FEBRUARY 2020 • APRIL 2020 Vol. 8 • No. 1
Simplicity in your plant The science of texture control in ice cream
How to brew alcoholfree beer
Artificial intelligence that transcends boundaries
CONTENTS FEBRUA RY 2020 - A PRIL 2020
Vo l. 8 • N o. 1
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NEWS
Retailer wins the battle against plastic Innovative ways of recycling Syntegon announces new CEO Sustainability the secret to selling ingredients Barentz and Matco enter joint venture
12 Digitalise your plant with IO-Link
10
INDUSTRY TALK
Predict future manufacturing trends
“IO-Link is a standardised communication technology (IEC 61131-9) that shortens commissioning time and allows plug-play device exchange. This technology allows the digital accessibility of basic devices”
13
DAIRY FOOD
Texture control using xanthan gum An inline policy for dairy food
16
FOOD SAFETY PRACTICES & TRAINING
Sensor range assures hygienic production Food safety auditing and certification
18
ALCOHOLIC BEVERAGES
The fast track to alcohol-free beer Sidel’s latest in beer canning technology
21
PACKAGING AUTOMATION
Artificial intelligence at the edge
18 Membrane de-alcoholisation unit for alcohol-free beer There are several different methods for producing de-alcoholised or non-alcoholic beer. Laitilan Wirvoitusjuomatehdas Oy brewery in Finland wanted to avoid wort-like flavours and achieve the best results when it came to taste and quality.
ADVERTISERS’ INDEX Emirates SkyCargo........................................................IFC.........www.skycargo.com/emiratesfresh Endress & Hauser ........................................................OFC.......www.za.endress.com ISW Shrink.......................................................................IBC........www.iswshrink.co.za Omron Electronics .......................................................22..........www.industrial.omron.co.za Polyoak Packaging........................................................21..........www.polyoakpackaging.co.za Roha SA............................................................................OBC......www.roha.com
Savannah Fine Chemicals..........................................13..........www.savannah.co.za Sidel..................................................................................19..........www.sidel.com Sollich KG........................................................................5............www.sollich.com South African Trade Promotions .............................9............John.t@satp.co.za Syspro..............................................................................11..........www.za.syspro.com Vega Controls SA ..........................................................6............www.vega.com/vegabar
2020 Quarter 1 | Food Manufacturing Africa
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EDITOR’S COMMENT
EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: Naresh Budraj ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Càndida Giambò-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za
INTERNATIONAL SALES
Africa’s economy to grow despite external shocks
Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com
Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk Contributor: Mark Wilson
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HE CONTINENT’S ECONOMIC growth remained stable in 2019 at 3.4 per cent and is on course to pick up to 3.9 per cent in 2020 and 4.1 per cent in 2021. This is the view of the African Development Bank’s 2020 African Economic Outlook. It revealed that slower than expected growth is due to the moderate expansion of the continent’s Big Five: Algeria, Egypt, Morocco, Nigeria and South Africa. These countries’ joint growth was an average of 3.1 per cent, compared with an average of 4.0 per cent for the rest of the continent. East Africa maintained its lead as the continent’s fastest-growing region, with average growth estimated at 5.0 per cent in 2019; North Africa was the second-fastest at 4.1 per cent, while West Africa’s growth rose to 3.7 per cent in 2019, up from 3.4 per cent the year before. Central Africa grew at 3.2 per cent in 2019, up from 2.7 per cent in
2018, while Southern Africa’s growth slowed considerably over the same period, from 1.2 per cent to 0.7 per cent. Africa needs to build skills in information and communication technology. Science, technology, engineering and mathematical skills are also critically important. The Fourth Industrial Revolution places bigger demands on educational systems producing graduates versed in these skills. In line with this trend, this edition of Food Manufacturing Africa looks at systems, programmes and technologies that can assist in growing these sectors. Syspro unpacks novel ways to manage and unpack data that will generate legible insights and proffer solutions to increase manufacturing in 2020 and beyond. You can find the full story on page 10. We also look at how you can digitalise your plant with Endress + Hauser on page 12. Everyone loves ice cream. This fact is attested to by the size of the global ice cream market – currently around 15 billion litres. If you want to know how to keep the texture of your ice-cream products, turn to page 13 for the full story. We also investigate the latest in new canning lines for the brewing industry (page 19). This facility is canning beer at an incredible pace! I hope you enjoy this edition. If you have any insights, news or trends please share them with me. I always look forward to hearing from you!
