food Marketing - Technology 1/2023

1/23 

Vol. 37 • 31377 

ISSN 0932-2744 

Cover: The Multiple Value 

of Almonds 

The Trend to 

Jackfruit 

Optical 

Potato Sorting 

Confectionery 

Packaging Future

lit modular casing 

UMPE 

less steel, 

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Differenzdruck-Begrenzungsventil 

Differential pressure limiting valve 

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E einschalig / doppelschalig 

Containment shell executions: 

E metallic / non-metallic 

E single / double shell 

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Editorial 

Healthy Diet and Healthy Planet 

Pulses – or legumes – are receiving a 

lot of global attention at the moment. 

And this is a good thing. They are a 

great source of protein and fibre and 

are beneficial for health in people, 

animals and the environment. Using 

the initiatives around World Pulse 

Day, a conference has been launched 

for later this year, which will discuss 

policy and behavioural change to 

move forward to a positive future in 

food systems. 

Scientists and experts speaking 

at the conference “Extinction or 

Regeneration” in London this May 

are advising that pulses are not only 

highly nutritious and cheap, they 

are also a healthy source of protein 

and sustainable. Shifting diets away 

from reliance on meat, fish and dairy, 

and towards proteins like lentils, 

chickpeas and beans would have 

multiple benefits. 

Vandana Shiva, activist, academic 

and campaigner, was very positive: 

“The Indian diet is based on pulses, 

as they are nutritious and affordable. 

They also have a wider environmental 

benefit; the harvesting of pulses 

leaves behind nitrogen-rich crop 

residues that help maintain and 

increase soil fertility – a far more 

sustainable process than using 

synthetic fertilisers. This also helps 

tackle food insecurity. I would 

encourage people to grow pulses 

for sustainability and to eat pulses 

for their health. I’m looking forward 

to speaking at the Extinction or 

Regeneration conference and playing 

a part in developing a policy roadmap 

towards a global food system that 

benefits the health of people, animals 

and our planet.” 

Philip Lymbery, Global CEO of 

Compassion in World Farming, the 

conference organisers, told us: “A 

common myth we hear perpetuated 

is that we need to continue intensive 

animal agriculture in order to feed the 

world. However, we already produce 

enough food to feed almost twice 

the current world population but 

much of it is wasted. The Extinction 

or Regeneration conference will 

explore solutions including shifting to 

regenerative food systems and more 

plant-based diets, including pulses.” 

Shireen Kassam, Professor in 

plant-based nutrition, University 

of Winchester, also commented: 

“Pulses are a great addition to the diet. 

Not only are they associated with 

a lower risk of heart disease, type 2 

Ian Healey 

Editor-in-Chief 

diabetes and a healthier weight, they 

have shown to improve both health 

span and lifespan. The majority of 

people are not eating nearly enough 

to reap the benefits, yet they can be 

incorporated into all traditional and 

cultural diet patterns and are a great 

source of healthy nutrients such as 

protein and fibre.” 

At Fi Europe in Paris we saw a lot of 

pulse and similar products and there 

will be increased innovation this year 

as well. Improving health, saving 

money and helping the planet. What 

is not to like! 

Photo: GS 

Cheers 

If you like it – subscribe! 

food Marketing & Technology • February 2023 

3 

food Marketing & Technology • February 2023

International Magazine March 2022 ISSN 2628-5851 

Technology & Marketing 

1/22 

Contents 

Subscribe now… 

Ingredients: Insect Proteins, More Sustainable BARF, Pet Nutrition, Plant-Based Food 

Processing: Healthy Kibbles, Hygienic Cooking, Modular and Flexible Solutions 

Packaging: Recyclable Packaging and Bags, Inline Tray Sealer 

Marketing: Vet's Corner, Pet Food Competence Network, Anuga FoodTec, IFFA, Interzoo 

PetFood PRO magazine wants to 

emphasize the high level of quality 

and care in the production of pet food 

through the choice of ingredients, the 

choice of technology and the choice 

of packaging materials. 

food Marketing & Technology February 2023 

1 Editorial 

42 Impressum 

Ingredients 

6 The “Morally Minded” Consumer Unwilling to 

Compromise on Values Drives 2023 Food Trends 

10 Battling the Challenges in Texturizing Ingredients 

12 Young Jackfruit: The Hottest Trending Vegan Ingredien 

16 Unlocking the Future of Nutrition: 5 key trends for 2023 

Processing 

18 Maximize Productivity and Reliability with Visibly 

Simple Foodborne Pathogen Detection 

20 R.S. Cockerill Relies on New Optical Sorters for Whole 

Potatoes 

22 Eco-Friendly, Energy Saving, Hygienic: Efficient 

Sanitisation with Microwave and Radio Frequency 

Systems 

24 Gears and Gear Racks made from Polyamide 

25 Home of Confectionery Diversity: Production lines for 

all capacity requirements 

28 Top Tips to Reduce Food Waste During Processing 

Packaging 

30 Confectionery market: High Turnovers and Highly 

Competitive 

34 Artisan Pork Snacks Win US Consumer Hearts 

36 Save Foods – Stock with Potential: Green Agricultural 

Technology Conquers the Market Demand for Probiotic 

Departments 

Technology & Marketing 

38 ADM Opens $30 Million Stateof-the-Art Production 

Facility in Spain to Meet Growing Demand 

41 Events 

www.harnisch.com

Vol. 37 • 31377 

ISSN 0932-2744 

1/23 

Cover: 

Trends for a new year will always include 

improving health, saving resources 

and underlining taste benefits. This 

year is no different. Almonds tick all 

the boyes. Almonds are packed with 

nutrients and bring a health halo to 

products without sacrificing on taste 

or convenience thanks to their texture 

and various forms. They are not only 

a great low waste ingredient thanks 

to their long shelf life, almonds are 

also grown in a zero-waste way, where 

everything is put to good use. 


of Almonds 

The Trend to 

Jackfruit 

Optical 


Confectionery 

Packaging Future 

Our Cover Story starts on page 6. 

Photo: Almond Board of California 

Ingredients: Jackfruit meat replacer 

Meat replacement products have been projected to provide 

more than 60% of the worldwide protein market by year 2040. 

Jackfruit have the same likeness and texture to pulled meat. 

This is why jackfruit has become popular in western cuisines as 

a food base for vegan meals like sandwiches, barbecues, tacos 

and the likes as meat replacement. We take a closer look in 

the article on page 12 

Processing: Potato processing 

The UK company R.S. Cockerill has become one of the largest 

independent potato packers in the country. The top-quality 

and budget-friendly prices are linked to their sorting equipment. 

The sorters automatically recognize surface abnormalities 

and diseases such as bumps and notches, skin discoloration, 

green colors and other defects reducing a reliance on 

manual labor. Read the full story on page 20 

Packaging: Confectionery solutions 

Most people enjoy a sweet tooth, but with the trend towards 

more sustainability, there is also an increase in demand 

for sweets, chocolate, biscuits, etc. with more eco-friendly 

packaging. This puts pressure on the confectionery industry 

to adopt packaging processes and materials which are gentle 

to natural resources. Many packaging producers already offer 

sustainable solutions. Find out more on page 30 

food Marketing & Technology • February 2016

Cover Story 

The “Morally Minded” Consumer 

Unwilling to Compromise on Values 

Drives 2023 Food Trends 

Innova Market Insights has revealed its top food and beverage trends for 2023. As tough and uncertain times 

push consumers to make hard choices, manufacturers need to get creative as cost, values, comfort and new 

experiences are priorities. Almonds, with their multiple health benefits, forms and formats are the perfect 

ingredient to do more with less. 

With the current economic environment 

forcing food price rises across 

the globe, many consumers will find 

themselves having to tighten their 

belts. But while people will be looking 

for ways to economise, cost still meets 

conscience and few will be willing to 

compromise on their morals to save 

money. 

According to Innova Market Insights, 

’redefining value’ is now the top global 

concern for consumers. This means 

that consumers are seeking brands 

that listen, understand and respond to 

their core values while providing quality, 

trust and confidence through product 

formulations, communications and 

wider sustainability actions. As a result, 

demand for plant-based products 

remains - but this sits alongside the 

need for moments of luxury and 

personal health which continue to be a 

big driver in food innovation. 

As a responsibly-grown, plant-based 

ingredient with 14 different forms to 

aid innovation and a strong nutritional 

profile, product manufacturers can 

feel reassured that almonds are a 

future-proof ingredient with sustained 

relevance when it comes to evolving 

consumer demand. 

Innova Market Insights’ key trend 

predictions for 2023 are: 

Redefining value 

Times are tough and consumers are 

having to weigh up product costs 

against the wider benefits they deliver. 

It’s important that manufacturers 

understand that sustainability remains 

a high priority in purchase decisions. 

Lu Ann Williams, Global Insights 

Director at Innova Market Insights, 

highlighted: “Combatting the impacts 

of an unstable economic climate 

requires a deep understanding of 

where consumers draw the line 

on compromise, and this year’s 

findings make it clear that brands 

must continue to demonstrate their 

sustainability credentials to market a 

product that consumers perceive to be 

truly ‘valuable’ beyond just price.” 

Dariela Roffe-Rackind, Director 

Europe & Global Public Relations at the 

6 


Cover Story 

Almond Board of California, comments: 

“When it comes to California almonds, 

manufacturers don’t need consumers 

to compromise as they deliver on value 

and values. Almonds are packed with 

nutrients and bring a health halo to 

products without sacrificing on taste 

or convenience thanks to their texture 

and various forms. 

“What’s more, as consumers continue 

to prioritise sustainability in their 

food choices, manufacturers can 

use California almonds in good 

conscience. Farmers have reduced 

the amount of water it takes to grow 

an almond by almost 50% since the 

1990s to the present day. Thanks also 

to widespread adoption of climatesmart 

regenerative ag methods such 

as whole orchard recycling, current 

almond farming practices offset 

about 50% of almond farming’s 

carbon emissions. What’s more the 

industry continues to be committed 

to finding new and innovative 

ways to reduce its impact on the 

environment.” 

Innova’s Market Insights in fact cited 

minimizing food waste as one of the 

top three actions consumers are taking 

when it comes to reducing costs in a 

conscious way and California almonds 

are a great choice for manufacturers 

who want to align with this consumer 

priority. 

Roffe-Rackind added: “There’s a lot 

of innovation happening when it 

comes to almonds and waste. Not 

only are almonds a great low waste 

ingredient thanks to their long shelf 

life, California almonds are also 

grown in a zero-waste way, where 

everything is put to good use. The 

nutritious almonds we eat are grown 

in a shell which is protected by a hull; 

the hulls then become livestock feed 

and the shells are used as livestock 

bedding. What’s more, almond 

hulls contain significant amounts of 

extractable sugar and antioxidants 

that can be used to make products 

such as nutraceutical bars, dietary 

supplements, skincare products or 

even for brewing beer and we are 

continually looking at more and more 

ways to use almond co-products.” 

Revenge spending 

With luxury spending under pressure, 

‘revenge spending’ is a new addition to 

the 2023 trends. 

This year’s report shows an elevation of 

the role food plays when it comes to joy, 

excitement and comfort. It revealed that 

global consumers have spent more on 

food and beverages post-lockdown to 

lift their mood. Despite 3 in 5 consumers 

saying they have a worsened financial 

situation; they are also likely to still 

make a one-time impulse purchase for 

a product that offers innovative flavor 

or taste benefits. 

Williams noted: “We are seeing brands 

and manufacturers respond to shopper 

demand for something a bit different, 

demonstrated by 35% average 

annual growth in food and beverage 

launches with a limited-edition claim 

over the past three years. There’s a 

clear opportunity for manufacturers 

to introduce products that can deliver 

a trendy, innovative twist on familiar 

foods that consumers are looking for.” 

Roffe-Rackind highlights: “Almonds 

can support manufacturers looking to 

develop products with more innovative 

and niche flavors as they are a great 

Photos: Almond Board of California 


7

Cover Story 

flavor carrier and pair well with so 

many sweet and savory ingredients. 

We’re already seeing this reflected in 

almond NPD with exciting products 

such as blueberry-flavored almond 

milk cheese and katsu curry nut and 

seed clusters.” 

