br />

Industry 4.0 Ready<br />

Uncompromising hygiene<br />

with NETZSCH pumps<br />

<strong>Technology</strong> ensuring equipment is<br />

Industry 4.0 Ready is being fitted as<br />

standard to all new Baker Perkins<br />

machinery.<br />

Industry 4.0 harnesses data from all the<br />

machines, devices and sensors in any<br />

manufacturing operation and enables<br />

them to communicate with each other<br />

via the Internet to make informed and<br />

timely decisions.<br />

Baker Perkins’ policy is to provide all<br />

machines ‘Industry 4.0 Ready’ to a level<br />

that allows interconnection with other<br />

systems via the Internet. The key unit<br />

is an eWON Flexy Gateway - a modular<br />

router and data gateway allowing<br />

linkage to remote devices with<br />

benefits based around data acquisition,<br />

handling and transmission.<br />

All systems will now sample and upload<br />

all data from the process equipment<br />

to a secure cloud or server, where it<br />

will be available to facilitate improved<br />

decision making. The major advantage<br />

with simpler control systems is that<br />

analysis is being carried out on the<br />

process as a whole, rather than discrete<br />

sections. Real time OEE (Overall<br />

Equipment Effectiveness), trending and<br />

basic maintenance are all included.<br />

Innovative features include a unique<br />

Baker Perkins machine center-lining<br />

system allowing operating parameters<br />

to be compared with previous settings,<br />

and alerting supervisors to potential<br />

problems caused either by operator<br />

changes or impending equipment failure.<br />

The next step in the development of<br />

Industry 4.0 will allow Baker Perkins<br />

to predict when key components need<br />

replacement. Intelligent analysis of<br />

process performance and machine<br />

condition will enable timely advice to be<br />

provided on potential machine problems<br />

or service and parts requirements,<br />

before they cause costly downtime.<br />

Performance optimization based on<br />

comparisons with similar machines will<br />

also be possible.<br />

The eWON Flexy modular router and<br />

data gateway has been used for some<br />

time by Baker Perkins to dial into<br />

customer’s control systems anywhere<br />

in the world when they call for remote<br />

support. It has also been used in the<br />

remote commissioning from the UK of<br />

a new extruder in India.<br />

Industry 4.0 is a fast developing<br />

technology that manufacturers can<br />

tailor to suit their own unique situations.<br />

With equipment and systems Industry<br />

4.0 Ready, Baker Perkins is ideally<br />

positioned to help customers, whatever<br />

the level of complexity required. fmt<br />

Gentle conveyance of sanitary<br />

and aseptic products<br />

Flow rates up to 140 m³/h<br />

Pressures up to 24 bar<br />

Pumps designed, manufactured and<br />

tested according to EHEDG, QHD, 3A<br />

and GOST-R standards<br />

FDA-certified elastomers<br />

High corrosion-resistant, crevice-free,<br />

wear-free and maintenance-free<br />

flexible rod<br />

Product and cleaning temperature up<br />

to 150° C<br />

Explosion protection according to ATEX<br />

CIP and SIP capable<br />

Decades of expertise in uncompromising<br />

hygiene<br />

NEMO® aseptic pump<br />

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

NETZSCH Pumpen & Systeme GmbH<br />

Business Field Food & Pharmaceutical<br />

Tel.: +49 8638 63-1030<br />

info.nps@netzsch.com<br />

www.netzsch.com<br />

Key No. 98838

Processing<br />

Shaping the Puzzle for<br />

Quality Formed Products<br />

Formed meat products are big<br />

business. Burgers and chicken nuggets<br />

dominate the market, but tastes are<br />

changing. One of the challenges for<br />

<strong>food</strong> manufacturers is the increased<br />

consumer demand for a variety of<br />

clean label products, as well as fish and<br />

vegetarian options, and all at prices<br />

that consumers consider to be good<br />

value.<br />

Ensuring the highest possible quality<br />

products within budget limitations,<br />

whilst continually innovating to meet<br />

consumer demand, can be made more<br />

challenging by the fact that creating<br />

perfectly formed <strong>food</strong> products is a<br />

very precise technical process. Rather<br />

like a jigsaw puzzle, every part of the<br />

process must be perfectly aligned<br />

and in place in order to complete the<br />

picture successfully.<br />

With over half a century’s worth of<br />

experience when it comes to forming,<br />

leading supplier of <strong>food</strong> processing<br />

equipment GEA has developed a<br />

package of information based on<br />

six key elements, with the aim of<br />

demystifying this multi-faceted process<br />

and highlighting the support GEA can<br />

provide to manufacturers.<br />

Application know-how<br />

GEA’s vast experience in formed<br />

product processing has enabled the<br />

company to develop creative ways of<br />

overcoming the technical challenges<br />

that can occur. For example, to ensure<br />

the best possible yields, the required<br />

level of moisture must be retained<br />

within formed products. Water also<br />

acts as a carrier for salts and other<br />

additives which extend shelf life and<br />

enhance flavor, texture, color and<br />

binding properties. However, binding<br />

water into chicken mass is often the<br />

one aspect of forming that can prove<br />

the most difficult. To overcome this,<br />

GEA has developed technology which<br />

mixes the ingredients in near vacuum<br />

conditions. This helps to open up the<br />

meat cells thereby improving the water<br />

retention of chicken.<br />

Equipment and Innovation<br />

Now into its ninth generation of<br />

forming equipment, GEA offers<br />

two primary production methods<br />

for formed products. Plate forming<br />

for low-medium production levels,<br />

for example using its MultiFormer<br />

machine, and rotary forming for<br />

high speed production of long-run<br />

standard products, such as with the<br />

GEA MaxiFormer. Versatility, capacity,<br />

yield, hygiene, sustainability and,<br />

above all, product quality have been<br />

the key drivers in the development of<br />

GEA’s equipment, innovating designs<br />

over the years in a continual quest to<br />

streamline processes using the latest<br />

technology, meeting and exceeding<br />

customer expectations.<br />

It’s all in the mix<br />

The importance of getting all factors<br />

well controlled early on in the process<br />

cannot be underestimated. Regardless<br />

of the forming technology used, it<br />

is often the upstream process of<br />

preparing the raw mix that has the<br />

biggest impact upon the success of<br />

operations further down the line. The<br />

mixture must be carefully prepared<br />

upstream with the right balance of<br />

ingredients at the right temperature<br />

and viscosity, to feed efficiently into<br />

the forming equipment. Manufacturers<br />

sometimes make the mistake of trying<br />

to mix all the ingredients together in<br />

one go. However, some ingredients,<br />

such as starches, are only effective<br />

during cooking and can inhibit the<br />

absorption of water if added too<br />

early. GEA has developed a range of<br />

equipment for accurate and effective<br />

mixing including the GEA CutMaster,<br />

GEA PowerGrind and GEA ProMix.<br />

Test before you invest<br />

Naturally, before any decisions are<br />

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

reassurance that any equipment<br />

purchased will prove to be a profitable<br />

investment. Feasibility studies, process<br />

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

to continue, even during the current<br />

COVID crisis. Tests are carried out at the<br />

GEA <strong>Technology</strong> Center in Bakel, The<br />

Netherlands, which remains fully up<br />

and running. Customers are welcome<br />

to visit the center for tests, but if this<br />

isn’t possible due to travel restrictions<br />

or company rules, GEA experts can<br />

carry out tests at a distance, after<br />

which results are collected and a<br />

test report including videos, pictures<br />

and, if possible, samples are shipped.<br />

Alternatively, ‘live’ interactive testing<br />

can also be arranged.<br />

Passion for Excellence<br />

Rather than simply supplying equipment,<br />

GEA prides itself on its passionate<br />

22<br />

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

Processing<br />

approach and knowledgeable staff,<br />

and has developed long term working<br />

relationships with <strong>food</strong> manufacturers<br />

around the globe, supporting them in<br />

providing excellence at every stage of<br />

production<br />

Service<br />

Any investment made in GEA’s<br />

equipment is supported by a longterm<br />

relationship, and a network of<br />

service engineers and stocks of spare<br />

parts are available around the world.<br />

Denmark-based producer of cooked<br />

chicken products Danpo installed a fully<br />

automated chicken nugget line from<br />

GEA, expanding its ‘Your Chicken’ brand.<br />

Product Technical Manager Per Ulrik<br />

Jørgensen commented: “I like working<br />

with GEA, I can speak to people and they<br />

understand what I am talking about.<br />

They provide a round-the-clock service<br />

with fast, easy solutions to improve the<br />

line capacity or performance.”<br />

A new digital channel which allows<br />

customers to access a range of services<br />

for their equipment, GEA Advance is<br />

now also being piloted. This new digital<br />

solution will allow GEA to modernize<br />

the way service colleagues interact with<br />

customers, allowing for rapid ordering<br />

of spare parts and real-time access to<br />

technical documentation.<br />

fmt<br />

Key No. 99050<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • February <strong>2021</strong> 23