Happy reading
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Food Manufacturing Africa | 2020 Quarter 1
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NEWS
SYNTEGON TECHNOLOGY APPOINTS CHIEF EXECUTIVE PROCESSING AND PACKAGING technology supplier Syntegon Technology has appointed Michael Grosse as chief executive officer. The announcement comes after the company name change from Bosch Packaging Technology and follows the acquisition by CVC Capital Partners from Bosch in 2019. Until recently, Michael Grosse was a member of the management board of Tetra Pak. Syntegon said he has relevant leadership and management experience in the international mechanical engineering industry, particularly in the areas of process and packaging technology for the food industry. Grosse, who will take up his post on 1 March 2020, will succeed Stefan Koenig,
underage drinking
who spent 24 years working for the Bosch Group, ten of which at Bosch Packaging or Syntegon Technology. He has led the company as CEO since 2017. •
SUSTAINABILITY A KEY SELLING POINT FOR NEW INGREDIENTS RESEARCH CONDUCTED BY the University of Nottingham has found that consumers are more likely to accept new, unfamiliar ingredients once they are aware of their sustainable features. Researchers from the University’s School of Biosciences conducted tasting sessions with 100 participants. Consumers tried biscotti and crackers made with Bambara Groundnut against standard commercial products. Bambara is a grain legume grown mainly in subSaharan Africa. The legume puts limited demands on soil, is capable of growing in nutrient-poor soils and is touted as a climate change-resistant crop. The ingredient is high in carbohydrates, protein and is gluten-free. It could also offer an alternative to rice and wheat flour. For each sample in the trial, participants were asked to rate their overall liking and emotional response based on the sensory properties of the product. The first tasting was done ‘blind’ with a red light masking the appearance of the products. Participants were then invited back for a second session where they were informed about global resource challenges and the sustainable features of Bambara and told which products contained this ingredient. The study determined that the main driver for accepting this new ingredient was how people felt when given information about its sustainability credentials. ‘Under the blind condition, no significant differences in overall liking were observed between standard and Bambara products, suggesting UK consumers accept the sensory
5
actions to stop
properties of products containing Bambara flour,’ explains Dr Qian Yang, assistant professor in sensory and consumer sciences at the University of Nottingham. ‘This indicates that as long as the products taste good, consumers will engage with the new sustainable crops. 'Interestingly, after being given the information about climate and sustainability issues we saw a shift towards more positive emotions towards the Bambara product and people felt guiltier when eating standard products,’ Yang concludes. •
S
YMBOLS OR WRITTEN age restrictions will be added to labels on alcohol drinks produced by members of the International Alliance for Responsible Drinking (IARD). The initiative, which also applies to alcohol-free extensions of alcohol brands, is one of five actions announced by IARD as part of a new drive to accelerate efforts to reduce underage drinking globally Recognising the growing importance of digital communications, IARD members, which includes AB InBev, Diageo and Heineken, will take further action to prevent minors from seeing or interacting with their brands online. ‘These five actions mark another step towards our goal of eliminating underage drinking. We proactively support strict enforcement of legal purchase and drinking age regulation,’ says Albert Baladi, CEO of Beam Suntory and IARD CEO chair. ‘We call on other producers, retailers and responsible adults to join us. We must ensure everyone reinforces the message that underage drinking is socially unacceptable,’ Baladi exclaims. IARD members include AB InBev, Asahi Group, Bacardi, Beam Suntory, Brown-Forman, Carlsberg, Diageo, Heineken, Kirin Holdings, Molson Coors, Pernod Ricard and William Grant and Sons. •
2020 Quarter 1 | Food Manufacturing Africa
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NEWS
ANSWERING CLEAN-LABEL DEMANDS DUPONT NUTRITION & BIOSCIENCES has introduced its PowerBake 6 000 and 7 000 enzyme series. The enzymes offer an emulsification solution that preserves the taste and quality of white bread and buns while meeting customer demand for clean labels. According to DuPont, the enzymes show an improvement on volume (five to 15 per cent) and initial softness (by 10 to 25 per cent) with zero compromises on crumb structure or shock tolerance when compared with traditional emulsification solutions. This enzyme solution is based on DuPont’s new lipase, specifically developed for its unique role in emulsification and, in particular, its benefits for crumb structure and dough strengthening. The PowerBake 7 000 series is the new DuPont oxidative module developed to ensure the best possible performance in white bread and buns. ‘Consumers are looking for bakery products with friendlier labels, driven by concerns about sustainable eating and heightened concerns of potential negative health effects,’ notes Maria Brandt, the regional industry leader for Europe, food enzymes for DuPont Nutrition & Biosciences. 'With our new PowerBake series, we can provide improver houses and bakeries with the ability to meet these needs while maintaining quality in sliced bread and buns.’ •