“Another example of how almonds can 

help bring joy and comfort is through 

chocolate. Making consumers happy 

was the top reason for increased 

chocolate consumption from 2020 to 

2021. Almonds can elevate chocolate 

products as they are the number 

one ingredient choice globally when 

it comes to consumers’ chocolate 

preferences, with consumers believing 

they make chocolate tastier, 

more satisfying and more indulgent 1 .” 

Unpuzzle health 

The ability to prioritize personal health 

and wellness remains key at a time 

when so much can’t be controlled, 

and food continues to play a vital role. 

This year’s “unpuzzle health” trend 

demonstrates an ongoing need to 

know how food delivers on personal 

health goals. 

With an ever-evolving range of diets 

and lifestyles, Innova Market Insights 

noted that on-pack messaging is a 

go-to source for busy consumers 

wanting to understand the health and 

nutritional value of a product. 1 in 2 

consumers globally said they would 

refer to “on-pack claims” over the 

ingredients lists or nutritional labels. 

Williams highlighted: “Consumers 

globally believe health claims 

represent the actual healthiness of a 

product, which is a key consideration 

when it comes to product packaging. 

In a complex health communication 

landscape, reinforcing belief in 

these claims is also key – so using 

ingredients that can support these 

claims is also more important than 

ever.” 

Roffe-Rackind noted: “Almonds 

are suitable for a whole range of 

dietary and lifestyle choices from 

vegetarian to keto to free-from. 

Manufacturers can feel confident 

when using almonds to respond to 

a wide variety of consumers’ health 

goals as they are one of the world’s 

most researched foods with over 

200 scientific publications to date 

evidencing their positive impact on 

heart health, gut health, cognitive 

function, weight management and 

skin health to name a few. In fact, 

globally, product introductions with 

almonds lead to a higher likelihood 

of health claims 2* due to their high 

nutrient content which support a 

variety of health needs. 

Plant-based: Unlocking a new 

narrative 

Momentum for plant-based 

continues, which is no surprise, but 

increasingly, demand for stand-alone 

plant-based innovation is driving this 

trend. Beyond substitutes for meat 

and dairy, consumers are looking 

for more variety and seeking real 

culinary creativity and worldwide 

flavor profiles, whether in prepared 

products, meal kits or inventive 

recipe combinations. 

Taste and texture have long been key 

challenges in plant-based food. This 

year’s research revealed that 32% of 

global consumers would still like to 

see improved texture in plant-based 

products, and almost one-third would 

like to see improved taste, flavor and 

texture in dairy alternative drinks. 

Williams highlights: “Whilst the 

texture challenge remains, the 

appeal is there and we’re seeing 

growing demand for plant-based in 

ethnic food categories that offer new 

flavor experiences. This opens up an 

exciting opportunity for plant-based 

food manufacturers. Cooking aids 

such as sauces or meal kits are great 

ways to allow consumers to recreate 

these flavors at home.” 

Roffe-Rackind adds: “Almonds are 

a great ingredient when it comes to 

standalone plant-based innovation 

because of their ability to deliver 

on multiple fronts - health, taste 

and texture - all key factors for 

consumers. In addition to their 

protein content (6g per 30g serving), 

almonds pair well with other plant 

proteins like legumes and lentils 

and their extensive portfolio of 

formats - including whole, sliced, 

slivered, flour, paste, butter, oil 

and milk – means there are endless 

possibilities for creating new and 

exciting plant-based products. For 

example, defatted almond flour, 

which is higher in protein than 

regular almond flour or meal, has an 

extra-fine texture and clean taste 

which allows other ingredients to 

shine through when used in product 

formulation so flavors can really 

stand out.” 

Williams concluded “Overall, it’s clear 

that complex times shouldn’t mean 

complete compromise, and the need 

for innovation and exploration in 

food and drink for both health and 

enjoyment is more important than 

ever.” 

fmt 

1 2022 Global Chocolate Study, Almond Board 

of California 

2 Innova Market Insights, Global New Product 

Introductions Report, 2021. May 2022. 

*Please note that Innova’s use of the term 

“health claims” refers to nutrient or ingredient 

claims e.g. “high source of protein” or “no 

preservatives”. There are no official health 

claims for almonds. 

8 


Cover Story 


9

Ingredients 

Battling the Challenges in 

Texturizing Ingredients 

by Nesha Zalesny 

Does anyone else feel like the pandemic 

has been like dropping a rock into a 

pond? There was the initial shock of the 

actual pandemic; but the ripple effects 

of that rock to the smooth surface of 

the water keep impacting the world. To 

most industries, the ripple effects on 

the supply chain have been tsunamilike. 

The food and beverage industry 

has been especially affected. Prior to 

2020, most ingredients were available 

and lead times were reasonable. The 

current situation is not nearly as 

optimal. The pandemic exposed a lot 

of vulnerability within many industries, 

but the food industry was perhaps one 

of the most visible. In many regions, 

grocery store shelves have sat empty 

for long periods. Within the food 

hydrocolloid business, buyers and 

suppliers alike have all faced little to 

no availability of many ingredients. 

Among the hardest hit, carob bean 

gum, starch and xanthan gum. In fact, 

few hydrocolloids remain as available 

as they were pre-pandemic. 

Carob Bean Gum Crisis 

Carob bean gum, used extensively 

in the beverage and dairy industries, 

has recently faced a major crisis. This 

incredibly useful hydrocolloid, also 

known as locust bean gum, is used 

extensively in foods. In ice cream it 

helps control ice crystal formation, 

slow melting characteristics, and 

provide a creamy mouthfeel. It is 

considered an essential ingredient 

in many dairy formulations. In plantbased 

milks and beverages, it provides 

a creamy mouthfeel more similar to 

full-fat dairy milk. Consumer concerns 

about climate change, animal welfare 

and their own health has led to 

incredible growth for plant-based milks. 

According to the Good Food Institute, 

retail sales of these beverages have 

experienced double digit growth in the 

US for the past four years. US sales 

in 2020 were estimated at $2.5 billion 

and accounted for 15% of the fluid-milk 

sold. West European sales of plantbased 

beverages were $3.5 billion in 

2020 which was an increase of 15% 

over the prior year. 

An examination of the label of most 

plant-based milks reveals two nearly 

ubiquitous ingredients; gellan gum and 

carob/locust bean gum. Carob bean 

gum is a natural ingredient derived from 

carob trees that grow in coastal regions 

along the Mediterranean. Morocco, 

Spain, Portugal, Italy, and Turkey have 

thriving carob industries. Prior to 2018, 

the seeds used to produce carob bean 

gum averaged between €2-3/kg. IMR 

International estimates the carob 

bean gum industry is growing at a rate 

of 3.3%. Demand for carob bean gum 

far outpaced the industry’s ability to 

supply’ Seed prices went from €2/kg 

to €25/kg in the course of a year. To 

remain profitable, suppliers had to 

increase the price of carob been gum. 

In the first quarter of 2021, the price 

reached as high as €100/kg. During the 

height of the crisis, very few suppliers 

were offering contracts and buyers 

were forced to spot purchase, at spot 

purchase prices. 

A further ripple in the supply crisis, 

a batch of carob bean gum sold in 

Europe was found to be contaminated 

with Ethylene Oxide (EtO). The legal 

limit for EtO in Europe is 0.1 mg/kg. 

This resulted in an European Union 

(EU) rapid alert (RASFF) to be issued. 

Unfortunately, the contaminated carob 

bean gum was used in a very popular 

ice cream texturizing and stabilizing 

blend used by several European ice 

cream manufacturers, all of whom had 

to issue their own alerts and/or recalls 

to consumers. 

Understandably, manufacturers 

started looking for ways to reduce 

or eliminate carob bean gum in their 

formulations. A major hydrocolloid 

supplier has developed a differentiated 

gellan gum that they claim stabilizes 

protein and provides mouthfeel. In 

essence replacing the gellan and 

carob gum blends usually found in 

these products. Guar manufacturers 

have created modified guar products 

that more closely resemble the 

performance of carob bean gum. Guar 

modification can be done by either a 

physical process, or by enzymatically 

treating guar gum. These remain a 

low-cost option for formulators looking 

for alternatives. The reformulation 

efforts, while slow are beginning to be 

felt. There is some controversy over 

the regulatory status of enzymatically 

modified products in the EU. These 

efforts, along with reformulating, has 

had an impact on the carob bean gum 

market. Some buyers have reported a 

drop in demand by as much as 75% of 

normal. 

Stiff Starch Situation 

One of the hardest hit texturizers 

in the food industry is also one of 

the most universal. Starch can be 

manufactured from a wide variety of 

raw ingredients, from corn, potato 

and wheat to rice and tapioca. Starch 

is comprized of long chains of glucose 

molecules which plants create to 

store energy. It is used throughout 

the food industry for mouthfeel 

and thickening. It is unique in that 

it is a bulk thickener, meaning that 

use levels for starch average 2-4% 

in most applications (most other 

hydrocolloids are well below 1% with 

some exceptions such as gum acacia 

and gelatin). Starch is also very widely 

used in a multitude of industrial 

applications such as paper, textiles 

construction and even oilfield. Prior 

to the pandemic, buyers of starch in 

food and/or non-food applications 

rarely, if ever, experienced shortages, 

and the average price for food starch 

was under €1.00/kg, although some 

specialty grades could be found at 

€2.00-3.00/kg. 

For the starch industry, one of the first 

ripples began in the second quarter 

of 2020. Starch buyers first started 

reporting not being able to purchase 

their usual starch. The ripple gained 

10 food Marketing & Technology • February 2023

Ingredients 

momentum when a weather pattern 

caused a freeze in Texas which further 

reduced availability of some of the 

ingredients used to produce modified 

starches. Drought in Europe and the 

war in Ukraine have diminished the 

availability of many of the traditional 

starch raw materials such as waxy 

maize and wheat. For most of 2022, 

modified starches have been difficult 

if not impossible to get. Most buyers 

have found themselves put on 

allocation, and very few are getting all 

the material they need. 

Putting further pressure on an already 

tight starch market, demand for 

paper grade starch for the packaging 

industry is also growing. According to 

Emarket, ecommerce sales grew 25% 

in 2021. While growth slowed to 9.7% 

in 2022 ecommerce remains a fastgrowing 

market. Imagine the paper 

packaging required to ship the number 

of groceries and packages ordered 

during the pandemic. Demand for 

paper grade starch higher than it has 

been in several years. 

As a result, food companies are 

scrambling to find alternatives to 

their usual starches. Formulators 

are having to switch from traditional 

waxy maize-based modified starch 

to more available native starches or 

alternative starches such as tapioca. 

Tapioca starch is a great choice for 

many applications. However, it is 

manufactured primarily in Thailand 

and historically costs nearly double 

that of waxy maize starch. There is 

also an increase in shipping costs. 

Because so many end users are having 

to find alternative starches, demand 

for tapioca is increasing. A higher 

demand will likely force an increase in 

the price. Other users are looking for 

alternative manufacturers. Qualifying 

new starches and new manufacturers 

takes time and adds expense of the 

finished product. 

Xanthan Gum Challenges 

Xanthan gum is another widely used 

texturizing hydrocolloid. Since its 

introduction to the food market in 

the late 1960s, food formulators have 

used it to add thickness to dressings 

and sauces, improve aeration in baked 

goods and stabilize foams in whipped 

products. Xanthan gum was largely 

patent protected until the early 1990s. 

When it went off-patent, many new 

manufacturers began producing it, 

including a few European and several 

Chinese companies. From the mid 

1990s, western buyers enjoyed low 

priced xanthan gum. This was largely 

due to lots of competition from 

manufacturers. Chinese producers 

were especially competitive. Chinese 

produced xanthan gum can cost less 

than half the price of western produced. 

Subsequently, Chinese manufacturers 

have grown rapidly. Unfortunately, 

there is now a mismatch in the 

geographic location of capacity and 

demand. Much xanthan gum capacity 

is in China, and most of the demand is 

in the west. 

Conditions in China have been very 

rocky for all industries including 

xanthan gum. Chinese energy prices 

increased significantly in 2021. 

When energy prices first increased, 

manufacturers were monitored not 

only for total usage, but also the 

intensity of energy usage. Production 

plants that generally ran three shifts 

a day, six to seven days a week, 

were suddenly reduced to running 

2 shifts a day, five days a week. In 

addition, shipping between China 

and Europe or the US ground to 

nearly a halt during the pandemic. On 

top of this, Chinese manufacturers 

were forced to shut down if any 

worker tested positive for COVID. 