Processing<br />

Grinding Innovations from well-proven<br />

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

The grinding of products, whose<br />

dusts are potentially explosive, places<br />

particularly high demands on the<br />

technology used and the design of a<br />

grinding plant with regard to safety,<br />

for both machines and their operators.<br />

The pressure shock resistant design of<br />

the complete grinding system up to an<br />

explosion overpressure of 10 bar(g) is<br />

the most frequently used version, which,<br />

however, is associated with a high level<br />

of equipment and corresponding space<br />

requirements.<br />

Thanks to the ATEX-compliant Condux®<br />

Compact plant concept, the installation<br />

of a high- performance grinding plant<br />

for numerous products is now much<br />

easier, since explosion protection<br />

valves or explosion suppression devices,<br />

explosion isolators, fans and even<br />

conventional dust filter systems are<br />

no longer required with the newly<br />

developed plant concept.<br />

The idea of a compact grinding system<br />

is not new but existing solutions<br />

show significant disadvantages<br />

when it comes to cleaning efforts<br />

and hygienic design. NETZSCH has<br />

therefore improved the decisive points<br />

of its Condux® Compact plant concept<br />

once again: The footprint or space<br />

requirement of the compact plant is<br />

80 % less than that of comparable<br />

standard grinding plants with the same<br />

throughput capacities. This also has an<br />

effect on the investment costs, which<br />

are approximately 30 % lower. By using<br />

the newly developed CycloFil cyclone<br />

filter in the Condux® Compact system,<br />

the integrated pre-separation of the<br />

grinding stock and the recirculation<br />

of the process gas allow a filter area<br />

that is over 90 % smaller than that of<br />

comparable mill sizes. With CycloFil, the<br />

degree of separation can be adapted to<br />

the operator’s requirements by means<br />

of exchangeable immersion tubes.<br />

These features of the new system result<br />

in various advantages. For example,<br />

24<br />

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

Processing<br />

the grinding system can be easily integrated into existing<br />

production systems thanks to the minimal space requirement,<br />

and the necessary cleaning when changing products is<br />

extremely quick thanks to easy access to the parts in contact<br />

with the product.<br />

The well-proven Impact Mill Condux® is the basis machine<br />

of this grinding system. The products are ground within this<br />

mill mainly by impact and shearing action. For use with a<br />

wide variety of products and final finenesses, this machine is<br />

available in various executions, as either a blast mill, pin-disc<br />

mill or wing-beater mill.<br />

In contrast to conventional grinding plants, the processing<br />

gas in the Impact Mill Condux® Compact streams in a circular<br />

motion. The product is fed directly to the mill via a pressureshock-resistant<br />

rotary valve and discharged after the grinding<br />

process via a separator with air lock. Parallel to this, the<br />

additional rinsing air fed through the valves and mill bearing<br />

is continuously discharged through the CycloFil to prevent<br />

a build-up of pressure. A subsequent aspiration system<br />

generates the vacuum needed to stabilise the system pressure.<br />

Thanks to the innovative CycloFil cyclone filter, the supplied<br />

energy is dissipated via the product and the system surface, so<br />

that no additional cooling is required. The warmth produced<br />

by the grinding process is mainly compensated along with the<br />

product when it leaves the machine and to a smaller extent by<br />

the system surface, and is therefore throughput dependent.<br />

The expected temperature increase, for e.g. of ground<br />

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

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

influence on the quality or the downstream process. For the<br />

grinding of particularly temperature-sensitive products, the<br />

system can be additionally cooled with liquid nitrogen.<br />

Especially the degree of innovation of the System was confirmed<br />

recently by the Fi Europe Innovation Award jury, who awarded<br />

the fine impact mill Condux® Compact as the winner of the<br />

Food Tech Innovation Award for the most innovative technical<br />

processing solution for <strong>food</strong> ingredients.<br />

fmt<br />

Highlights of the NETZSCH Condux® Compact:<br />

• Compact design = Low space requirement<br />

• Low investment costs<br />

• Low feeding height<br />

• ATEX conform<br />

• Hygienic design<br />

• Fast and easy cleaning<br />

• Low maintenance costs<br />

• Easy and clear operation<br />

• Easy access<br />

• Dust-free filling<br />

• Universal operation<br />

Firm, chewy and bouncy:<br />

the right balance for<br />

noodles<br />

Enhance the taste of your noodles with<br />

GEA technology: a stronger, chewier<br />

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

At GEA we have developed processing<br />

technologies for noodles starting from their<br />

unique taste.<br />

We have focused on encapsulating a history<br />

of consumption going back thousands<br />

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

versatile product, suitable for every<br />

preparation and recipe.<br />

Discover<br />

GEA’s noodles processing technology<br />

gea.com/noodles<br />

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

Key No. 99510

Ingredients<br />

The Plant-Based Boom - A New High-<br />

Capacity Manufacturing Solution to Keep<br />

up with Consumer Demand<br />

The global <strong>food</strong> industry is facing<br />

the enormous challenge of feeding<br />

a population of 10 billion people, a<br />

number we are expected to reach by<br />

2050.<br />

Our <strong>food</strong> supply chains are very complex,<br />

comprising multiple steps, from the<br />

farm to storage, transport, processing,<br />

retail and ending eventually on the<br />

consumer’s plate. The way we produce<br />

out <strong>food</strong> takes its toll on the planet,<br />

taking up 70% of the world’s available<br />

freshwater for agriculture in addition<br />

to a tremendous amount of energy,<br />

and contributing to nearly a quarter<br />

of global green-house gas emissions.<br />

Despite all of this, one-third of all <strong>food</strong><br />

produced ultimately goes to waste.<br />

With population growth comes an<br />

expected change in demographics. A<br />

shift towards more urban lifestyles,<br />

with the majority of the world<br />

eventually living in cities, suggests<br />

an increase in purchasing power.<br />

With the growing awareness among<br />

consumers of balanced and proteinrich<br />

diets, there is a tendency towards<br />

putting as much protein on the plate<br />

as possible. Looking at our existing<br />

protein value chain, it is estimated that<br />

with livestock farming, 45% of protein<br />

produced worldwide is lost during the<br />

conversion of plant protein to animal<br />

protein. Beyond these inefficiencies,<br />

the overproduction of animal-based<br />

protein for human consumption has<br />

been the leading cause of the most<br />

recent pandemics, from COVID-19 and<br />

SARS to swine flu and bird flu, among<br />

many others.<br />

Today, consumers are compelled to<br />

reconsider their <strong>food</strong> choices and look<br />

for alternative sources of proteins.<br />

Moreover, they are exploring a wide<br />

range of <strong>food</strong>s and expect more<br />

choice in the products available on<br />

the market. Researchers around the<br />

world are therefore looking for novel<br />

proteins sources which could be used<br />

for human consumption. In this race,<br />

plant-based proteins top the charts<br />

as they are becoming increasingly<br />

popular among consumers. Through<br />

twin-screw extrusion technology, it is<br />

possible to use plant-based protein<br />

sources to create products that mimic<br />

animal-based meat such as chicken<br />

pieces, burgers, pulled pork, tuna,<br />

etc. Pioneering <strong>food</strong> producers have<br />

had huge success with recent plantbased<br />

meat market launches and the<br />

enthusiasm of consumers in buying<br />

such products is in turn fueling the<br />

plant-based revolution.<br />

It is expected that, by 2040, the global<br />

protein market share will be dominated<br />

by alternative proteins, including<br />

both plant- based and cultured meat,<br />

26<br />

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

Processing<br />

leading to a considerable reduction<br />

in traditional meat products. This has<br />

intrigued many companies from the<br />

traditional meat and dairy industries,<br />

encouraging them to diversify their<br />

portfolios and cater to the needs of the<br />

market. According to the 2019 ‘US State<br />

of the Industry Report’ by the Good<br />

Food Institute (GFI), between 2017<br />

and 2019 there was a 31% increase in<br />

the retail sales of plant-based meat,<br />

compared to only 5% for animal-based<br />

meat products. This explains the actions<br />

of <strong>food</strong> giants like Nestlé, PepsiCo and<br />

Kraft Heinz who are stepping into<br />

plant- based meat sector. Additionally,<br />

many traditional meat producers such<br />

as Tyson and Hormel have launched<br />

their own plant-based meat brands<br />

such as ‘Raised & Rooted’ and ‘Happy<br />

Little Plants’ respectively.<br />

The role of technology in<br />

mimicking meat:<br />

Despite the existing concerns in the<br />

<strong>food</strong> system, and especially in the<br />

protein value chain, it is still a challenge<br />

for consumers to fully shift to plantbased<br />

diets. People love the sensory<br />

experience involved in eating meat, not<br />

only from the flavor but also from the<br />

texture of the product. The bite and<br />

chewiness that is provided by a meat<br />

product is missing in traditional meat<br />

alternatives such as tofu and tempeh.<br />

Extrusion is the leading technological<br />

solution used in the production of<br />

plant-based meats, which enables<br />

alternative sources of protein to be<br />

transformed into meat-like products.<br />

With the advent of high-moisture<br />

extrusion in particular, it is now<br />

possible to mimic meat products more<br />

closely. Plant proteins in their raw state<br />

are typically globular in structure. As<br />

Key No. 98981<br />


Kohlhoff <strong>food</strong> <strong>Marketing</strong> Hygienetechnik & <strong>Technology</strong> • February GmbH & <strong>2021</strong> Co. KG<br />