UK RETAILER WINS THE BATTLE AGAINST PLASTIC ICELAND IS TRIALLING plastic-free and low-plastic packaging solutions across several of its fruit and vegetable lines. The amount of plastic packaging used on its fresh produce lines has been reduced by 93 per cent. The trial was launched in 33 UK stores on 22 January 2020 and covers 38 fruit and vegetable lines. Products involved in the trial will utilise packaging solutions that are either plastic-free or have significantly reduced plastic content. Phase one of the trial saw 27 products including oranges, peppers and tomatoes launched in redeveloped packaging. A further 11 product lines will be added in phase two, which will launch on 4 March this year. The new trial supports Iceland’s goal to remove plastic packaging from its entire range of ownlabel products by 2023. An estimated seven tonnes of plastic will be removed because of the trial, while up to 440 tonnes could be removed if it proves successful and is rolled out nationwide. ‘We understand that consumers are aware of the amount of plastic being used to package produce across the industry. We’ve been working hard to develop user-friendly, sustainable alternatives,’ said Richard Walker, managing director at Iceland. •
Scientists reveal an innovative way
of recycling plant-based plastics A GROUP OF SCIENTISTS from the Universities of Bath and Birmingham have developed a new chemical method of recycling plant-based plastics. Current recycling methods result in lower quality plastic that must be used for lower grade products such as water pipes and traffic cones instead of beverage bottles. The new method, published in ChemSusChem, converts plastics back into their constituent chemical molecules potentially allowing them to be recycled repeatedly into new plastics without losing quality. ‘Most plastic is currently recycled using mechanical methods, where they are chipped into granules and melted down before being moulded into something
8
new. Melting plastic changes its properties, and reduces the quality, which limits the range of products in which it can be used,’ said professor Matthew Jones from the University of Bath and one of the authors. ‘Our method of chemical recycling overcomes this problem by breaking down plastic polymers into their chemical building blocks, so they can be used again to make virgin plastic without losing any properties,’ he points out. The team’s method uses lower temperatures and more environmentally friendly catalysts than previous methods. It has been trialled on plant-based PLA, which is made from starch or crop waste instead of petrochemicals and is used in biodegradable food
Food Manufacturing Africa | 2020 Quarter 1
packaging. ‘PLA is used as a sustainable alternative for single-use plastics. Whilst it’s biodegradable under industrial conditions, it doesn’t biodegrade with home composting, Dr Paul McKeown from the University of Bath notes. ‘There is no single solution to the problem of plastic waste. The approach must be a combination of reducing, reusing and recycling. Our method of chemical recycling could allow carbon to be recycled indefinitely – creating a circular economy rather than digging more up from the ground in the form of fossil fuels or releasing it into the atmosphere as a greenhouse gas,’ McKeown concludes. •
NEWS
Barentz and Matco Foods enter joint venture
INGREDIENTS DISTRIBUTOR BARENTZ has formed a joint venture with agribusiness Matco Foods, as it targets growth in Pakistan. Located in Pakistan, Matco Foods exports to over 60 countries around the globe from its four
rice processing plants and one rice glucose plant. According to Dutch-based Barentz, the new joint venture will better serve the rapidly growing Pakistani food processing market and will focus initially on human nutrition and pharmaceutical products. The collaboration will utilise Matco Foods’ extended network within the local Pakistani food industry combined with Barentz’ broad ingredients portfolio. ‘We had a good partnership with Matco Foods and we both see complementary business opportunities in the local Pakistani market. ‘Pakistan has a fast-growing economy with a good variety of multinational and local food manufacturers. Our broad ingredients portfolio in combination with Matco Foods’ strong local network will certainly add value to the local life science markets, starting with human nutrition and pharmaceuticals,’ says Hidde van der Wal, CEO of Barentz. Khalid Ghori, CEO of Matco Foods adds. ‘We have invested in processing facilities to produce ingredients such as rice glucose syrup, rice proteins and maltodextrin. Through these activities, we have an excellent insight into and an extended network with the food industry. We are proud to have set up this joint venture with Barentz and to further explore their strong global ingredient portfolio.’ Established in 1953, Barentz has operations in more than 60 countries with a strong presence in Europe and Asia. •
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2020 Quarter 1 | Food Manufacturing Africa
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INDUSTRY TALK
Manufacturing trends
reflect the decade ahead
As we enter a new decade, the only way African manufacturers can stay ahead of competitors and win the market in today’s quickly transforming environment is to embrace change, writes Mark Wilson.