An added problem occurred when 

some Chinese produced xanthan 

gum was found to have excess levels 

of ethylene oxide (EtO). The EU has 

added testing requirements for any 

Chinese manufactured xanthan gum 

imported into Europe. This adds time, 

compliance complexity, and cost 

to any xanthan gum shipment from 

China. All these factors have resulted 

in a deficit in the availability of xanthan 

gum that western producers cannot 

completely cover. Chinese xanthan 

production accounts for 60-70% of 

world production. Consequently, the 

average price of xanthan gum has 

increased over 200% in the past year 

and there is no immediate end in sight 

for these upward price pressures. 

Nesha Zalesny is a Food Scientist and Partner at 

IMR International SanDiego, CA, USA 

What to Expect in 2023 

Other hydrocolloids than those 

mentioned above, have faced their 

own challenges. Two back-to-back 

super typhoons in the Philippines 

reduced seaweed availability for 

producing carrageenan. The lack of 

paper packaging material has made 

harvesting lemons difficult, so the price 

of lemon peel for pectin production 

has increased. Shipping by both sea 

and land has seen massive price 

fluctuations. New regulations such as 

the Uygur Forced Labor Prevention 

Act (UFLPA) in the US are creating 

waves. Buyers and suppliers alike are 

facing very rough waters in the coming 

year. 

The decrease in demand for carob 

bean gum has meant that prices are 

starting to correct and availability is 

improving. This may be a bright spot 

for buyers of LBG that will continue 

to use it. Unfortunately for starch 

and xanthan gum buyers things aren’t 

likely to improve. For starch, the 

addition of capacity to keep up with 

current demand is unlikely given the 

looming recession which has caused 

a reluctance to launch big capital 

investment projects. Chinese xanthan 

gum manufacturers are coming 

back, but progress is slow. It is very 

unlikely that prices for these very 

useful hydrocolloids will return to prepandemic 

levels anytime soon. fmt 


11

Ingredients 

Young Jackfruit: The Hottest Trending 

Vegan Ingredient 

by Rico R. Magda 

One of the effects of Covid 19 pandemic 

is the awareness of food consumers 

to healthy food eating. The results 

are the responsive replies of some 

food companies to search and supply 

the markets with some fresh and 

exotic fruits and vegetables. At this 

phase, so many meat consumers have 

begun turning the table to plant-based 

alternatives because of an increasing 

focus on health and environmental 

issues. They include wide lines of 

products like coconut, frozen and 

organic fruits and the surfacing of 

popular young jackfruit consumable as 

salad, smoothie, and vegan meals. 

One of the manufacturers is a Dutch 

company called “Explosive Fruits” that 

offers organic fruits, coconut products, 

and young jackfruits since 2016. This 

export-import company started in 

2016 with handful of imports from 

Thailand like frozen coconut water 

and coconut flesh.With the onset of 

Covid 19 pandemic, explosive food 

supply direction has been changed 

by supplying the processing sections, 

which supply hotels through out 

Europe. They timed this with the 

reopening of hospitality industry in 

many countries with the expectation 

of getting the needed boost to surpass 

the previous purchasing level. 

Recently, this food importer has added 

frozen young jackfruit to their assorted 

lines. They agree that that young 

jackfruit fantastically substitutes real 

meat, resembling its structure calling it 

a real meat substitute when prepared 

in right way. This is one thing among 

other, that vegans are getting more 

attention about it. 

Why Thailand young jackfruit? 

The food quality and the superior 

taste definitely give this company the 

reason picked the Thailand variety. 

Results from their tests show that 

their clients prefer the Thai immature 

jackfruit. And there’s no problem with 

the supply since Thai growers harvest 

and freeze young jackfruit for storage, 

which makes the supply available the 

year round. 

The popularity of young jackfruit is 

attached to the growing consumer’s 

health and environmental awareness. 

Consumers now want not just 

something organic, which points 

something to ‘environment-friendly’. 

Consumers rather want more foods 

that are unprocessed with less or no 

animal meat. This gives fruits and 

vegetables a good entry for this trade. 

And why market to Europe? 

There’s an overwhelming demand 

for exotic food products in Europe, 

though there are also demands for 

local produce. Exotics like banana 

hearts, immature young jackfruits, etc 

do not grow in Europe, so we need 

to import them elsewhere, Explosive 

Fruit managers reasoned out. This 

company exports to almost all parts of 

Europe. Some of its leading European 

consumers are from Spain, Czech 

Republic, France, and England to 

name a few. These countries are well 

ahead going to a healthier vegan style. 

England, for example, purchase a 

substantial amount of coconut water 

and flesh in pure form. These are not 

heated or treated and healthier than 

the pasteurized products. 

Tofu is one of the vegetarian staples 

used mostly in East Asian cuisines. 

And many years after its discovery, 

tofu inches its way into westernized 

dish as a meat and dairy substitute. 

Now, for our new trending ‘tofu’ comes 

this young immature jackfruit that 

chefs and culinary people adds to their 

cuisines as a plant-based substitute 

with a big success. 

In reality, many are unfamiliar with this 

vegan ingredient. Jackfruit is somewhat 

related to ‘camansi’ or breadfruit, or 

fig and found abundantly in India as a 

native species. Now this species has 

spread far and wide to Southeast Asia 

and the Pacific. 

Jackfruit is a versatile fruit 

Jackfruit grows massively, averaging 

10 to 20 lbs but exceptional species 

can yield heavily with 100 lbs or more. 

The versatility of the fruit comes from 

the fact it can be fried, consumed raw, 

steamed or canned. If you don’t know 

how to prepare the immature fruit for 

cooking, you’ll be thinking the whole 

stuff is useless. That said, its heaviness, 

spiky, pungent characteristics serve 

as a drawback for those adventuring 

in this ingredient. But when prepared 

nicely, it becomes a savory dish 

that explodes into meat-like texture 

as a meat substitute. In India and 

Bangladesh, immature fruit known as 

‘gaacha pasha’ (tree goat) is used as 

an inexpensive substitute to mutton. 

Some botanists, indeed, believe that 

the fruit is less exploited due to its 

intrinsic nutritional load. It has high 

protein, fiber, potassium, Vitamin B, 

lower calorie and carb than corn or rice. 

Unlike avocado, jackfruit grows on less 

irrigation water, which is a good plant 

to combat world hunger. 

Who introduced this to the 

Western restaurant market? 

After meticulously learning about 

the versatile jackfruit nutritional 

properties and amazing uses, a certain 

Annie Reyes has formed the Jackfruit 

Company. To make a stronger steps 

in helping local farmers in India, Reyes 

built a distribution channel from India 

to the USA, thus, making the stuff 

always available for the American 

consumers. 

Aside from the Jackfruit Company, 

another company called Kanara 

has tinkered on this low-impact yet 

versatile crop. They add some twists 

to the distribution chain by adding 

chefs and restaurants because they 

know that chefs can further create 


Ingredients 

fmt 


13

Ingredients 

new recipes or improve the existing 

recipes. An example of this is 

developing a recipe to taste like classy 

meaty dishes like ‘pulled pork’. Both 

Karana and the Jackfruit Company 

make the ingredients available 

through out the year by fashioning it 

into pre-cut, cleaned and ready-touse 

ingredient. 

Meanwhile, the continuing use of 

young jackfruit, some surprising 

creative dishes, as they appear in 

menus and cookbooks, developments 

have surfaced. To mention some 

of them, these include taco filling, 

meatball base, menudo ingredients, 

and teriyaki bowlpart. 

Young jackfruit’s nutrition 

Raw and young jackfruit have the 

same likeness and texture to pulled 

meat. This is why jackfruit becomes 

popular in western cuisines as a food 

base for vegan meals like sandwiches, 

barbecues, tacos and the likes as meat 

replacement. As a base replacement 

to meat, jackfruit does not promise to 

give you the same amount of protein 

you get in meat. Let’s see what one cup 

(165g) of sliced, raw jackfruit can give 

you. This amount provides 157 calories, 

3 g of carbohydrates, 1g of fat and 2.8g 

protein. Besides, it gives excellent 

source of vitamin C and potassium. 

To wit, the United States Department 

of Agriculture (USDA) has provided 

the following nutrition data: Calories 

(157g), Fat (1.1g), Sodium (3.3mg), 

Carbohydrates (38.3g), Fiber (2.5g), 

Sugars (32g) Protein (2.8g), Vitamin C 

(22.6mg), and Potassium (739mg). 

Most of the fruit’s calories come 

from carbs. A cup serving has 38.3g 

of carbs. From this carbs, 32g comes 

from sugar and 2.5g come from 

dietary fibers. Jackfruit has a glycemic 

score of 75 and a medium glycemic 

load. Score of 70 or over is considered 

glycemic that can raise blood sugar 

levels. The score gives an estimate of 

how food may influence the levels of 

blood sugar. 

Due to its very low level of fat content, 

jackfruit is considered as a hearthealthy 

food.It has only 1g of fat per 

cup; no saturated and transfat. 

Jackfruit acts only as a replacement 

for chicken or pork and doesn’t give 

high amount of protein that you can 

find in animal meat. 

For every cup of young jackfruit, it has 

only about 3g protein while the same 

cup of meat contains 20+g. Some 

micronutrients also abound in raw 

jackfruit like potassium. A cup of this 

raw, young fruit gives 739mg, which is 

about 15.7% of the daily value. It is also 

rich in Vitamin C, A, copper, manganese, 

and magnesium. Vitamin C is about 

23mg or 25% of daily value. The same 

cup of sliced young jackfruit gives 157 

calories carbs, protein, and fat. 

For the reason that raw jackfruit has 

fiber content and no saturated fats, 

this makes the stuff a good dietary 

pattern, according to the American 

Heart Association. And this pattern 

can lower cholesterol levels by 10%. 

So consider it adding to your shopping 

list and reduce the risk of heart stroke. 

Vitamin C is supportive of the immune 

system, repairing damaged cells and 

in absorbing essential nutrients like 

iron. If you add jackfruit seeds to 

your dishes, you get a protein called 

jacalin. Studies have shown that 

this protein protects the immune 

system from HIV infection. Some 

of you, especially older adults who 

have poor quality sleep due to lack 

of magnesium, may take a serving of 

young (cooked) jackfruit. It contains 

about 48mg magnesium, although the 

recommended allowance is from 300 

to 350mg to top up your daily target. 

A cup of raw jackfruit has 0.07mg 

manganese. This micronutrient is 

valuable in bone formation, mineral 

density, and risk of fractures. When 

you substitute jackfruit for meat, 

you lower the risk of having type 2 

diabetes. Why is this so? When you 

do this, you cut more calories and 

saturated fats while ingesting more 

fiber and beneficial micronutrients. 

With this fat and more fiber, insulin 

sensitivity is thus improved, with 

gains on the positive side in reducing 

type 2 diabetes. 

Having allergy to jackfruit is uncommon, 

though some people show allergy to 

latex exudates from some tropical fruits. 

Though it is not yet well-established, 

some chemicals in jackfruit may pose 

interference with medication during 

surgery, which may give drowsiness 

to patients. So have consultation with 

your doctor before surgery. 

As a meat substitute for fries, wraps, 

pies, and other dishes, you can 

prepare fresh unripe jackfruit this way. 

Unripe jackfruits are also available 

in ethnic stores or groceries canned, 

salted, or preserved. For fresh green 

jackfruit, cut it into halves or smaller 

without removing the skin. When you 

have the ideal size, boil for 30 to 60 

minutes the chunks until soft and 

have a stringy texture like pulled pork 

or chicken. Finally, peel off the skin 

and separate seeds and pods. 

Aside from Dutch companies, some 

Korean food companies have been 

joining the scene aimed at targeting 

some meat-alternative markets. 