27<br />

Isaac-Newton-Straße 2 · 59423 Unna · Germany<br />

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

www.kohlhoff-hygiene.de<br />

For more information about our hygiene technology devices<br />

for <strong>food</strong> processing companies please visit our web pages

Processing<br />

they are processed inside the extruder,<br />

the plant-proteins are denatured due<br />

to shear loading and the increase in<br />

temperature, which re-aligns them into<br />

long fibers. The cooling die is a vital<br />

attachment to the extruder. As the<br />

restructured protein flows through the<br />

cooling die, phase separation results in<br />

a fibrous and layered structure, which<br />

is then cooled to a solid product exiting<br />

the cooling die. This meat substitute,<br />

typically a rectangular slab due to<br />

current cooling die designs, can then<br />

be further processed to create diverse<br />

products such as ground meat, pulled<br />

pork, burger patties and chicken pieces.<br />

The cooling die is also the main<br />

bottleneck in the high-moisture<br />

extrusion process. Until now, the<br />

throughput has been limited to 500<br />

kg/h, making it difficult for the industry<br />

to keep up with consumer demand and<br />

to compete with the high volumes<br />

produced by the meat industry. To<br />

address this, Bühler is excited to<br />

announce the launch of a new high<br />

performance cooling die, the PolyCool<br />

1000, with a throughput of up to 1000<br />

kg/h. This novel solution is unparalleled<br />

in the industry and will revolutionize<br />

the production of sustainable meat<br />

alternatives and other protein products.<br />

With the ability to double throughput<br />

on one line, the cost per kilogram<br />

of product becomes much cheaper,<br />

allowing producers to reduce the<br />

sales price and reach more consumer<br />

markets.<br />

Bühler, as a complete solution provider<br />

for the meat substitute value chain, is<br />

heavily engaged in innovation in this<br />

area. Specializing in both dry and high<br />

moisture extrusion, Bühler enables its<br />

customers to find solutions with their<br />

customized recipes in order to achieve<br />

the desired layered and fibrous texture,<br />

like that of meat. Bühler’s application<br />

centers located in Minneapolis (USA),<br />

Uzwil (Switzerland), Wuxi (China), and<br />

soon in Singapore, enable customers to<br />

carry out trials for recipe and process<br />

optimization with the expert support<br />

of Bühler’s technology team. In order<br />

to cater to the growing demand, plantbased<br />

meat producers need to increase<br />

the throughput of their processes.<br />

Bühler’s unique solution of a cooling<br />

die with a throughput of 1000 kg/h<br />

makes it the market leader among<br />

state-of-the art technological solution<br />

providers. In addition to extruder<br />

systems and cooling dies, Bühler<br />

provides solutions for pre-processing<br />

of the material using pre- conditioners.<br />

These pre-conditioners can provide an<br />

additional retention time for the raw<br />

ingredients which might be needed<br />

to stimulate certain physicochemical<br />

reactions, improving the functionality<br />

of the recipe components. Bühler has<br />

several partnerships with downstream<br />

processors of the extruded product,<br />

thereby supporting customers in<br />

finding the full bean-to-burger solution.<br />

Technological advancements in<br />

the meat substitute segment have<br />

prompted numerous start-ups to<br />

launch in this market. According to<br />

the GFI report quoted above, USD 457<br />

million was invested in the plant-based<br />

sector in 2019 alone. Hence, the growth<br />

in this segment is an indicator of the<br />

growing interest from consumers for<br />

such products.<br />

Popular and futuristic protein sources<br />

for meat substitutes:<br />

Current popular plant-based meats in<br />

the market are produced from soy or<br />

pea protein-based recipes. For highmoisture<br />

extrusion for example, basic<br />

products can be formulated by mixing<br />

33% soy protein concentrate with 66%<br />

water, or 45% pea protein isolate with<br />

55% water in the recipe. The extrusion<br />

conditions also differ depending on the<br />

recipe. Typical temperatures need to<br />

reach up to 145-150 °C when extruding<br />

soy protein concentrate, while for pea<br />

protein isolates, temperatures are in the<br />

range of 130-145 °C. The configuration<br />

of the screw elements are also adjusted<br />

depending on the protein sources in<br />

order to provide the necessary amount<br />

of shear loading inside the extruder.<br />

These process parameters are optimized<br />

thanks to experience and scientific<br />

understanding.<br />

Other protein sources gaining<br />

popularity more recently are chickpea,<br />

lentil, potato, fava bean, and<br />

mycoprotein, which all have great<br />

nutritional properties and can be used<br />

to produce meat-like structures. With<br />

the advancement of fermentation<br />

technology, single-celled proteins<br />

such as algae, yeast, and bacteria will<br />

become more important in the near<br />

future.<br />

In conclusion, scientists and industries<br />

around the world are continuously<br />

engaged in exploring the nutritional<br />

and functional aspects of alternative<br />

protein sources in order to make our<br />

protein value chain more efficient. Meat<br />

substitutes present an unparalleled<br />

opportunity for sustainability in our<br />

<strong>food</strong> systems. With the new PolyCool<br />

1000, Bühler proves it is committed to<br />

leading the way in developing the best<br />

solutions for the alternative protein<br />

industry.<br />

fmt<br />

28<br />

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

Processing<br />

Interpack and Components <strong>2021</strong><br />

Canceled due to Covid-19 Restrictions<br />

In agreement with its association and<br />

industry partners as well as the trade fair<br />

advisory committee, Messe Düsseldorf<br />

has decided to cancel both interpack and<br />

components <strong>2021</strong>, due to the restrictions<br />

related to the COVID-19 pandemic. The<br />

trade fairs were scheduled to take place<br />

from February 25 – March 3, <strong>2021</strong> at the<br />

fairgrounds in Düsseldorf, Germany.<br />

“We have made every effort to do justice<br />

to interpack’s tremendous importance<br />

for the processing and packaging<br />

industry, even during this pandemic<br />

– above all because we have received<br />

encouragement from the industry in<br />

support of a face-to-face event and have<br />

a tried and tested hygiene concept to<br />

protect everyone involved. Ultimately,<br />

however, feedback from our exhibitors<br />

has shown that the uncertainty is too<br />

great, and we are thus unable to host<br />

an interpack event that would meet<br />

the standards of a leading international<br />

trade fair,” explained Wolfram N. Diener,<br />

President & CEO of Messe Düsseldorf.<br />

“On November 25, the Federal<br />

Government and the German states<br />

decided to implement stricter measures<br />

in Germany, and to possibly even extend<br />

these measures into the New Year. This,<br />

unfortunately, does not give cause for<br />

hope that the situation will improve<br />

significantly over the course of the<br />

coming months. This will affect all Messe<br />

Düsseldorf events in the first quarter. We<br />

are now focusing on the next edition of<br />

interpack, which will take place in May<br />

2023 according to plan, and which we<br />

will supplement with extended online<br />

offers,” added Diener.<br />

“For the industry, in-person meetings<br />

and live experiences are still extremely<br />

important, especially when it comes to<br />

complex technology. Both enable a direct<br />

market comparison, new ideas, leads and<br />

networks are created. Online formats<br />

only partially achieve this. We are now<br />

looking forward to a successful interpack<br />

2023, where the industry can once again<br />

come together at its leading global<br />

trade fair in Düsseldorf,” added Richard<br />

Clemens, Managing Director of the<br />

VDMA Food Processing and Packaging<br />

Machinery Association.<br />

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Key No. 99395

Packaging<br />

Successfully Filling the Gap: Cereals now<br />

in Paper Packaging<br />

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

manufacturers have identified this development and are already using environmentally friendly substrates,<br />

however, the reluctance on the part of many <strong>food</strong> producers to switch from plastic-based solutions to paper<br />

remains high. The innovation driver Sappi and the packaging machine manufacturer ROVEMA demonstrate<br />