This meat replacement venture has 

been projected to have more than 

60% of world-wide protein market by 

year 2040. 

fmt 

The Author: 

Rico R. Magda is a Plant Pathologist at the 

University of the Philippines at Los Baños 

and a regular contributor to FMT 


Ingredients 

A Sustainable Lifestyle through a Sensory 

Co-operation: New Research Project 

• Symrise 4-year research consortium established with Wageningen University & Research (WUR) and 

other industry partners 

• Partners are examining factors that influence flavor release and sensory quality of meat alternatives 

• The project will help to develop meat alternative products with improved sensory quality 

Burger patties with soy protein, 

nugget with pea protein or fish sticks 

with Mycoprotein – consumers are 

increasingly switching to plant-based 

versions of popular meat-based 

products. As the market is growing 

exponentially, it also offers considerable 

potential to develop further products. 

Some consumers reject plant-based 

alternatives because they are put off by 

the taste and texture of these products. 

Symrise has therefore partnered with 

scientists from Wageningen University 

& Research in the Netherlands, and 

other industry specialists. The share 

an aim of better understanding how 

to improve the sensory quality of 

meat alternatives and win over new 

consumers. 

“Appetite comes with eating,” as 

the saying goes. After all, many 

factors, such as the texture of food, 

exist beyond taste and play an 

important role in creating the feeling 

of enjoyment as one eats. This and 

other topics form the subject of a 

public-private partnership between 

Symrise and Wageningen University 

& Research (WUR) and other industry 

companies. The research will provide 

the food industry with findings on how 

to create tastier alternatives for meat 

products – a crucial step on the path to 

more sustainable nutrition with more 

plant-based products. 

How do components that are 

released while eating influence 

taste? 

Clearly, there is still a difference in the 

taste and mouthfeel of products from 

strictly plant-based proteins compared 

to animal proteins. For this reason, the 

Taste, Nutrition & Health segment at 

Symrise is working on this topic. 

“As part of the consortium project, we 

are looking into finding the relationship 

between the structure and the inherent 

characteristics of meat alternatives 

and are examining them. We want to 

understand how the product structure 

changes when people chew food 

and how it affects the perception of 

taste and mouthfeel. Our team of 

researchers can contribute their wealth 

of application expertise with this to 

enable customers to create greattasting 

plant-based products,” said 

Katja Tiitinen, Sensory & Consumer 

Insights Director F&B in EAME. 

Symrise is also supporting the joint 

project with WUR in the following three 

key areas: 

• Understanding of sensory 

characteristics of products on the 

markets 

• Optimizing the sensory performance 

and release of taste and flavor during 

chewing 

• Providing taste recipes 

“As the first team of researchers on 

this topic worldwide – to the best 

of our knowledge – the consortium 

studies how the characteristics 

of meat alternatives change while 

chewing by combining in vitro and 

in vivo evaluations with sensory 

tests,” Tiitinen added. “This research 

cooperation thus represents an 

important initiative for a sustainable 

lifestyle,” she concluded. 

The consortium comprises Symrise and 

Wageningen University & Research, 

as well as the companies Nissin Food 

Holdings, Starfield Food & Science 

Technology, AAK, Vivera and GoodMills 

Innovation. 

Symrise is a global supplier of 

fragrances, flavors, food, nutrition 

and cosmetic ingredients. Its clients 

include manufacturers of perfumes, 

cosmetics, food and beverages, 

pharmaceuticals and producers of 

nutritional supplements and pet 

food. Headquartered in Holzminden, 

Germany, the Group is represented 

by more than 100 locations in Europe, 

Africa, the Middle East, Asia, the 

United States and Latin America. 

Symrise works with its clients to 

develop new ideas and market-ready 

concepts for products that form 

an integral part of everyday life. 

Economic success and corporate 

responsibility are inextricably linked 

as part of this process. 

fmt 


15

Ingredients 

Unlocking the Future of Nutrition: 

5 key trends for 2023 

FrieslandCampina Ingredients launches a new consumer trends magazine, outlining the key nutrition trends 

driving the food, drink and supplement industries in 2023 and beyond. 

FrieslandCampina Ingredients, the 

global innovator in healthy and 

functional ingredients, has announced 

the release of its third annual magazine 

detailing five key trends that will 

drive the evolution of food, drink and 

supplement industries in 2023. The 

magazine, titled ‘Shaping the future of 

Nutrition 2023’, offers expert insights 

into current consumer drivers to help 

brands identify new areas for innovation 

and new product development (NPD) in 

the adult nutrition sector. 

While 2022 saw several seismic shifts in 

consumer behaviours, like health of the 

planet beating health of the population 

to the top consumer priority for the first 

time, 2023 looks set to be an evolution 

of these macro trends. This year, 

FrieslandCampina Ingredients believes 

brands that focus of building credibility 

and truly helping consumers get the 

most out of life, at every stage, will stand 

out from the crowd. 

The five key trends shaping consumer 

habits in the specialized adult nutrition 

sector are: 

Building trust for planet-first nutrition – 

The health of the planet has cemented 

itself as the top consumer priority. And 

while this looks set to continue for the 

foreseeable, consumers are becoming 

increasingly sceptical – 38% do not trust 

companies to be honest about their 

environmental impact.i However, 83% 

of consumers are more likely to trust 

sustainability claims that are verified 

by a third party.ii Working together as 

a cohesive industry to lower our impact 

on the environment will help companies 

big and small meet their sustainability 

targets and bolster trust among 

consumers at the same time. 

Resilience and the power of positive 

nutrition – As the world adjusts to post- 

COVID life and the global cost of living 

crisis, consumers are feeling stressed, 

and are increasingly seeking out a sense 

of balance to build resilience. To do this, 

many are turning to positive nutrition – 

or focusing on adding beneficial foods, 

drinks and supplements to their diets, 

rather than removing less nutritious 

foods. As a result, consumers are 

looking for solutions that offer healthy 

indulgence – and fortified and nutritious 


Ingredients 

desserts, drinks and snacks that satisfy both body and 

mind will be high on the consumer agenda in 2023. 

Alternative proteins find their own feet – As plant-based 

becomes more mainstream, consumers increasingly 

expect high-quality, highly nutritional products that go 

beyond recreating animal-based applications. Emerging 

technologies, such as precision fermentation, are 

opening up new opportunities in 2023 for brands – but 

mastering taste and texture remains paramount. In 2023 

and beyond, FrieslandCampina Ingredients believes that 

the protein market will continue to evolve; combining 

animal, plant-based and novel proteins to keep up 

with consumer lifestyle choices and to feed a growing 

population. 

Going for gut health – In an era defined by uncertainty, 

it’s no surprise that consumers are turning their 

focus inwards and prioritising overall well-being. With 

rising consumer awareness of the gut microbiome’s 

role in supporting improved mental health, stress 

and sleep, brands can attract consumer attention by 

creating accessible self-care moments. And thanks 

to ingredient innovations in the space, unique and 

trending formats can be created, such as teas, shots 

and fortified gummies using good-for-gut ingredients 

such as prebiotics. 

Vitafoods Europe is 

The era of active ageing – Out planet is now home to 

8 billion people, including a growing number of older 

individuals. As healthcare evolves, global emphasis is 

shifting from ‘healthy’ to ‘active’ ageing, with older adults 

focused on getting the most out of life. This offers a wealth 

of opportunities for brands to create solutions targeting 

emerging markets like Japan and South Korea with 

products that support long-term strength, balance and 

mobility. 

“We’re living in tumultuous times. So, it can be difficult 

to predict exactly what the future will hold. However, 

what’s clear is that in 2023 consumers will continue 

to prioritise health – both their own and that of the 

planet,” says Vicky Davies, global marketing director 

for Performance, Active and Medical Nutrition at 

FrieslandCampina Ingredients. “Despite several market 

challenges, there is huge opportunity for brands to tap 

into these evolving trends. From mood-boosting gut 

health supplements to edible moments of indulgence, 

new ingredient innovations are inspiring product 

development across the adult nutrition space.” 

“But to truly stand out from the crowd,” Vicky continues, 

“brands will need to bolster trust and credibility to 

win the faith of consumers, especially when it comes 

to sustainability. At FrieslandCampina Ingredients, 

collaboration is our DNA. Using our latest insights, our 

experts can work with brands to create on-trend nutritious, 

efficacious and sustainable solutions to help support 

consumers at all stages of life.” 

fmt 

Every year, thousands of nutraceutical 

experts look forward to joining friends, 

colleagues and suppliers at Vitafoods 

Europe. They love tasting new 

products, listening to world-class 

speakers, discovering new ingredients 

and connecting with fantastic people 

from across our industry. 

Experience it for yourself 

9-11 May Geneva 

1-12 May Online 

Register now at 

vitafoods.eu.com

Processing 

Maximize Productivity and Reliability 

with Visibly Simple Foodborne 

Pathogen Detection 

Following consultation with customers, Thermo Fisher Scientific’s innovative enhancements to its SureTect 

food pathogen PCR system include the use of ergonomic tools and color-coded plates and reagents to drive 

confidence in right-first time results 

Thermo Fisher Scientific has simplified 

the workflow for the SureTect PCR 

System, by introducing streamlined 

handling and fail-safe color-coded 

plates and reagents, to smart, intuitive 

software and instrumentation. 

In the pursuit of food safety, every 

test matters. There’s no room for 

uncertainty and no time for retests. 

When Thermo Fisher experts asked its 

customers to share their challenges, 

they put streamlining staff training and 

eradicating human error at the top of 

the list. 

The enhanced SureTect PCR System 

workflow, part of Thermo Fisher’s 

commitment to continual improvement 

and leadership through innovation, 

has been designed to help laboratories 

the world over protect public safety 

their own reputation and profitability. 

Features include: 

Streamlined handling: Ready-to-use 

reagents and ergonomic tools provide 

a streamlined workflow and ease-ofhandling, 

simplifying staff training and 

boosting laboratory productivity. 

• Pre-dispensed lysis and PCR 

reagents reduce hands-on time 

• Clearly oriented lysis and 

assay plates reduce the likelihood of 

human error 

• Pierceable lysis tube seals 

reduce handling steps and risk of 

cross-contamination 

• Workflow tools to simplify the 

workflow and reduce risk of operator 

error for a superior user-handling 

experience 

• Internal positive control (IPC) 

in every PCR well provides confidence 

in each and every result 

Fail safe: Color-coded plates and 

reagents reduce the likelihood of 

human error, enhancing confidence in 

right-first time results. 

• Color indicator in Proteinase 

K reagent enables pipetted wells to be 

visually tracked, quickly and easily 

• Assay strips color-coded 

to target pathogen for simple, rapid 

identification 

Smart instrumentation: The updated 

features are supported by fully 

automated amplification, detection, 

data collection, analysis and 

interpretation, using Thermo Scientific 

RapidFinder Analysis Software v2.0 or 

later. 

Validated for a broad range of targets 

and matrices according to ISO 16140- 

2:206 by AFNOR and AOAC certification 

requirements, the SureTect PCR Assay 

workflows provide the ultimate solution 

for any food laboratory’s pathogen 

detection requirements. 

fmt 


Processing 


19

Processing 

R.S. Cockerill Relies on New 

Optical Sorters for Whole Potatoes 

From humble beginnings growing 

vegetables for hungry neighbors 

during the Great Depression, R S 

Cockerill has grown to become one 

of the largest independent potato 

packers in the United Kingdom today. 

They credit much of this success to 

their top-quality potatoes and budgetfriendly 

prices. These often-conflicting 

goals are both addressed with the help 

of Key Technology’s Herbert OCULUS 

optical sorters for whole potatoes, 

which automate defect removal to 

improve production efficiencies while 

ensuring final product quality. 

“Before Herbert OCULUS, we were 

sorting by hand, but that was getting 

increasingly difficult as the labor 

market got tighter and extreme 

weather began making incoming 

product quality more variable. We 

wanted to automate sorting to take 

some pressure off our workforce at the 

same time we wanted to improve the 

consistency of our final product quality 

when incoming defect loads would 

spike,” said David Elvidge, Operations 

Manager at Cockerill. “We’ve been 

so happy with our first OCULUS, we 

bought four more last year.” 

Installed at Cockerill’s retail packing 

facility in York, UK, five Herbert 

OCULUS sorters inspect whole, 

washed potatoes – finding and 

removing those with defects to ensure 

Cockerill achieves their final product 

quality specifications. The sorters 

recognize surface abnormalities and 

diseases such as bumps and notches, 

skin discoloration, green colors and 

defects like mechanical damage, scab, 

cracks and black dot. They can also 

be programmed to reject potatoes 

with dimensions above or below the 

desired length and width. 

“Over the years, we’ve spoken with 

different optical sorter suppliers and 

visited sites across Europe to see a 

variety of technologies in action,” said 

John Robinson, Engineering Manager 

at Cockerill. “For whole potatoes, it’s 

clear to us that OCULUS is the winner. 

In addition to delivering reliable results, 

it’s well-built and easy to operate. 

Among other things, we appreciate the 

straightforward user interface.” 

“We’ve always enjoyed working with 

Key. Whenever we have a question, 

it’s easy for us to get in touch with 

them,” said Nick Larmour, Technical 

Manager at Cockerill. “If needed, Key 

technicians can even access our 

OCULUS sorters remotely, which 

helps us operate continuously at peak 

performance.” 

Herbert OCULUS conveys product 

over a series of rollers to present 

a complete 360-degree view of 

each tuber to the color cameras. 

Compared to traditional cascade 

bulk sorters, this unique method 

of sorting offers gentler handling 

and provides 20 percent more 

surface inspection to maximize 

defect removal. In addition to 

capturing images of all ‘good’ and 

‘bad’ potatoes, Herbert OCULUS 

can collect detailed data about the 

throughput and grading results, 

including what percentage of the 

potatoes rejected had each type of 

defect and the size of the potatoes. 

“Thanks to OCULUS, we’ve reduced 

our reliance on manual labor. We 

used to have four to eight workers 

dedicated to manual inspection 

on each line. We struggled to hire 

enough people and we struggled to 

achieve consistent defect removal 

since workers get tired and tend to 

remove either too much or too little,” 

explained Larmour. “OCULUS makes 

objective, black-and-white sorting 

decisions hour after hour so we’ve got 

more consistent final product quality. 

At the same time, we’ve been able to 

increase our line throughput by 20 to 

25 percent.” 

Cockerill produces more than 1,500 

metric tons of potatoes in retail packs 

for supermarkets every week and even 

more in bulk to food processors. They 

selected midsize Herbert OCULUS 


Processing 

systems from Key’s five available 

models to handle their line capacities 

of two to eight metric tons of product 

per hour. 

“Every customer always wants to 

remove all critical and major defects, 

but different SKUs allow for various 

amounts of minor defects, so we 

program the sorter at the beginning 

of each product run to meet the exact 

specifications required,” said Bartosz 

Wozniak, Production Manager 

at Cockerill. “During a product 

changeover, it takes just a couple 

of taps on the sorter’s touchscreen 

to recall a recipe saved to memory. 

Or, when we’re running a brand-new 

SKU, an operator can create a new 

sort recipe in less than five minutes 

by selecting from a list of defect types 

and choosing the allowable amount of 

each.” 

“At the end of the day, our success 

depends on the success of our 

customers, so providing a reliably 

high-quality product on time and 

at an affordable price is vital. Our 

Herbert OCULUS sorters achieve 

consistent defect removal at 

increased throughputs while lowering 

labor requirements. Plus, they’re easy 

to run and maintain,” said Elvidge. 

“This technology has transformed 

the nature of our business – we can’t 

imagine having to operate without our 

OCULUS sorters again.” 

fmt 

HRS Heat Exchangers operates at 

the forefront of thermal technology, 

offering innovative and effective heat 

transfer products and systems for highly 

viscous applications worldwide, focusing on 

managing energy efficiently. 

Pasteurisation 

Sterilisation 

Heating & Cooling 

Evaporation 

CIP Systems 

Process Skids 

MANAGING ENERGY EFFICIENTLY 


HRS Heat Exchangers 

info@uk.hrs-he.com | +44 (0)1923 336 313 

www.hrs-heatexchangers.com21

Processing 

Eco-Friendly, Energy Saving, Hygienic: 

Efficient Sanitization with Microwave and 

Radio Frequency Systems 

SAIREM, a world-leading specialist in 

microwave (MW) and radio frequency 

(RF) industrial solutions based in Lyon, 

France, showcase the company’s 

sanitisation technologies at Food 

Ingredients Europe. The company 

innovative systems which are 

suitable for either decontamination of 

ingredients such as powders, spices, 

peppercorns, flours, and nuts etc. or 

as disinfestation of plant-based food 

and ingredients such as, cereals, soft 

wheat and many more. Responding to 

client needs, the French company has 

developed highly efficient processes to 

produce ingredients that are healthy, 

clean, and fully compatible with the 

requirements of organic farming 

certification. 

Chemical free destruction 

of potentially contaminated 

ingredients 

Decontamination with Sairem RF and 

MW systems enable the complete 

destruction of mould, yeast, and bacteria, 

without the use of toxic chemical 

products. The use of not allowed gas 

was one of the most cited reasons for 

product withdrawal in Europe the last 

years. This is a major advantage for food 

processors and suppliers serving the 

health -and environment- conscious 

consumers of today. Sairem’s systems 

are ideal for superfood trend products 

and ingredients to produce plantbased 

protein alternatives. Valuable 

ingredients such for example nuts are 

treated with extreme care, therefore 

resulting in a high-quality end product 

and reduction of 4-5 Log. The efficient 

RF and MW process, which only lasts 

a few minutes, ensures that each 

ingredient is quickly and uniformly 

brought to the required temperature. As 

the processing time is so short, there is 

no alteration of the physical, chemical, 

and organoleptic properties - all product 

characteristics are perfectly preserved. 

Other successful applications include 

peppercorns (3.4 Log reduction) 

or maize starch powder (6,87 Log 

reduction). 

RF and MW technology for 

disinfestation from egg to insect 

Many high-quality ingredients are 

exposed to the risk of contamination 

SAIREM's MW and RF technology is 100% electric and therefore produces no CO 2 

emissions and consumes 50% less energy compared to traditional heat 

treatment processes. 


31377 

Processing 

by parasites, and in particular 

larvae, moths, and beetles. By the 

implementation of Sairem’s RF and 

MW technology, parasites and microorganisms 

are deactivated by short, 

homogenous exposure to a microwave 

field in a temperature-controlled 

processing cavity. For example, 

products such as dates, whose high 

sugar content makes them particularly 

vulnerable to moths and beetle larvae, 

the speed of the process ensures 

perfect disinfestation while preserving 

all organoleptic properties. 

Sairem assigned French technical 

institute ARVALIS to conduct a study on 

the effectiveness of weevil eradication 

by applying Sairem’s microwave heat 

treatment. The treatment tested had 

excellent disinfestation results of adult 

weevils and their offspring. 

Fast, energy-saving, cost-efficient 

The low maintenance and costeffective 

Sairem systems can process 

large amounts of product either in 

batches or in a continuous process 

in tunnels or the patented tubular 

system. MW energy efficiency and 

volumetric heating keep power 

consumption at a lower level than that 

of other processing technologies. As 

Sairem’s MW and RF technology are 

100% electric solutions, they have no 

CO 2 

emission and consume 50 % less 

energy compared to traditional heat 

treatment processes. 

SAIREM equipment: innovation 

and versatility in action 

Not only does this equipment provide 

a speedy, efficient process, it has the 

added advantage of being very compact 

with a small floor footprint that saves 

space. It is extremely user-friendly, 

offering easy loading and unloading 

as well as a color touch screen HMI, 

and a USB and ethernet connection 

for remote control. Apart from daily 

cleaning, there is no need for regular 

maintenance, and it complies with all 

hygiene regulations and standards. 

Sylvain Tissier, Business Development 

Manager at Sairem, explains: “Sairem 

Sylvain Tissier, Business Development Manager 

at SAIREM 

systems are extremely versatile and 

efficient. They can be used for sanitising 

in the role of decontamination and 

disinfestation. We have designed them 

to provide fast and effective processes, 

ensuring high-performing, cost-saving 

results.” 

SAIREM offers standardized systems 

as well as systems specifically adapted 

to customer requirements. 

fmt 

1/23 

Vol. 37 • 

ISSN 0932-2744 

Come and see for yourself: 

www.harnisch.com 


of Almonds 

The Trend to 

Jackfruit 

Optical 


Confectionery 


Perfectly positioned. 

The international specialist magazines from Dr. Harnisch Publications 

You can now explore our newly designed website, with a 

clear focus on responsive design and easily usable applications. 

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

find bonus news coverage, events, subscription and 

general information on all our magazines. Take a look at 

www.harnisch.com for all relevant content. 

Our publications include: 


- Technology & Marketing - 

23

Processing 

Gears and Gear Racks made from 

Polyamide 

Gears and gear racks used for transmitting torque and forces within gearboxes are typically made of 

hardened steel. For many other uses and applications, gears and racks made from plastic are the better 

choice. These generally require no lubrication and are cheaper, lighter, quieter, and more resistant to 

corrosion than metal gears. That is why Ganter is expanding its range with polyamide gears and racks that 

can transmit high forces and torques. 

Gears and racks made from polyamide 

are preferred in mechanisms that must 

transmit high torques at low speeds. This 

includes packaging machines, chemical 

and pharmaceutical manufacturers as 

well as food production. The components 

are combined to convert rotational 

movements into linear movements or 

vice versa. Synchronous, symmetrical, 

or even proportional movements can be 

easily achieved when used with clamping 

jaws, grippers, or assemblies. 

Standard parts specialist Ganter 

has considered the basic principles 

of gearing and introduced the spur 

gears GN 7802 and gear racks 

GN 7822 made from strong and 

long-lasting polyamide. Due to 

their low coefficients of friction, 

these require no lubrication, and 

are made of FDA-compliant glass 

fiber-reinforced plastic suitable for 

use in food-processing applications. 

The components are also available 

in grey or blue for better visual 

detectability. 

The polyamide gears and racks from 

Ganter are designed for temperatures 

up to 120 °C and for contact with 

aggressive media such as acids, gases, 

and saltwater. Plastic gears are lighter 

and more economical than metal 

gears and therefore lower the weight 

and cost of devices, systems, and 

machines. 

The gears and racks are designed 

as an involute gear with a 20° angle, 

the design structure helps to reduce 

torque variation and allow for greater 

assembly flexibility. Ganter offers spur 

gears GN 7802 designed in module 

sizes from 0.5 to 3. The polyamide gear 

racks GN 7822 can be ordered with 

module sizes from 1 to 3 and feature a 

steel core to prevent deformation. 

fmt 


Processing 

Home of Confectionery Diversity: 

Production lines for all capacity 

requirements 

Winkler und Dünnebier Süßwarenmaschinen GmbH (WDS) is one of the world’s leading manufacturers of 

confectionery machines. The company is continuously developing its production facilities and has a range of 

machines and plants that covers the entire spectrum of moulded sweets. WDS stands for the highest quality 

and reliability. 

Winkler und Dünnebier Süßwarenmaschinen GmbH (WDS) is looking forward to finally returning to the 

leading trade fair interpack (May 4 - 10) in Düsseldorf in 2023. The main slogan this year is “WDS – Home of 

Confectionery Diversity: Production lines for all capacity requirements.” 

At the trade fair, WDS will present 

tailor-made production lines from 

laboratory scale to high-performance 

plants and demonstrate the trendsetting 

use of technologies and 

advantages of production lines for 

chocolate, gum and jelly, toffee, 

fondant and hard candy. On display will 

be the WDS plants ConfecECO and 

ConfecVARIO, which enable the flexible 

manufacturing of chocolate or jelly 

products. The expandable ConfecECO 

is the entry-level line for series 

production. With orderly demoulding 

and product post-treatment on a 

small scale, a complete jelly plant will 

be presented at interpack 2023. The 

innovative ConfecVARIO machine 

concept enables unprecedented 

production possibilities with variable 

line configurations and a new type of 

drive system. 

The multimedia-equipped exhibition 

stand covering 650 m 2 also offers 

plenty of space for the WDS 

“sweetOTC” division and a new 

generation of laboratory depositor 

machine that enables product 

development and production of 

innovative dosage forms for OTC 

sweets or supplements. 

Other WDS focal points at interpack 

are the WDS ConfecPRO, with its 

modular system concept presented 

using the depositor section as an 

example, and the time-tested quality 

of WDS mogul plants, which will be 

presented in an exciting virtual setting. 

ConfecECO: The entry line into 

series production 

ConfecECO is the entry line into serial 

production and is aimed at aspiring 

ConfecECO trade fair plant: entering series production successfully 


25

Processing 

companies and smaller manufactures. 