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

automated production of stand-up pouches to sealable barrier paper.<br />

‘Sustainability’ challenge<br />

As part of a company-wide sustainability<br />

strategy, a well-known cereal<br />

manufacturer wanted to completely<br />

switch its packaging from plastic to<br />

paper. The company that produces<br />

organic products such as flour, porridge<br />

oats, muesli and bread mixes still<br />

occupies a niche role in the German<br />

market. Only one Austrian competitor<br />

has so far made strides in this direction<br />

to the same extent. The company also<br />

placed high demands on its partner<br />

ROVEMA with regard to efficient<br />

packaging processes based on highquality<br />

and above all, environmentally<br />

friendly packaging materials. In the<br />

project to adopt paper with special<br />

barrier properties as the material for<br />

the stand-up pouches, that are used<br />

for different product groups and in<br />

different sizes, the packaging specialists<br />

from Fernwald called on the innovation<br />

leader Sappi to support them. The two<br />

companies have been development<br />

partners since 2018.<br />

Sustainable materials demand<br />

high expertise<br />

For ROVEMA, it was clear that the<br />

only way they could find a sustainable<br />

substrate solution for the customer, to<br />

ensure maximum performance, was<br />

with the help of Sappi. “The smooth<br />

production of stand-up pouches relies<br />

not only on our special expertise<br />

in machine configuration. Every<br />

parameter in this process is important,<br />

in order to ensure high, continuous<br />

production,” says Gerhard Kuss, head<br />

of application technology at ROVEMA<br />

GmbH, explaining the challenge. “This<br />

is because, unlike in the case of standup<br />

pouches or flat pouches made from<br />

composite materials, the resourceefficient,<br />

paper-based alternatives<br />

need to be handled much more<br />

carefully during the packaging process<br />

and during production of the pouches.<br />

Paper tolerates only a small amount of<br />

tension transfer here and tears more<br />

easily. The perforation resistance of<br />

the paper used also needs to be taken<br />

into account much more during the<br />

subsequent filling”.<br />

This is precisely where Sappi’s extensive<br />

expertise came into play. Once they<br />

had carefully examined the customer’s<br />

specific requirements, Sappi’s paper<br />

specialists then selected the right<br />

material for the packaging of sensitive<br />

<strong>food</strong> products. As well as an efficient<br />

grease and oil barrier function, the<br />

paper-based alternative should also<br />

have required optimum heat-seal<br />

properties. The Sappi Guard product<br />

line was therefore chosen, with its<br />

30<br />

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

Packaging<br />

and could be optimally configured to<br />

the packaging process even in printed<br />

form. Another key benefit is that it can<br />

be recycled in the paper waste cycle.<br />

innovative range of functional papers<br />

specially developed for the flexible<br />

packaging market. Thanks to their<br />

integrated barriers, there is no need for<br />

any additional application of coating<br />

or lining to achieve the required<br />

capabilities with these functional papers.<br />

After a few weeks of testing, during<br />

which Sappi and ROVEMA studied<br />

the interaction of the packaging<br />

material and the packaging machine<br />

and coordinated them optimally to<br />

one another, the perfect substrate<br />

was found for the customer in the<br />

form of Sappi Guard Nature MS in a<br />

grammage of 80g/m². The material<br />

not only offered the perfect mix of<br />

formability and stability, but also a<br />

high level of sealability. Guard Nature<br />

MS also offered excellent print results<br />

Development based on<br />

partnership ensures a competitive<br />

edge<br />

The paper-based packaging material<br />

demonstrated its capabilities in the<br />

process that was perfectly coordinated<br />

by Sappi and ROVEMA. The precise<br />

coordination of packaging material and<br />

machine played a major role in ensuring<br />

the high quality of the packaging<br />

process. In the automated shaping of<br />

stand-up pouches in particular, folding,<br />

seal times and seal temperature –<br />

common sources of error in the process<br />

– need to be perfectly synchronized in<br />

order to ensure a reliable product.<br />

In addition, due to the longer seal times,<br />

switching to paper-based packaging<br />

material can result in a drop in output<br />

of up to 30 percent, however, in this<br />

pilot project, performance loss was kept<br />

to 10-15 percent. One of the reasons for<br />

this was software specially developed<br />

by ROVEMA, which is integrated into<br />

the precise packaging process. This<br />

enables parameter changes to be<br />

directly synchronized virtually in real<br />

time, so the process can be adapted<br />

accordingly. Individually defined limit<br />

values and plausibility calculations<br />

prevent incorrect changes in the<br />

process and thus keep the performance<br />

stable. This is a level of precision that is<br />

not yet common in relation to paperbased<br />

packaging materials in particular.<br />

The successful pilot project demonstrates<br />

how Sappi’s expertise in<br />

sustainable barrier packaging solutions<br />

made from paper, together with the<br />

technical expertise of the packaging<br />

machine manufacturer Rovema, have<br />

successfully filled a gap in the packaging<br />

industry. Customers who are looking<br />

to use resource-efficient packaging<br />

materials can now benefit from the<br />

combined knowledge and wealth of<br />

experience of the two partners, get the<br />

optimum packaging solution – tailormade<br />

and customized – and thus gain<br />

a clear competitive edge.<br />

fmt<br />

Gerhard Kuss<br />

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Packaging<br />

Bespoke Solutions in Meat Packaging<br />

Support Danish Crown’s China Expansion<br />

Ishida Europe has designed and<br />

installed a series of bespoke packing<br />

lines for specialist meat producer<br />

Danish Crown’s new greenfield<br />

factory in China.<br />

Working in close partnership with the<br />

customer, Ishida has supplied its own<br />

and ancillary equipment for the four<br />

lines, which are handling a variety<br />

of products including minced and<br />

diced pork, ribs and steaks, as well<br />

as quality control for thermoformed<br />

packs of pork. The factory is now in<br />

operation and will have a capacity for<br />

14,000 tonnes of meat to be processed<br />

and packed each year when it is up to<br />

full speed.<br />

working relationship established<br />

between our two teams and the<br />

continuing dialogue between them<br />

ensured that any issues or problems<br />

could be discussed and quickly dealt<br />

with to keep the project on time and<br />

budget and enable us to meet our<br />

performance targets.<br />

“In addition, the company has an<br />

office in China which ensures a fast<br />

response in terms of service support<br />

and spare parts.”<br />

The Ishida models installed at the<br />

factory include the company’s advanced<br />

RV-214 multihead weigher,<br />

QX-1100 Twin tray sealers, DACS-G<br />

checkweighers, IX-GN x-ray inspection<br />

systems and its weigh-price-labellers.<br />

Additional equipment integrated<br />

into the lines includes dicers, slicers,<br />

batching tables, labellers and<br />

cartoners. Ishida also gave factory<br />

personnel comprehensive training<br />

on all its machines and provided<br />

a technician on-site permanently<br />

Ishida’s ability to devise complete<br />

solutions in line with customer<br />

requirements and efficiency and<br />

throughput targets, along with the<br />

excellent performance and reliability<br />

of its equipment, were key reasons<br />

for the company’s selection by Danish<br />

Crown.<br />

“We felt that Ishida offered the most<br />

relevant experience and the best<br />

solutions,” explains Nicolai Linde,<br />

Senior Manager Projects, Production<br />

and Supply Chain. “Having a single<br />

point of contact helped to speed up<br />

the process. In particular, the close<br />

32<br />

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

Packaging<br />

during the first months<br />

of operation to ensure a<br />

trouble-free start up.<br />

A key requirement of<br />

the overall design was<br />

to ensure maximum<br />

flexibility in the lines’<br />

ability to handle a wide<br />

variety of products and<br />

pack types. For example,<br />

the multihead weigher is<br />

able to discharge diced<br />

meat directly into trays, or<br />

transfer ribs to a batching<br />

table for styling in the trays.<br />

Similarly, the QX-1100 tray<br />

sealers which currently seal<br />

MAP trays are also able to<br />

handle skin packs, which<br />

will enable Danish Crown<br />

to meet growing demand<br />

in the Chinese market for<br />

bone-in products.<br />

“Although we were not<br />

previously familiar with<br />

Ishida’s tray sealers, they<br />

have proved to be very<br />

reliable and deliver<br />

consistently high-quality<br />

seals,” comments Nicolai<br />

Linde.<br />

As another example of the<br />

excellent performance of<br />

the Ishida machines, the<br />

company’s IX-GN 4044 x-ray<br />

inspection systems and DACS-G-015<br />

checkweighers are also providing<br />

quality control and weight checks on<br />

two separate thermoforming lines.<br />

Danish Crown is one of the world’s<br />

largest exporters and one of Europe’s<br />

largest producers of pork. The<br />

new China factory in Shanghai was<br />

established to meet growing consumer<br />

demand in the Chinese market for<br />

high quality meat products, supplied<br />

via supermarkets and e-commerce.<br />

“Our objective was to build the new<br />

factory to Danish standards,” explains<br />

Nicolai Linde. “For this reason, we<br />

focused on sourcing the very best<br />

European equipment throughout.” fmt<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • February <strong>2021</strong> 33

Packaging<br />

Independent Cart <strong>Technology</strong> Underpins<br />

Integrated Packaging Concept<br />

Advanced packaging solution integrates seamlessly into modern component fabrication line thanks to<br />

innovative in-machine and between-machine transportation technology<br />

Cama Group prides itself on the way<br />

it designs, develops and deploys<br />

new technologies, in order to bring<br />

heightened integration, throughput,<br />

accuracy and quality levels to the<br />

packaging industry.<br />

Its machines, which see action all<br />

over the globe in a huge variety of<br />

packaging applications, are designed<br />

to offer the perfect blend of modular,<br />

accessible and hygienic mechanical<br />

frameworks, coupled to the very latest<br />

technology the automation world has<br />

to offer; including advanced and tightly<br />

integrated in-house-developed robotic<br />

pick-and-place solutions.<br />

In a recent project, Cama’s high-tech<br />

pedigree was really put to the test,<br />

when it was tasked with designing and<br />

integrating one of its Breakthrough<br />

Generation (BTG) CL 175 cartoning<br />

machines into an electrical component<br />

fabrication line at one of the world’s<br />

largest automation vendors, Rockwell<br />

Automation.<br />

In addition to proving the integration<br />

capabilities of the control solution,<br />

Cama had to demonstrate that its<br />

machine would fit seamlessly into the<br />

rest of the line, the majority of which<br />

had been developed and built by US<br />

company Calvary Robotics, a specialist<br />

in the design and build of automated<br />

assembly, test and material-handling<br />

systems.<br />

According to Giovanni Panzeri,<br />

Automation Project Leader at<br />

Cama: “The line with which we were<br />

integrating is for the assembly of a<br />

wide range of contactors, the model<br />

type of which vary depending on the<br />

contact configuration, the voltage and<br />

the applicable local certifications, such<br />

as CE and UL. The line is designed to<br />

be as flexible as possible, so that small<br />

batches of the various contactor models<br />

can be fabricated – to order in a just-intime<br />

fashion – as efficiently as possible,<br />

with minimum re-engineering and<br />

downtime. As a result, our packaging<br />

solution had to deliver a commensurate<br />

level of flexibility, to adapt and change<br />

to the various product throughputs.”<br />

Cama and Rockwell Automation had<br />

already worked very closely before on a<br />

number of industry-leading packaging<br />

machines, so the relationship had a<br />

significantly strong foundation. But it<br />

was Cama’s experience with the global<br />

automation supplier’s independent cart<br />

technology (ICT) that helped seal the<br />

deal… and provided the all-important<br />

physical link into the rest of the line.<br />

“Cama was one of the first companies<br />

to deploy the iTRAK ICT in a customer<br />

application,” Panzeri explains, “so<br />

we already had a good grounding<br />

in its operation and how it could be<br />

leveraged to deliver the additional<br />

flexibility many end users require. Using<br />

iTRAK, with its near limitless motion<br />

profiles, the individual product carriers<br />

within our machine, controlled by the<br />

central PLC, are pitched automatically<br />

based on the width of the product or<br />

product groups that require insertion<br />

into the cartons. Thanks to this, the<br />

cartoner can work intermittently or<br />

Photos: CAMA Group.<br />

34<br />

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

Packaging<br />

continuously depending on the product<br />

and throughput required.<br />

“The CL 175 comprises three main<br />

operating stations,” he elaborates. “In<br />

the first, carton boxes are picked from<br />

a magazine and opened out as they<br />

are placed into pockets on the iTRAK<br />

carriages. Once placed, two pockets/<br />

boxes at a time are presented to the<br />

insertion station, where the contactors<br />

are pushed into the boxes. Following<br />

insertion, the boxes are closed and sealed<br />

before passing to a printing station,<br />

where the individual product-specific<br />

information is printed and verified,<br />

before the cartons leave on an exit<br />

conveyor. After the products leave on the<br />

conveyor, the iTRAK carriages recirculate<br />

under the track ready for loading with<br />

the next round of cartons. The cartoninsertion<br />

system exploits a software<br />

interpolator, which delivers coordinated<br />

movement between the iTRAK and the<br />

servo-controlled pushers. As well as<br />

delivering far greater accuracy and axis<br />

synergy compared to a more traditional<br />

pneumatic systems, this approach also<br />

reduces mechanical stresses.<br />

“Advanced in-machine automation is<br />

second nature to us, thanks to our broad<br />

experience using robotics and linear/<br />

rotary servo technologies,” Panzeri adds.<br />

“But a vital element of this installation was<br />

the way in which the CL 175 integrates<br />

with the downstream assembly processes,<br />

so as not to cause any bottlenecks. This,<br />

as it turns out, was made possible using<br />

another of Rockwell Automation’s ICT<br />

technologies, MagneMotion Lite.”<br />

Preceding the CL 175 cartoning machine,<br />

the Calvary Robotics line comprises<br />

three assembly machines, a productprinting<br />

module and two testing<br />

stations, arranged in a ‘U’ shape. All<br />

of the assembly and testing steps are<br />

interlinked using the MagneMotion ICT,<br />

so the best possible solution would see<br />

the MagneMotion technology extended<br />

into the packaging operation.<br />

delivers seamless interactions across all<br />

elements of the line, as if it is one large<br />

machine, so our packaging solution<br />

was simply another step in a larger<br />

process. Full EtherNet/IP connectivity<br />

across the machines and larger devices<br />

and I/O Link at the component level<br />

means that full integration is possible,<br />

as is the creation of fully transparent<br />

data pathways, creating a true Industry<br />

4.0 solution. This interconnected<br />

architecture also means that all stations<br />

along the line work in harmony with<br />

each other. As each batch variation is<br />

fed from the primary MES system, every<br />

machine is geared up to undertake the<br />

correct assembly, printing, testing and<br />

packaging processes – with absolute<br />

minimal human interaction.”<br />

Rockwell Automation’s choice of Cama<br />

for this application is testament to the<br />

strength of their mutual relationship<br />

and reinforces the capabilities of<br />

modern integrated control solutions.<br />

“We are often selected by Rockwell<br />

Automation to act as product testers<br />

for new hardware and the fruits of<br />

this testing and evaluation are evident<br />

in an application such as this,” Panzeri<br />

adds. “This line is a graphic example<br />

of three engineering teams working<br />

together with a common goal, which<br />

is underpinned by a very powerful<br />

integration model.<br />

“Indeed, this line is a great shop window<br />

for all of our technology, teamwork and<br />

capabilities and reflects the direction in<br />

which the packaging industry is moving,”<br />

Panzeri concludes. “ICT technology both<br />

in machine and between machines is<br />

creating the foundation for flexible<br />

manufacturing and production, where<br />

the idea of a production line will soon<br />

become redundant. Smart-conveying<br />

solutions are creating the basis for<br />

production grids, or matrices, where<br />

products only visit the stations they<br />

need, but without creating mechanical<br />

complexity, batch-adaptation hurdles or<br />

transportation conflicts.”<br />

fmt<br />

“Thanks to the complete integration<br />

and the holistic control environment,<br />

having MagneMotion as the in-feed<br />

supply solution was a straightforward<br />

proposition,” Panzeri explains. “The<br />

Allen-Bradley control architecture<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • February <strong>2021</strong> 35