In addition to the production of 

chocolate products, the ConfecECO 

series is also suitable for pectin, 

toffee and fondant products. With a 

production capacity of up to 600 kg/ 

hour for chocolate and 300 kg/hour 

for jelly products depending on the 

mass type, product size and weight, 

ConfecECO is the ideal machine to 

fulfil the special requirements of the 

target group. The range of products 

that can be produced on this line 

includes solid and filled sweets of 

different sizes along with the use of 

silicone or polycarbonate moulds. This 

machine type is also suitable for the 

production of gum and jelly products 

with added food supplements. A 

ConfecECO in jelly configuration with 

post-treatment will be on display at 

interpack. Orderly demoulding will be 

demonstrated live. 

ConfecVARIO: Chocolate products, 

jelly products & OTC sweets with 

just a single machine 

ConfecVARIO is a new, highly 

innovative machine concept for the 

production of chocolate products, gum 

and jelly sweets as well as OTC sweets. 

With ConfecVARIO, WDS has moved 

beyond concepts of conventional 

confectionery machines and is setting 

standards in the production of today 

and tomorrow. The novel, chainless 

drive system with switch technology 

enables maximum flexibility and a 

ConfecVARIO: an ingenious machine concept 

The state-of-the-art Product Technology Lab of Winkler und Dünnebier Süßwarenmaschinen 

variety of new plant layouts. Variable 

production of different products 

and masses in different line sections 

is also possible. To cool, heat and 

hold the polycarbonate moulds, 

ConfecVARIO is equipped with the 

innovative, chainless VarioCABINET 

multifunctional cabinet. 

The excellent accessibility of the plant 

enables optimal and accelerated 

maintenance and cleaning work, which 

can often be carried out partially 

and during operation thanks to the 

innovative control concept. 

Taking into account all relevant 

hygienic aspects, the ConfecVARIO is 

also available as a qualified production 

plant for OTC sweets according to 

customer requirements. Customers 

and visitors at interpack will be able 

to see the advantages for themselves 

on a fully assembled ConfecVARIO in 

chocolate configuration. 

sweetOTC – Complete solutions 

for actively effective sweets 

With the WDS division “sweetOTC”, the 

company is one of the leading suppliers 

of technologies and machines for the 

production of actively effective OTC 

sweets and supplements. 

In this area, WDS offers its customers 

complete solutions in a customized, 

GMP-qualified design. This includes 

brainstorming, the development of 

individual confectionery products, 

The new WDS depositor machine: qualified 

product development 


Processing 

customized production processes, 

ensuring the exact and reproducible 

dosing of active ingredients as well as 

a comprehensive after-sales service. 

To meet the requirements from this 

area as well as others, the WDS 

technical centre, specialized in 

the development of new and the 

optimization of existing depositing and 

moulding processes in confectionery 

production, has been expanded 

considerably. 

In addition to the latest laboratory 

depositor machines and pilot 

equipment, the technical center also 

houses a showroom with production 

plants such as a ConfecECO and a 

ConfecVARIO. 

Product development and 

manufacturing for new (growth) 

markets 

The latest WDS laboratory depositor 

machine for product development 

and manufacturing in the sweetOTC 

environment will also be presented 

at interpack. To avoid contamination 

and cross-contamination, the 

EasyClean concept has been further 

developed and optimized. Together 

with risk assessment (FMEA) and a 

qualification concept in accordance 

with applicable GMP regulations, this 

new generation of WDS laboratory 

depositor machines is ideal for 

anyone who wants to tap into the 

opportunities and growth potential of 

new markets in the field of innovative 

and alternative dosage forms. 

Starch-free WDS production 

technology for manufacturing 

gum and jelly products with 

functional properties 

One of the key topics for WDS 

at interpack will be starch-free 

production under GMP conditions. 

Fruit gums and jelly products have 

OTC products: Starch-free dosing 

a very high acceptance among 

consumers. The market for such 

dietary supplements and OTC 

products has developed equally 

rapidly. Since the conventional 

production of fruit gum confectionery 

with mould starch does not meet the 

strict hygienic GMP regulations, WDS 

has developed a new and innovative 

plant technology for depositing and 

demoulding in polycarbonate moulds 

especially for the production of OTC 

fruit gum products. 

Like this 

shape? 

USE OUR TECHNOLOGIES 

TO BOOST YOUR BUSINESS! 

The most important aspects of this 

technology include the high-precision 

spraying of the mould cavities prior 

to depositing, a particularly precise 

dosing process for the mass and the 

orderly demoulding of the products 

from the mould in a way that is gentle 

on the product. 

The WDS trade fair team is already looking 

forward to the leading trade fair in May 

and invites all customers and visitors to 

visit the WDS stand in Hall 1, B 66. fmt 

Orderly demoulding is mandatory for starchless 

moulding processes 

Hall 3 

Booth 3D96 

SCHAAF TECHNOLOGIE GMBH 

www.foodextrusion.de 


27

Processing 

Top Tips to Reduce Food Waste During 

Processing 

By Matt Hale 

According to some estimates, over a third of all the food produced globally is wasted. The UK generates 

around 9.5 million tonnes of food waste a year, of which some 1.5 million tonnes (16%) comes from 

manufacturing 1 . While not all of this material is edible, in terms of efficiency and reducing greenhouse gas 

(GHG) emissions, prevention of this waste is preferable to other methods such as food redistribution or use 

as animal feed, or recycling, energy generation or disposal via anaerobic digestion, composting, incineration 

or landfill. 

Waste food is food which cannot be 

consumed by somebody. With large 

numbers of people going hungry across 

the globe, and increasing pressure 

on land, there is a moral imperative 

to maximize the amount of produced 

food which is actually consumed. Food 

production is also a significant source of 

global GHGs, and waste food generates 

further emissions without any nutritional 

benefit. Reducing food waste is a key 

factor to mitigate climate change. 

Waste food also has significant financial 

costs for businesses. Not only does 

the raw material have a cost, but 

additional costs are associated with 

the redistribution or disposal of waste 

food products. As food and energy 

costs have undergone massive inflation 

over the last 12-18 months, the need to 

control costs and maximize utilization 

of expensive ingredients has also 

increased. 

There are a number of approaches 

which businesses can use to assess and 

reduce food waste, and in most cases 

a mixture of valorization, utilization and 

process improvement (or implementing 

LEAN processes) will be required. 

Some key areas to consider include: 

1. Improve packaging 

Good quality packaging improves 

the shelf life of food and therefore 

reduces waste in the distribution chain 

and in households. However, there is 

increasingly a balance between reducing 

the use of plastics and non-recyclable 

materials, while increasing product shelf 

life (wrapping cucumbers in plastic is a 

classic example). 

Choosing the right packaging during the 

manufacturing process can improve 

shelf life and reduce handling, improving 

efficiencies and reducing waste. Accurate 

and consistent weighing is also 

important, as even a few grams surplus 

in each pack can quickly add up to large 

sums of money. 

2. Improve forecasting 

Inaccurate forecasting can mean you 

waste raw materials and ingredients. 

Don’t assume that you need to produce 

a certain number of products unless 

you have clear evidence for such 

Careful equipment choice can help to reduce food waste 


Processing 

demand (such as agreed orders or 

demand modelling). Ordering enough 

ingredients to produce a certain volume 

of product but actually producing less, is 

one of the biggest sources of waste in 

food businesses, particularly when using 

fresh or perishable ingredients. 

The HRS R Series can be run in reverse, 

effectively emptying the heat exchanger 

tube(s) of product 

Better and more accurate forecasting 

models allow you to guess less and 

maximize the use of ingredients. 

3. Measure and plan 

Without measuring waste, you can’t 

tell if you are reducing it, or adequately 

calculate what it is costing you. Feeding 

this data into company-wide systems so 

that it can be analysed centrally helps to 

identify areas of inefficiency and waste, 

allowing manufacturers to streamline 

processes and reduce waste. 

Having systems in place to measure 

waste and efficiently plan production 

can greatly reduce the amount of waste 

generated. For example, producing 

subsequent or similar batches of 

product may reduce the need to empty 

processing lines between production 

runs. 

4. Review quality control systems 

Quality control is vital to maintain 

standards and food safety, but there is 

a need to avoid overzealous standards 

which may result in ingredients which 

are perfectly usable being discarded. 

Likewise, under- or overcooking-food, 

or having unnecessary trimmings or offcuts 

results in unnecessary waste. 

As well as making sure that the quality 

standards and specifications being 

applied are appropriate for the product, 

it is also important to make sure that the 

processes used for quality assurance 

are operating correctly, whether that is 

calibrating equipment or training staff. 

5. Involve staff 

As with other areas, staff awareness, 

education and involvement play a huge 

role in minimizing waste. Employees 

should be invested and committed 

to reducing waste and building it into 

company culture. 

As well as educating staff about the 

impacts of waste, they should be 

encouraged to take part in a full dialogue 

as employees often have useful insights 

into the manufacturing processes. 

Recognizing and rewarding innovative 

ideas can help waste prevention become 

an ingrained habit and a key value within 

the organization. 

6. Improve ‘disposal’ of 

unavoidable waste 

Even with the best will in the world, 

some ‘waste’ is likely to be generated. 

This should be dealt with in a way which 

maximizes its usefulness or value. 

According to the food waste hierarchy, 

in order of preference these disposal 

options are: 

a. Redistribution to people 

b. Use for animal feed 

c. Anaerobic digestion 

d. Composting 

e. Incineration with energy recovery 

f. Incineration, landfill or disposal via 

sewerage systems 

It may also be possible to utilize certain 

products in novel ways, for example 

vegetable oils and animal by-products 

(ABPs) can be converted into biodiesel 

where facilities allow. 

7. Use technology to reduce waste 

during production 

New technology or equipment may 

help increase utilization, for example 

by recovering more usable protein from 

meat carcases. Another option is to 

optimize existing production processes, 

particularly when it comes to production 

changes or cleaning-in-place (CIP). 

Depending on the product, such cleaning 

is handled and product complexity this 

may be required several times a day 

between production batches. If product 

remaining in equipment is ‘flushed’ 

using pigging systems, large quantities 

of otherwise usable product could be 

lost. Careful product design can also 

recover product. For example, the 

HRS R Series of heat exchangers uses 

a scraper bar within the inner tube to 

enhance product flow, prevent fouling 

and minimize pressure drop. It has the 

unique feature is that when configured 

correctly, the unit can be run in reverse, 

effectively emptying the heat exchanger 

tube(s) of product without damaging it or 

changing its characteristics, so it can be 

recovered and utilized. 

Due to the amount of product saved, 

and the fact that it is often unnecessary 

to install additional product recovery 

systems, the R Series heat exchanger 

can quickly pay for itself, and in the long 

term can be a more economic option 

than alternative systems which have 

lower capital costs. 

1 WRAP: Food surplus and waste in the UK – 

key facts at https://wrap.org.uk/sites/default/ 

files/2021-10/food-%20surplus-and-%20wastein-the-%20uk-key-facts-oct-21.pdf 

The Author 

Matt Hale, International Sales & Marketing 

Director, HRS Heat Exchangers 


29

Packaging 

Confectionery market: High Turnovers 

and Highly Competitive 

Most people enjoy a sweet tooth, 

but with the trend towards more 

sustainability, there is also an increase 

in demand for sweets with more 

eco-friendly packaging. This puts 

severe pressure on the confectionery 

industry to adopt packaging processes 

and materials which are gentle to 

natural resources. Many producers 

of packaging already are able to offer 

sustainable solutions for chocolate, 

biscuits, etc. 

The European confectionery industry 

is one of the most dynamic and 

largest sectors in terms of production 

and export. More than 12,000 

companies produce 14.7 million tons 

of confectioneries each year, says 

the European association Caobisco. 

Worldwide, however, the USA are the 

biggest producers of confectionery 

with a predicted turnover of 264 billion 

Euro in 2023 and the largest absolute 

growth, according to Euromonitor 

International, over the next five years. 