Packaging<br />

Elopak Records One Billion Natural<br />

Brown Board Cartons<br />

The volume of Elopak’s Natural Brown<br />

Board cartons will surpass one billion<br />

units in February <strong>2021</strong>. The milestone<br />

is good news for the company’s<br />

sustainability efforts, as the lower CO 2<br />

footprint of these cartons means an<br />

estimated 3,000 tons of greenhouse gas<br />

emissions have been avoided as a result.<br />

The reduction in CO 2<br />

emissions resulting<br />

from the use of Natural Brown Board is<br />

equivalent to approximately 1,400 round<br />

trip flights for one person London - New<br />

York.<br />

The news comes after Elopak recorded<br />

a significant increase in its sale of<br />

Natural Brown Board cartons in 2019,<br />

with brands responding to increased<br />

consumer interest in the environmental<br />

credentials of their products by making<br />

the transition to sustainable packaging<br />

solutions. Today approximately 20% of<br />

the Pure-Pak® milk cartons Elopak sells<br />

in Western Europe are produced with<br />

Natural Brown Board.<br />

Speaking on the news, Elopak’s Director<br />

Sustainability Marianne Groven stated,<br />

“Beverage cartons already have strong<br />

environmental credentials when<br />

compared with alternatives such as plastic<br />

bottles. It is encouraging to see that our<br />

customers are embracing innovations<br />

that offer a more sustainable solution,<br />

such as the Natural Brown Board.<br />

Together we can aim even higher and<br />

help consumers make conscious choices.”<br />

Launched in 2017, in partnership with<br />

supplier Stora Enso, Elopak was the first<br />

packaging company to provide gable<br />

top cartons made with Natural Brown<br />

Board. These Pure-Pak® cartons are<br />

renewable and recyclable. They have a<br />

lower CO 2<br />

footprint owing to reduced<br />

wood consumption and the elimination<br />

of the bleaching process. Their rustic,<br />

natural look effectively communicates<br />

this commitment to sustainability and<br />

instantly stands out on the shelves.<br />

“This is an exciting milestone for us as<br />

Elopak was the first company to offer<br />

gable top cartons made with Natural<br />

Brown Board. We were also the first in<br />

our industry to announce that we are a<br />

carbon neutral company offering carbon<br />

neutral cartons, and the first to offer<br />

fully renewable cartons made entirely<br />

from wood,” Elopak’s Chief <strong>Marketing</strong><br />

Officer (CMO) Patrick Verhelst stated.<br />

“Our customers are very responsive<br />

to consumers’ desire to reduce their<br />

environmental impact. A lot of them<br />

offer organic, green or otherwise<br />

sustainable products and they want<br />

a packaging solution that reflects<br />

this ethos and instantly signals their<br />

commitment to the environment.<br />

With its unbleached, natural look the<br />

Pure-Pak® cartons with Natural Brown<br />

Board effectively communicates that<br />

inherent sustainability at first glance,” he<br />

continued.<br />

Several customers were quick to embrace<br />

the Natural Brown Board with Arla<br />

being the first major brand to adopt the<br />

innovation for its line of organic EKO<br />

products in Sweden. In June 2018, when<br />

Arla launched its Arla Organic range of<br />

milk and drinking yoghurts, the brand<br />

opted again for one liter Pure-Pak®<br />

cartons with Natural Brown Board, which<br />

were rolled out across the Netherlands,<br />

Denmark, Sweden, Germany and Finland.<br />

Some customers have taken the concept<br />

further and removed the renewable<br />

plastic cap. Norwegian dairy, TINE,<br />

transitioned from a white carton<br />

with a cap to a Natural Brown Board<br />

carton without a cap, resulting in a<br />

carbon footprint reduction of around<br />

40%. Sweden’s second-largest dairy<br />

Skånemejerier has also removed the caps<br />

on all their Hjordnära organic milk oneliter<br />

cartons, launching its organic milk<br />

in new Pure-Pak® cartons with an easy<br />

opening funnel feature to replace the<br />

plastic closure.<br />

Since its launch, Elopak’s Natural Brown<br />

Board has served as a platform for<br />

further sustainability-focused innovations,<br />

including the Pure-Pak® Imagine launched<br />

in 2020. The carton is a modern version of<br />

the company’s original Pure-Pak® carton,<br />

containing 46% less plastic and designed<br />

with a new easy open feature. It has no<br />

plastic screw cap and is 100% forest-based<br />

made with Natural Brown Board, making<br />

it Elopak’s most environmentally friendly<br />

carton to date.<br />

fmt<br />

36<br />

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

Packaging<br />

Digitized Silo Fill Level Monitoring<br />

Nanolike is pleased to introduce a new<br />

digitized fill level monitoring solution<br />

for <strong>food</strong> and beverage silos. The goal<br />

is to simplify inventory and order<br />

management processes in the <strong>food</strong> and<br />

beverage industry. Another aim is to<br />

help the manufacturers and suppliers<br />

of raw materials and additives optimize<br />

their silo replenishment processes. This<br />

not only saves costs but also reduces<br />

the environmental impact by enabling<br />

route optimization. The new digitized<br />

silo fill level monitoring solution stands<br />

out through highly efficient sensor and<br />

cloud connectivity technology using the<br />

Sigfox 0G wireless network. It requires<br />

zero maintenance for years and needs<br />

neither an external power supply<br />

nor a data line, which saves costs and<br />

ensures that the digitization investment<br />

is amortized very quickly. This makes<br />

Nanolike technology highly disruptive,<br />

as it can replace any alternative sensor<br />

technology used exclusively to manage<br />

replenishment management.<br />

Users of Nanolike‘s digitized silo fill<br />

level monitoring solution are found<br />

in almost all sub-sectors of the <strong>food</strong><br />

industry, from soft drink and fruit juice<br />

producers, dairy product manufacturers,<br />

breweries and coffee roasters, to legume<br />

processors and industrial bakeries as well<br />

as jam, instant and convenience <strong>food</strong><br />

manufacturers – and that‘s by no means<br />

an exhaustive list. Nanolike’s digitized<br />

silo fill level monitoring solution isn’t just<br />

for large silo operators; it also targets<br />

silo manufacturers who aspire to include<br />

this technology in their portfolios and,<br />

above all, raw materials and additives<br />

manufacturers aiming to offer their<br />

customers automatic replenishment,<br />

vendor-managed inventory (VMI)<br />

or similar solutions as part of their<br />

digitization strategies.<br />

Quickly and easily mounted on the exterior<br />

base of the silo, the Nanolike sensors<br />

give users 24/7 access to information on<br />

fill levels and demand forecasts in realtime.<br />

This digital solution makes it much<br />

easier to monitor the silo fill levels and<br />

greatly reduces users’ workload, as they<br />

no longer have to climb to the top of<br />

silos at different locations to check the<br />

fill levels. Instead, all required inventory<br />

management tasks can be done in less<br />

time from the safety of the office. An<br />

integrated early warning system alerts<br />

the silo operator to potential bottlenecks,<br />

helping to prevent any shortages of raw<br />

materials and additives.<br />

Based on real-time data, the mobile<br />

application also facilitates the<br />

automation of purchase processes<br />

as silo operators can chose to place<br />

orders directly from their smartphones.<br />

Such an integrated solution, which<br />

can be implemented with just a few<br />

clicks, greatly simplifies communication<br />

between <strong>food</strong> manufacturers and<br />

their suppliers. What is more, it makes<br />

it possible to optimize the supply to<br />

distributed silos at a higher level, leading<br />

to overall savings in transport logistics,<br />

which ultimately also improves the long<br />

term CO 2<br />

balance. The data from the<br />

Nanolike sensors are consolidated in a<br />

central cloud from where they can be<br />

imported into existing software systems<br />

and customer clouds, or retrieved via<br />

smartphone app at any time.<br />

The digitized fill level monitoring solution<br />

from Nanolike is extremely simple to<br />

implement, as it is self-calibrating, does<br />

not require active calibration, and also<br />

filters out undesirable environmental<br />

influences. Before filling a silo, the user<br />

sets the sensor to zero via the mobile<br />

phone app and manually enters the fill<br />

load once in the software. From thereon,<br />

the changing fill level is calculated in<br />

the cloud, based on a comparison of<br />

sensor data recorded before and after<br />

filling. The measurement corridor can<br />

include just the one load, which doesn’t<br />

have to be a full load, or it can map the<br />

state between a completely empty and<br />

completely full silo.<br />

fmt<br />

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

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • February <strong>2021</strong> 37

<strong>Marketing</strong><br />

No More VOCs: Waterless Offset Printing<br />

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

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

printing quality.<br />

The demands placed on flexible<br />

packaging manufacturers are<br />

growing. Packaging should be more<br />

environmentally friendly, more cost<br />

efficient – and all that while delivering<br />

superb printing quality and being<br />

safe for consumers and workers alike.<br />

On top of that, the <strong>food</strong> industry is<br />

seeing a general trend towards a<br />

diversification of products, resulting<br />

in smaller printing runs. The use of the<br />

right printing method plays a major<br />

role in meeting these expectations.<br />

But flexographic and gravure printing,<br />

the established industry standards,<br />

are increasingly reaching their limits<br />

in accommodating some of these<br />

aspects.<br />

VOCs: Harmful to workers and<br />

the environment<br />

One such puzzle that has been<br />

plaguing the industry for years is how<br />

to avoid volatile organic compounds<br />

(or VOCs) in the printing process. The<br />

term encompasses a variety of gases<br />

and small particles that are released<br />

during the production, use, or even<br />

storage of certain products, such<br />

as cleaning liquids or paint – with<br />

harmful consequences on both<br />

the environment and the workers<br />

Workers at printing plants come into contact<br />

with VOCs at various touchpoints<br />

interacting with VOCs. Long-term<br />

exposure with VOCs can lead to<br />

anything from eye and throat<br />

irritation to loss of coordination,<br />

chronic fatigue, or even cancer.<br />

In flexible packaging printing, VOCs<br />

occur mainly through the use of<br />

solvents in inks and the cleaning liquid<br />

used on the printing presses. In cases<br />

where conventional offset printing is<br />

used, the dampening water becomes<br />

an additional contributor of VOC.<br />

And while the environmental harm<br />

of VOCs has largely been contained<br />

through air filters in printing facilities,<br />

the detrimental effects on workers’<br />

health remain. Although significant<br />

strides have been made in reducing<br />

VOCs, it was not possible to avoid<br />

them completely – until now.<br />

One solution to rule them all<br />

Toray Industries, Inc. has developed<br />

the first ever printing system that is<br />

100 percent VOC-free. What is more,<br />

the solution makes no compromises in<br />

printing quality or <strong>food</strong> safety.<br />

One key to achieving this is the<br />

use of waterless offset printing<br />

with Comexi’s CI8 printing press. In<br />

offset printing, the inked image<br />

is transferred – or offset – from a<br />

printing plate to a blanket made<br />

of rubber, which in turn transfers it<br />

onto the printing surface. While this<br />

printing technique has become an<br />

established method in such fields as<br />

newspaper printing, label printing,<br />

plastic card printing and others, it<br />

is still relatively unheard of in the<br />

flexible packaging world.<br />

Yet, offset printing comes with a<br />

number of features ideally suited<br />

for the present challenges in flexible<br />

packaging printing: Offset printing<br />

plates are a lot easier to produce than<br />

the cylinders required for rotogravure<br />

printing or photopolymer plates for<br />

flexographic printing. This allows<br />

more flexibility in terms of short-term<br />

printing, facilitating smaller printing<br />

jobs at a low cost point. Furthermore,<br />

the use of waterless offset printing<br />

can already reduce the amount VOCs<br />

by up to 80 percent compared to<br />

conventional offset printing.<br />

However, conventional offset printing,<br />

the most common offset printing<br />

method, is fairly limited in the choice of<br />

substrates that can be used. Moreover,<br />

conventional offset printing requires<br />

dampening water to repel the ink<br />

in places that are not printed. The<br />

stained dampening water becomes a<br />

source of VOCs and also creates waste<br />

water that subsequently needs to<br />

be purified before further use. Thus,<br />

while conventional offset printing<br />

comes with a number of advantages<br />

in terms of flexibility and economy,<br />

it cannot fully eliminate VOCs in the<br />

printing process.<br />

Bringing waterless offset<br />

printing to the flexible<br />

packaging industry<br />

To forego this issue, Toray is relying<br />

on a technology that the company<br />

has been successfully working on for<br />

decades: waterless offset printing. In<br />

38<br />

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

<strong>Marketing</strong><br />

on-site tests, the Comexi CI8 offset<br />

printing press could easily be adapted<br />

to this environmentally friendly<br />

version of offset printing. Here, a<br />

silicone polymer is used as an ink<br />

repellant instead of a dampening<br />

solution, eliminating one major<br />

source of VOCs.<br />

Inks and cleaners: Completing<br />

the puzzle<br />

The test also featured the second<br />

central element of Toray’s new<br />

printing solution: water-washable<br />

EB inks. Reducing VOCs in inks has<br />

been a goal of manufacturers for a<br />

while, resulting most recently in the<br />

introduction of water-based inks. The<br />

concentration of organic solvents,<br />

the main contributors to VOCs, is<br />

between five and 30 percent in these<br />

inks – compared to up to 80 percent<br />

in regular oxidative inks. However, a<br />

remnant of VOCs remain, not only in<br />

the ink itself, but also in the liquids<br />

used for cleaning the printing presses.<br />

These require the use of organic<br />

solvents in order to eliminate any<br />

remaining ink, and they contain<br />

relatively high levels of VOC. A waterbased<br />

cleaning liquid could alleviate<br />

this problem – but it can only be used<br />

with the new kind of water-washable<br />

EB ink developed by Toray.<br />

The ink itself does not contain<br />

any organic solvents, making it<br />

completely VOC-free. At the same<br />

time, the combination of special ink<br />

formulation and waterless printing<br />

achieves a particularly strong adhesion<br />

to a wide variety of substrates. These<br />

special inks are cured using an<br />

electron beam (EB) instead of UV light<br />

and therefore do not include any of<br />

the photo-initiators limited by <strong>food</strong><br />

packaging regulations. Consequently,<br />

there is no risk of any VOCs or<br />

photo-initiators migrating into the<br />

printing substrate. The new solution<br />

is therefore particularly safe for <strong>food</strong><br />

packaging.<br />

Finally, water-washable EB inks allow<br />

the use of water-based ink cleaners.<br />

As this cleaning process is mostly done<br />

by hand, it is the most significant<br />

factor where workers still come into<br />

direct contact with VOCs. Eliminating<br />

harmful particles here is therefore<br />

especially important to maintaining<br />

workers’ health. Together with waterwashable<br />

EB inks and waterless offset<br />

printing, these water-based cleaners<br />

form the first completely VOC-free<br />

printing system in the world.<br />

The future of flexible packaging<br />

printing is VOC-free<br />

With the combination of waterless<br />

offset printing, water-washable EB<br />

inks, and water-based cleaning liquid,<br />

Toray’s new printing system is the<br />

first in the world to be completely<br />

VOC-free. And it has already been<br />

put to the test. A European converter<br />

completed a series of tests to print<br />

OPP, PA boil, and PET retort pouches<br />

with Toray’s technology and a Comexi<br />

CI8 press – with resounding success.<br />

However, the Japanese material<br />

technology specialist is not merely<br />

hoping to offer flexible packaging<br />

manfuacturers a more sustainable and<br />

healthier alternative – the solution is<br />

also meant to bring superior printing<br />

quality.<br />

This sentiment is expressed in the<br />

brand name P4E, which in future will<br />

include all VOC-free printing solutions.<br />

The name stands for “Epoch-making,<br />

Ecology, Excellence and Efficiency”<br />

for the printing industry. An<br />

ambitious goal that the company is<br />

alread planning on expanding. “We<br />

want to move towards contributing<br />

to a circular economy in flexible<br />

packaging printing and help achieve<br />

the Sustainable Develeopment Goals<br />

(SDGs) set by the United Nations”,<br />

Toray Industries, declares.<br />

In keeping with the company’s<br />

own sustainability vision, Toray has<br />

contunuously been seeking technical<br />

developments that will help create a<br />

greener future. Recycling has been<br />

one dream in the flexible packaging<br />

world for some time. In order to<br />

make it a reality, Toray Industries’<br />

film business segment is currently<br />

working on applying mono-material<br />

subtsrates to the process. At the<br />

same time, the company is hoping<br />

to extend VOC-free printing to other<br />

printing segments, as well. Thus,<br />

Retort packaging samples using Comexi CI8 press<br />

and Toray’s novel printing system<br />

Toray is working to provide the right<br />

solutuon for the future of flexible<br />

packaging – more sustainable, more<br />

adaptable, and just as high-quality as<br />

the currently leading solutions. fmt<br />

The Author<br />

Mr Takayuki Kamei is General Manager,<br />

Electronic Information Materials Division,<br />

Toray Industries, Tokyo, Japan<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • February <strong>2021</strong> 39

Events<br />

Fairtrade Launches Virtual for all Middle<br />

East Africa <strong>2021</strong><br />

Focus on Middle East Africa’s (MEA) agro<strong>food</strong> & plastprintpack sector on 31 May to 02 June<br />