Chocolate especially is what 

consumers prefer above all. In the 

European ranking by Chocosuisse in 

2020, Switzerland led the per-capita 

consumption of chocolate with 

more than eleven kilograms per year, 

followed by Germany (9.2 kg), Estonia 

(8.3 kg) and Denmark (8.2 kg). Estonia 

even had the highest per-capita 

consumption of confectionery in 2022, 

according to Euromonitor – every 

inhabitant statistically ate a total of 

13.6 kg. Prognostics say that this trend 

in the Baltic country will experience a 

large growth over the next five years. 

A current survey by the German online 

platform Statista shows: Women 

eat more sweets. In the year 2022, 

about 34 percent of women said they 

consume sweets or savory snacks 

every day. The number for men was 

23 percent. In a different study, one 

quarter of the participants told the 

market investigators of POSpulse, that 

since the pandemic they have been 

consuming more sweets and snacks. 

Manufacturers source the main raw 

ingredients for confectionery and 

snack foods mostly from Germany 

or the EU, according to the German 

Federal association BDSI. This makes 

the confectionery industry not only an 

important partner for the German and 

European agriculture, short transport 

distances also mean that it contributes 

to saving resources. International 

trade is of course important for the 

confectionery industry, too. Using 

roughly 400,000 tons of cocoa, the 

most important raw ingredient for 

chocolate, German manufacturers 

of confectionery process 10 percent 

of the global annual crop. All in all, 

European manufacturers use about 

half of the world’s available cocoa, 

according to Caobisco. 

Currently, the industry like many 

others faces an existential crisis: 

Exploding costs for energy and raw 

materials, but also disruptions to 

delivery chains and the availability of 

raw materials disproportionately affect 

small and mid-size family businesses. 

For example, in autumn 2022, the cost 

increase for sugar was 100 percent, 

butter was 57 percent more expensive, 

and wheat 60 percent. “For our 

companies, the enormous pressure 

30 


Packaging 

from rising costs leads to them 

questioning production sites or even 

their very existence. This is not only 

caused by the soaring cost of energy 

and raw materials in 2022, but also 

by negative pressure dependent on 

location, which in Germany has been 

higher than average for a long time. 

This includes expenditures on wages, 

taxes and the growing lack of qualified 

personnel”, says Dr. Carsten Bernoth, 

CEO of the German Federal association 

of German producers of confectionery 

(BDSI). ‘”For our producers, it is 

impossible to compensate for these 

considerably rising costs by saving or 

by proportionately raising sales prices.” 

In spite of the crises, confectionery 

is one of the segments of the food 

industry with the highest turnover; 

this segment achieves the fourth 

highest. It is therefore no surprise that 

the confectionery market is one of the 

most competitive within the German 

retail market. And the industry is 

facing new requirements. Especially 

the growing awareness of consumers 

regarding health and the environment 

is creating a new demand for 

sugarfree varieties and packages that 

are more environmentally friendly. 

For manufacturers of confectionery 

this also means they have to create 

their packaging processes to be more 

flexible and more efficient. There is 

a growing trend towards automated 

production and packaging processes, 

and their sweet delicacies more 

often come in a sustainable wrap. For 

example, we have the first chocolate 

bars that are not wrapped in an inner 

aluminum foil and are just packaged 

in cardboard – however, as this is in 

direct contact with food, it needs 

a coating. Confectionery producer 

Fazer now uses a light, dispersion 

coated cardboard from Metsä Board 

for its advent calendars. Switching 

to the new material has reduced the 

use of plastics by 1,200 kg each year 

compared to the previous PE coated 

cardboard, says the company. The 

advent calendar is now also fully 

able to be recycled, the light weight 

and the new material’s efficient use 

of resources also cut its carbon 

footprint by one quarter. “Virgin fiber 

cardboard offers the necessary safety 

for advent calenders, especially where 

chocolate and cardboard come into 

direct contact. Our dispersion coated 

cardboard also has neutral sensory 

properties, which means the taste 

of the chocolate is preserved for a 

long time”, says Olli Haaranoja, Sales 

Director at Metsä Board. 

Packaging chocolate at high 

speeds 

An output of 250 bars of chocolate per 

minute is the rate of a new wrapping 

machine, marketed by Sacmi as part 

of the brand Carle & Montanari. It also 

processes new eco-friendly packaging 

materials. The machine is the result 

of a new approach to machine 

construction at Sacmi Packaging 

& Chocolate, which goes beyond 

traditional mechanical concepts and 

makes it possible to package sensitive 

products at high speeds and with 

constantly high quality. The wrapping 

machine produces chocolate bars with 

an inner and outer wrapping, where 

the inner wrapping is sealed on three 

sides while the outer wrapping is 

made of precut cardboard or paper. 

Sensors attached to the system 

monitor the consumption, work hours 

food Marketing & Technology • February 2023 31

Packaging 

and efficiency indicators. In case of 

inconsistencies within the packaging 

process, the machine automatically 

issues an alert message and opens 

a remote connection to the service 

department. 

A newly developed multi-style wrapping 

machine for chocolate truffles by 

Sacmi also processes eco-friendly 

foils. Using a top twist configuration, it 

wraps up to 500 chocolate truffles per 

minute, including sensitive products 

or those with irregular shapes. It is 

said to be the first wrapping machine 

with hybrid technology and not only 

uses mechanical, but also powerful, 

energy efficient servo drives. Other 

than that, the wrapping machine is 

equipped with real-time maintenance 

functions. As soon as the ideal settings 

for each motion have been defined, 

live diagnostics assure that deviations 

are immediately noticed and downtime 

can be avoided. 

Confectionery packaging for the 

circular economy 

Consumers increasingly expect 

sustainable packaging for confectionery. 

In a shared project, interpack exhibitors 

Sabic, confectionery manufacturer 

Mars and recycling service provider 

Landbell have recently developed 

flexible packaging for a snack bar. The 

monomaterial used is made up of 

certified, circular polypropylene from 

the Trucircle portfolio by Sabic. The 

circle starts with collecting mixed old 

plastics, coordinated by the Landbell 

Group. The mixed material is then 

changed by a thermal anaerobic 

process into pyrolysis oil, which serves 

as an alternative raw material for a 

novel PP polymer which is suitable for 

contact with food. From pellets made of 

this substance, manufacturer Taghleef 

then makes BOPP films. 

Chocolate popular in Europe 

According to CAOBISCO, the chocolate 

and confectionery association 

in the European Union, Finland is 

among the top five when it comes to 

chocolate consumption in Europe. 

Only Switzerland, Germany and 

Estonia consume more chocolate, the 

UK comes fifth. 

The northern European confectionery 

manufacturer Orkla has recently 

invested in a new packaging machine 

especially for chocolate products 

with different folding varieties by 

Theegarten-Pactec, to increase 

packaging capacity at the Finnish 

production site Vaajakoski. The 

investment was preceded by a 

lengthy testing phase. “For us it was 

the perfect opportunity to test our 

packaging machine CHS first under 

real conditions in confectionery 

production. An endless stream 

of products, constant operation, 

different packaging materials and 

product qualities, cleaning and 

maintenance work during operation 

or even difficulties like a shutdown 

of processing systems – there is 

much that cannot be fully covered 

by a simulation. In the end, such 

tests are indispensable to give a 

new development the final touches 

and bring it to market readiness”, 

says Daniel Schibur, Head of Sales 

at Theegarten-Pactec. Alongside 

general function tests, special focus 

was placed on the two-track feed 

of the machine – a specialty of the 

CHS. The challenge: Divert a portion 

of the products from the endless 

product stream of the main belt into 

the two-track feed of the CHS while 

32 


Packaging 

at the same time making sure that an 

even exchange happens between the 

two tracks. Each of the two feeding 

tracks must continually receive 900 

products per minute, which are then 

combined in the packaging process 

into a one-track stream of 1,800 

products per minute. An integrated 

camera system and effective 

placement of sensors now constantly 

check the product stream arriving at 

the main belt. This guarantees that 

the two product streams in front of 

the machine do not differ by more 

than five products. The machine 

can be flexibly switched to nine 

different folding varieties: Double 

twist, protected twist, top twist, side 

twist, tin foiling, bottom fold, side 

fold, Vienna fruit fold and – right now 

– envelope fold. 

bag or sealing machines, which are 

used in the confectionery industry 

for packaging individual products, 

says the manufacturer. Even very 

small foreign bodies are detected 

with a high degree of accuracy. And 

as individual bars rather than entire 

sales units are checked right after 

leaving the tubular bag machine, and 

are then if necessary ejected, there is 

also a saving of costs. 

fmt 

Theegarten-Pactec has also partly 

acquired the Turkish mechanical 

engineering company Makrev 

Packaging. The company based in 

Istanbul produces clocked wrapping 

machines for chocolates and jellies, as 

well as entire automated and feeding 

systems. Through the acquisition, 

Theegarten-Pactec wants to add to 

their portfolio and attract customers 

in the medium performance and price 

segment, below the high performance 

machines manufactured in Dresden. 

Inspection system for snacks and 

sweets 

As everywhere in the food industry, 

foreign bodies are absolutely not 

wanted in sweets or snacks. Modern 

inspection systems therefore 

guarantee safety at today’s packaging 

machines. A new X-ray inspection 

system by Mettler-Toledo, for 

example, was developed especially 

to detect foreign bodies in small, 

individually wrapped snacks and 

sweets at high production speeds. 

It makes a cost efficient inspection 

possible right after flow wrapping 

or sealing individual products. The 

compact inspection system is 

equipped with an integrated ejection 

mechanism and supports operation 

at belt speeds up to 120 meters per 

minute. This makes it possible for the 

first time to adjust X-ray inspection 

to the high speeds of many tubular 


Packaging 

Artisan Pork Snacks Packs Win US 

Consumer Hearts 

Benestar Brands benefits from efficient collaboration with tna solutions 

tna solutions worked in collaboration 

with the US pork snack company 

Benestar Brands to develop a highly 

efficient processing and packaging 

line for its bespoke rinds and cracklins. 

Installed in 2019, the complete solution 

from tna matched Benestar Brands’ 

ethos of delivering extremely satisfying 

products perfectly. The new line helped 

Benestar Brands improve its product 

quality tenfold, while significantly 

reducing energy use and enhancing 

efficiency. 

“tna solutions has been a fantastic 

partner throughout the process,” 

commented Jose Gomez, Chief 

Technical Officer at Benestar Brands. 

“The company’s experts have a deep 

understanding of our industry, while 

being open to listening to our specific 

challenges and finding out-of-thebox 

solutions. The accommodation 

of our specific needs, from footprint 

restrictions and frying demands to 

intricate seasoning, helped facilitate 

our partnership with tna and develop 

an excellent product to satisfy every 

pork fan.” 

From feeding to baggers – 

complete line solution 

Working collaboratively since 2005, 

Benestar Brands and tna’s engineers 

have developed the world’s most 

advanced approach to pork rind 

manufacturing. Every piece of the 

process, from feeding & frying to 

distribution systems & packaging, is 

optimized to ensure better products and 

a faster return on investment. The tna 

batch-pro 12 frying technology reduces 

rejects to less than 3%, while unique fryer 

design minimises oil use, contributing to 

product and material savings. 

In addition, the tna batch-pro 12 fryer 

system provides direct-fire heating for 

improved energy efficiencies and lower 

operating costs, while the accurate 

and flexible tna intelli-flav® OMS 5.1 

seasoning system allows for consistent 

coverage without costly ingredient 

losses, further contributing to a healthy 

bottom line. Last but not least, the tna 

robag® 3e, high-performance vertical 

form fill and seal (VFFS) packaging 

system enabled Benestar Brands to 

efficiently pack both pork rinds and 

cracklins on the same line at a high 

speed. 

“I have witnessed tna’s cutting-edge 

approach to innovations first-hand,” 

Gomez continued. “The company is a 

technological trailblazer, outperforming 

other suppliers on the market. What’s 

more, the partnership doesn’t stop there. 

tna’s exceptional training program and 

remote support ensures staff receive 

detailed instruction from an industry 

expert – something other vendors can’t 

deliver.” 

Quality first 

With a wide portfolio of natural, proteinrich 

and keto-friendly snacks, Benestar 

Brands puts specific emphasis on 

delivering consistently high product 

quality to its loyal customer base. 

Investing in tna technology has helped 

the company to extend snack shelf life, 

while improving the quality with an eye 

on continuous improvement. 

tna was involved in the optimization 

of processing and packaging from the 

outset, with the pork rinds and cracklins 

being fully tested at its technical 

centrer facility in Texas, U.S., prior to 

the equipment purchase. The toughest 

products were put to the test to ensure 

a consistent texture, seasoning and 

flavor. tna provided guidance and 

technical support throughout the entire 

manufacturing process, ensuring the 

product could be brought to market 

quickly and efficiently. 

“Our partnership with Benestar Brands 

has been very exciting and has fuelled 

the engineering innovation of our team,” 

says Adam Holloway, tna Regional 

Sales Manager, North America. “Pork 

rinds have very different product 

characteristics to traditional snacks 

we have been working with, such as 

potato and tortilla chips. We brought 

the years of processing experience 

in terms of treating food products 

in oil baths, while Benestar Brands 

contributed specific application 

knowledge – two key ingredients for a 

successful outcome.” 

Resource efficiency 

Achieving efficiency gains and reducing 

environmental impact were high on 

the agenda for Benestar Brands when 

selecting a new production line, driven 

by regulatory changes and increasing 

pressures from retailers and consumers. 

tna helped Benestar Brands to replace 

direct heating with heat exchanger 

technology, reducing energy use in the 

most energy intensive process – frying. 

tna installed a LO NOx burner, reducing 

harmful nitrogen oxides (NOx) emissions 

and helping the company comply with 

Californian regulatory requirements. 

Thanks to its three-stage oil filtration 

system, the continuous frying technology 

from tna ensures efficient oil 

management and turnover, eliminating 

the need to discard oil on a daily basis 

after every single production run, saving 

costly material. The new fryer also lowers 

fatty acids levels, enabling nutritionally 

appealing, consistent end-product that 

tastes great and has a desirable color 

and texture. 

34 


Packaging 

Achieving the highest quality levels 

whilst driving sustainable processes was 

of great significance to Benestar Brands, 

which is keen to stay true to its values 

and its customers. 

What the future holds 

Hitting existing production targets is 

critical. However, new assets must 

not only have the capacity to take 

on current output demands but also 

handle any forecasted production 

requirements. Able to handle both 

pork rinds and cracklins, as well as 

multiple bag sizes from 1.5 oz to 8 

oz, multipurpose equipment from 

tna safeguards Benestar Brands’ 

future operations with its inherent 

flexibility. 

With increasing pressures throughout 

the entire supply chain to do more to 

protect the environment, Benestar 

Brands is looking to further collaborate 

with tna experts on ways to reduce 

energy consumption, film and product 

waste, achieving a more sustainable 

production. 

“The opportunities for future 

collaborations are endless,” adds 

Holloway. “To meet market demands 

for energy-efficient and sustainable 

processing and packaging technologies, 

tna continuously invests in technological 

innovation, and we look forward to 

building a greener, more sustainable 

snacks industry together with Benestar 

Brands and Jose Gomez personally.” fmt 


Packaging 

Save Foods – Stock with Potential: 

Green Agricultural Technology Conquers 

the Market 

The take-away from Berlin’s International Green Week: Sustainability in agriculture and food is more than 

just a passing trend. It is a megatrend. The market is characterized by high and dynamic growth. Save Foods 

is an emerging supplier of green agricultural technology. Its solutions help to reduce the use of pesticides 

and sustainably reduce food waste. 

The food industry is facing massive 

challenges. “We want to bring together 

goals that sound contradictory: food 

security, climate adaptation, climate 

protection and farms with a future.” 

This call was issued by Cem Özdemir, 

the Federal Minister of Food and 

Agriculture. On the occasion of the 

International Green Week in Berlin, 

which ended on January 29, he called 

for a sustainable transformation: “We 

need pragmatic solutions together 

with agriculture, the food industry and 

society”. 

Save Foods is a company that offers 

pragmatic innovations for the entire 

value chain “from farm to fork”, from 

farmers to end consumers. The 

American agricultural technology 

company is developing green, costeffective 

and safe solutions to extend 

the shelf life of retail fresh food by up to 

50 percent and prevent contamination 

with pathogens. 

“The fight against food waste is the 

order of the day, because a frightening 

46 percent of the world’s fruit and 

vegetables never reach people’s 

plates, but spoil on the way to retail,” 

explains Dan Sztybel. He is the CEO 

of the Israeli subsidiary of the US 

agricultural technology company 

Save Foods, which was founded in 

2009 as a research and development 

institute. Since May 2021, Save Foods 

has been listed on the US technology 

exchange. 

Trend: Green substitute for 

pesticides 

Save Foods works with natural 

fruit acid mixtures and oxidantsthat 

are particularly healthy and 

environmentally friendly. These costeffective 

solutions, of which ten are 

now patented, reduce pesticides in the 

plug-and-play process and are easy to 

implement in existing systems. After 

successfully completing numerous 

pilot projects worldwide, the 

company’s position is now excellent. 

Save Foods is already commercially 

active in the USA, Mexico and Israel. 

On the occasion of Green Week, 

Christoph Minhoff, Managing Director 

of the Federation for Food Law and 

Food Science e.V., pointed out that 

for consumers, sustainability, taste 

and – especially in view of inflation 

– affordable prices were essential 

decision-making criteria. 

Save Foods solutions meet all of these 

criteria consistently. They are not only 

ecologically friendly and safe, but also 

economically sustainable. These are 

all aspects that are increasingly being 

demanded by capital market investors. 

Against this backdrop, Save Foods’ 

stock is an interesting growth stock 

for anyone looking for new investment 

opportunities within the green 

technology sector. 

fmt

Marketing 


37


ADM Opens $30 Million State-of-the- 

Art Production Facility in Spain to Meet 

Growing Demand for Probiotic 

ADM one of the world’s leaders in 

science-backed nutrition solutions, 

announced today that it has opened 

a new production facility in Valencia, 

Spain to help meet rising global 

demand for probiotics, postbiotics and 

other products that support health 

and well-being. 

The production facility represents an 

investment north of $30 million and a 

more than five-fold increase in ADM’s 

production capacity, increasing it to 50 

metric tons per year. The facility will 

allow ADM to supply growing markets 

for probiotics and postbiotics in the 

U.S., Asia-Pacific and Europe. ADM 

expects its customer base will more 

than triple over the next five years 

as more people recognize the links 

between the gut microbiome and many 

aspects of health and look for products 

tailored to their specific needs. 

The facility, the world’s first to produce 

both probiotics and postbiotics at the 

same site, will help the company fulfill 

its expansion strategy in the health and 

well-being sector. ADM is on its way 

to realizing its ambition to increase 

health and wellness revenue from over 

$500 million in 2022 to $2 billion within 

10 years. 

“Health and well-being is one of the 

three enduring trends powering 

ADM’s growth strategy: Consumers 

are increasingly aware of the role 

their gut microbiome can play in their 

everyday lives, and they’re seeking 

nutrition solutions that are backed up 

by science-based research,” said Mark 

Lotsch, president, Global Health & 

Wellness. “ADM is a leader in meeting 

this growing global demand, and we’re 

continuing to invest in the cutting edge 

of health and nutrition,” he said. 

The site will produce ADM’s awardwinning 

probiotic BPL1* and the 

heat-treated BPL1 postbiotic, as 

well as other ADM proprietary strains, 

supplying a broad range of customers. 

It will also be able to support further 

growth in ADM’s UK-leading Bio-Kult 

brand of products. 

The new facility is located close 

to ADM’s pioneering research and 

development center in the University 

of Valencia Scientific Park, where ADM 

scientists undertake activity including 

next-generation genome sequencing 


Packaging 



and early-stage testing of new bacterial 

strains. 

Market research estimates that the 

probiotic supplements retail market 

could surge to $10.4 billion by 2027 

from about $8.3 billion in 20221. 

That growth is being driven by rising 

demand for science-based probiotic 

formulas that are used in dietary 

supplements, and also dairy products, 

food, healthy snacks and beverages, 

as well as pet and animal well-being 

products. 

fmt 

*BPL1® is a trademark registered for Biopolis S.L. 

in the EU and other countries. 

1Euromonitor – Passport Data 2023 


Events 

MARCH APRIL MAY 

28-30 March 

Lagos, Nigeria 

food + bev tec 

fairtrade Messe GmbH & Co. KG 

Kurfürsten Anlage 36, 

69115 Heidelberg, Germany 

Tel.: +49-6221/4565-0 • Fax: +49-6221/4565-25 

info@fairtrade-messe.de 

www.fairtrade-messe.de 

23-25 April 

Cologne, Germany 

Let`s meet at 

ISM + ProSweets Cologne 

Koelnmesse GmbH 

Messeplatz 1, 50679 Cologne 

Tel: +49 1806 002 200 

www.ism-cologne.de 

prosweets-cologne@koelnmesse.de 

4-10 May 

Dusseldorf, Germany 

interpack 

Let`s meet at 

Messe Düsseldorf GmbH 

Postfach 10 10 06, 40001 Düsseldorf, 

Germany 

Tel.: +49 211 45 60 01 • Fax: +49 211 45 60 6 68 

www.interpack.com 

8-11 May 

Milano, Italy 

TUTTO FOOD 

Camera di Commercio Italo-Tedesca 

Italienische Handelskammer München-Stuttgart e.V. 

Landaubogen 10, D-81373 München 

Tel.: +49-89-961661-86 

messner@italcam.de 

www.italcam.de 

9-11 May 

Geneva Switzerland 

Let`s meet at 

Vitafoods Europe 

Informa Exhibitions, 5 Howick Place, 

London SW1P 1WG, Great Britain 

Tel.: +44 20 337 73111 

www.vitafoods.eu.com 

28-30 May 

Cairo, Egypt 

Food ingredients Africa 

Informa Markets 

PO Box 12740, de Entree 73, 

Toren A, 1100 AS Amsterdam Zuid Oost, 

The Netherlands 

Tel.: +31-20-409 9544 • Fax: +31-20-363 2616 

www.figlobal.com 

JUNE JULY SEPTEMBER NOVEMBER 

8-10 June 

Addis Abada, Ethiopia Let`s meet at 

Agrofood 

fairtrade Messe GmbH & Co. KG 

Kurfürsten Anlage 36, 

69115 Heidelberg, Germany 

Tel.: +49-6221/4565-0 

Fax: +49-6221/4565-25 

info@fairtrade-messe.de 

www.fairtrade-messe.de 

16-19 July 

Chicago, IL, USA 

Let`s meet at 

IFT Food Expo 

Institute of Food Technologists 

252 W. Van Buren, 

Suite 1000, Chicago, IL 60607 

Tel.: +1-312-782-8424 

Fax: +1-312-782-8348 

www.ift.org 

26-28 September 

Nuremberg, Germany 

Powtech 

NürnbergMesse GmbH 

Messezentrum, 

90471 Nuremberg 

Tel.: +49 911 86 06 49 09 

Fax: +49 911 86 06 49 08 

www.powtech.de 

7-9 November 

Dubai, UAE 

Gulfood Manufacturing 

Dubai World Trade Centre, 

P.O. Box 9292, Dubai, UAE 

Tel: (+971) 4 308 6124 

info@dwtc.com 

www.gulfood.com 

Let`s meet at 

Let`s meet at 

8-30 November 

Frankfurt, France 

Food ingredients Europe Let`s meet at 

Informa Markets 

PO Box 12740, de Entree 73, 

Toren A, 1100 AS Amsterdam Zuid Oost, 

The Netherlands 

Tel.: +31-20-409 9544 

Fax: +31-20-363 2616 

www.figlobal.com 

This list of events is accurate, to the best of our knowledge. However potential visitors are recommended to check with the 

organizer since some details are subject to change. We make no claims to be complete and are grateful for any corrections 

or completions. Please contact: food@harnisch.com 


41

Last Page 

Advertiser’s Index • December 2022 

Page Company Location 

5 Fairtrade GmbH & Co. KG Heidelberg, Germany 

21 HRS Heat Exchangers Ltd. Watford, UK 

17 Informa Exhibition London, UK 

27 Schaaf Technologie GmbH Bad Camberg, Germany 

9 Symrise AG Holzminden, Germany 

Cover 2 Urschel Laboratories Inc. Chesterton, IN, USA 

19 WENGER Manufacturing, Inc. Sabetha, KS, USA 

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

if something should be not quite right. 

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