After the success of the Virtual<br />

agro<strong>food</strong> & plastprintpack Africa in<br />

November 2020, the German trade<br />

show specialist fairtrade Messe is<br />

launching another digital format<br />

with the Virtual for all Middle<br />

East Africa from 31 May to 2 June<br />

<strong>2021</strong>. The organizers’ aim with this<br />

event is to contribute to deepening<br />

global relations with the Middle<br />

East and Africa in the agro<strong>food</strong> &<br />

plastprintpack sector.<br />

A brief review of November’s Virtual<br />

for all Africa also gives an indication<br />

of what participants at the new event<br />

can expect. A total of 2,353 registered<br />

participants from 87 countries<br />

attended. 64 exhibitors from 17<br />

countries received 8,783 visits to their<br />

virtual stands and their products<br />

were consulted 2,008 times. 3,540<br />

visitors attended 67 panel discussions,<br />

presentations and product demos<br />

with a total of 98 speakers. These<br />

facts, together with high satisfaction<br />

scores on both the exhibitor and<br />

visitor side, have made Virtual for all<br />

Africa the most important agro<strong>food</strong> &<br />

plastprintpack online event with an<br />

Africa focus.<br />

“30 years of experience in organizing<br />

international trade fairs in the Middle<br />

East and 25 years in Africa enable<br />

us to establish the new Virtual for<br />

all Middle East Africa on a solid<br />

footing. At the same time, we are<br />

going down innovative digital paths<br />

so that our exhibitors and attendees<br />

can communicate and do business<br />

in the best possible way,” explains<br />

Martin März, fairtrade founder and<br />

managing partner.<br />

And fairtrade managing director<br />

Paul März outlines: “Virtual for all<br />

MEA <strong>2021</strong> will benefit from two<br />

innovations: Firstly, in addition to<br />

our proven partners in the Maghreb<br />

and in West and East Africa, we are<br />

setting further regional focuses. In<br />

Africa with Egypt and South Africa<br />

and in the Middle East with Saudi<br />

Arabia, UAE, Iran, Iraq, Jordan, Oman,<br />

Qatar, Kuwait and Bahrain.<br />

And secondly we will complement<br />

the award-winning event platform<br />

we already used for Virtual for all<br />

Africa 2020 by a mobile app that<br />

will bring notifications regarding<br />

appointments between exhibitors and<br />

attendees directly to the smartphones,<br />

helping to ensure that agreed B2B<br />

appointments actually happen.”<br />

Participation for visitors is<br />

complimentary. Exhibitors can choose<br />

between various exhibitor and<br />

sponsorship packages.<br />

In addition to the B2B meetings,<br />

Virtual for all Middle East Africa <strong>2021</strong><br />

will offer a large-scale conference<br />

programme extending over the<br />

entire three days addressing relevant<br />

and currently highly debated topics.<br />

For three days, the focus will be on<br />

Middle East Africa and on agricultural<br />

production, <strong>food</strong> and beverage<br />

technology, <strong>food</strong> ingredients, <strong>food</strong><br />

trade, as well as plastic, printing and<br />

packaging materials, raw materials<br />

and technology.<br />

• agro: To diversify Africa’s<br />

economies and revive its rural<br />

areas, the African Development<br />

Bank (AfDB) has committed US$<br />

24 billion towards agricultural<br />

industrialization. According to the<br />

German Engineering Federation<br />

VDMA, MEA’s agricultural<br />

machinery imports amount to well<br />

over €2 billion annually.<br />

• <strong>food</strong> + bev tec: Imports of <strong>food</strong><br />

processing & packaging technology<br />

account for €4.683 billion in 2019<br />

(VDMA)<br />

40<br />

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

Events<br />

• <strong>food</strong> ingredients: With 1.6 billion<br />

inhabitants, MEA has long been<br />

one of largest <strong>food</strong> markets in<br />

the world. Expenditure in the F&B<br />

sector is growing steadily, and F&B<br />

production is by far the largest<br />

segment of the MEA processing<br />

industry.<br />

• <strong>food</strong> + hospitality: According to the<br />

African Development Bank, MEA’s<br />

annual <strong>food</strong> imports are estimated<br />

to rise from US$ 85 billion to US$<br />

170 billion by 2025.<br />

• plast: Since the Middle East is a<br />

huge exporter of plastics in primary<br />

forms, and Africa only produces<br />

39% of its required plastic raw<br />

materials itself but imports 61%,<br />

the Middle East & Africa fit very<br />

well together to outbalance their<br />

needs. African Imports of plastics<br />

raw materials, for instance, grew<br />

by 5.9% annually between 2011<br />

and 2017, from 4,220 kt to 5,939<br />

kt, +41%. And the Middle East’s<br />

exports of such material grew<br />

from 16,607 kt in 2011 to 25,280<br />

kt in 2017, an annual increase of<br />

7.25%. (EUROMAP) MEA’s imports<br />

of plastics technology made up for<br />

€1,779 billion in 2019. (VDMA)<br />

• print: MEA’s imports of printing<br />

& paper processing technology<br />

represent €1,368 billion in 2018, up<br />

7.8 per cent to 2017. (VDMA)<br />

• pack: MEA’s imports of packaging<br />

technology make up for €2.291<br />

billion in 2019, +3.2% compared<br />

with 2018. (VDMA)<br />

fmt<br />

Q2 <strong>2021</strong><br />

31 May-2 June<br />

Middle East Africa agro<strong>food</strong><br />

fairtrade Messe GmbH & Co. KG<br />

Kurfürsten Anlage 36,<br />

69115 Heidelberg, Germany<br />

Tel.: +49-6221/4565-0<br />

Fax: +49-6221/4565-25<br />

info@fairtrade-messe.de<br />

www.virtual-africa.com<br />

www.fairtrade-messe.de<br />

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

Hamburg, Germany<br />

Snackex<br />

European Snacks Association<br />

Rue des Deux Eglises, 26<br />

1000 Brussels, Belgium<br />

Tel: +32-2 538 20 39<br />

Email: esa@esasnacks.eu<br />

www.snackex.com<br />

18-21 July<br />

Chicago, IL, USA<br />

IFT Food Expo<br />

Institute of Food Technologists<br />

252 W. Van Buren,<br />

Suite 1000, Chicago, IL 60607<br />

Tel.: +1-312-782-8424<br />

Fax: +1-312-782-8348<br />

www.ift.org<br />

Virtual<br />

Let’s meet here<br />

Let’s meet here<br />

Let’s meet here<br />

Q3/4 <strong>2021</strong><br />

1 September<br />

Palexpo, Le Grand-Saconnex, Switzerland<br />

Vita<strong>food</strong>s Europe<br />

Informa Exhibitions,<br />

5 Howick Place,<br />

London SW1P 1WG,<br />

Let’s meet here<br />

Great Britain<br />

Tel.: +44 20 337 73111<br />

www.vita<strong>food</strong>s.eu.com<br />

4-8 October<br />

Munich, Germany<br />

drinktec<br />

Messe München GmbH<br />

Messegelände<br />

81823 München, Germany<br />

Tel: +49-89-949-11318<br />

Fax: +49-89-949-11319<br />

www.drinktec.com<br />

Let’s meet here<br />

30 November-2 December<br />

Frankfurt, Germany<br />

Food ingredients South America<br />

Informa Markets<br />

PO Box 12740, de Entree 73,<br />

Toren A, 1100 AS Amsterdam Zuid Oost,<br />

The Netherlands<br />

Tel.: +31-20-409 9544<br />

Fax: +31-20-363 2616 Let’s meet here<br />

www.ubm.com<br />

<strong>food</strong> <strong>Marketing</strong> & <strong>Technology</strong> • February <strong>2021</strong> 41

Last Page<br />

Advertiser’s Index • February <strong>2021</strong><br />

Key No. Page Company Location<br />

94441 Digital ANDRITZ AG Leuven, Belgium<br />

99050 23 Bühler AG Uzwil, Switzerland<br />

99395 29 Coperion GmbH Stuttgart, Germany<br />

99601 4 European Snack Association Brussels, Belgium<br />

97065 5 fairtrade GmbH & Co. KG Heidelberg, Germany<br />

99420 9 J. Rettenmaier & Söhne GmbH Rosenberg, Germany<br />

98981 27 Kohlhoff Hygienetechnik GmbH & Unna, Germany<br />

98838 21 NETZSCH Pumpen & Systeme G Waldkraiburg, Germany<br />

99510 25 Pavan S.p.A. Galliera Veneta, Italy<br />

99030 15 Schaaf Technologie GmbH Bad Camberg, Germany<br />

99498 Cover TOMRA Sorting NV Leuven, Belgium<br />

99411 Cover 4 URSCHEL Chesterton, IN, USA<br />

99382 19 WENGER Manufacturing, Inc. Sabetha, KS, USA<br />

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

something should be not quite right.<br />


ISSN 0932-2744<br />

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PREVIEW • APRIL <strong>2021</strong><br />

Flow Packaging<br />

Texture<br />

Color Sorting<br />

Health & Wellness<br />

… and lots more<br />

42<br />

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

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