Mark Wilson managing director, Syspro Africa
T
hose who wish to thrive and not just survive are leveraging the latest in growth-inducing Industry 4.0 technologies. The answer is simple: Leverage new technologies and cater to changing customer demands. 1. MACHINE LEARNING & AI Manufacturing is such a massive industry that it can take time for changes to be implemented across the board. The adoption of newer technologies such as artificial intelligence and machine learning will be no different. While progress might be slow within the African manufacturing industry, it is moving towards the ubiquitous use of these technologies. AI, machine learning and advanced analytics offer manufacturers the opportunity to improve efficiency and increase profit margins. These benefits cannot be ignored as the more complexities manufacturers face, the greater the opportunity to use these technologies to get the competitive edge. These technologies aren’t just limited to one area of your business: they can improve your performance in every area. Whether on the factory floor, in your supply chain, or in your customer relations, there are numerous ways machine learning, AI and advanced analytics can improve your business practices. 2. IoT BECOMING MORE PROMINENT Manufacturers are leveraging IoT, which entails the interconnection of unique devices within an existing Internet infrastructure. This can achieve cost reduction and increase efficiency, improve safety, meet compliance
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requirements and product innovation. The increased adoption of IoT will also see an increase in the amount of data that manufacturers produce. Data may be the crude oil of the 21st century, but without the ability to analyse and action based on tangible, accurate insights, it is simply taking up space. This is where artificial intelligence (AI) and machine learning comes in – the ability to manage volumes of data, generate legible insights and proffer solutions will greatly increase manufacturers’ responsiveness, improving efficiency and helping identify new business opportunities. Manufacturers are now understanding that IoT empowers them to make informed strategic decisions by providing crucial, realtime information. 3. CONNECTED FACTORIES Smart manufacturing is the development of a connected ecosystem of people and equipment that communicate in realtime. The benefits of smart manufacturing range far and wide: optimisation of organisational systems, improved product quality, increased efficiencies in the allocation of resources and amplified customer satisfaction. The new factory environment is being advanced by Cloud computing and smart sensors. Smart sensors can convert information into different units of measurements, communicating with multiple machines, while recording statistics and feedback. It can also assist in shutting down devices if a safety or performance issue arises. 4. ATTRACTING AND MAINTAINING TECH-SAVVY EMPLOYEES As manufacturers rely on technology, the need for tech-savvy employees increases. The challenge is that there are not enough skilled employees to fill the number of open jobs. Advocates for the manufacturing industry are educating the next-generation workforce about exciting opportunities for careers in a skilled trade. It will take more than marketing to bring these workers in the
Food Manufacturing Africa | 2020 Quarter 1
door and keep them engaged. The incoming workforce must be part of an organisation that’s innovative, future-proof and understands the need for a collaborative and flexible work environment. What keeps the next-gen worker coming back is the ability to make a difference and contribute to the bottom line. If leadership in your organisation acts as a bottleneck by not providing tools to enable efficiency, you will ultimately lose talent.
“The ability to manage volumes of data, generate legible insights and proffer solutions will greatly increase manufacturers’ responsiveness, improving efficiency and helping identify new business"
5. ADVANCED FOOD TRACKING AND PACKAGING The World Health Organisation indicates that around 600 million people suffer food poisoning every year and 420 000 die as a result. When an outbreak occurs, investigators can spend days or weeks tracking its source. Technology is playing a pivotal role in risk detection as opposed to disaster recovery. This is known as traceability, where technologies such as ERP allows manufacturers to meet consumer demands for food transparency while enhancing the ability to identify, respond to and even prevent food safety issues. While the food and beverage industry is under pressure, changing trends in packaged goods continue to drive growth. German-based VDMA Food Processing and Packaging Machinery Association estimate that just over seven million tonnes of packaged food were sold in South Africa last year. It is expected that demand will rise by six per cent until 2022.
INDUSTRY TALK THE HITS OF 2019 As we enter the new decade, we have the chance to look back at the technologies which after been successfully implemented, have had a positive effect on the African manufacturing industry. The hits of 2019 include: FUTURE-READY SOLUTIONS Advanced technologies, such as enterprise resource planning (ERP) systems hold power to disrupt Africa’s dominant agricultural, extractive and manufacturing industries. This offers the continent unparalleled opportunities to transform and thrive for years to come. Plugging in artificial intelligence (AI) into ERP reduces inaccuracies commonly felt throughout the supply chain, meaning better outputs for the entire business process. Manufacturers must be agile to respond to market demand without increasing costs and waste or sacrificing efficiency. To unlock the sector’s potential, manufacturers should seek out an all-in-one solution that provides them with mobility and constant connectivity. ADOPTING THE CLOUD Mobility is gaining prominence as a concept of Industry 4.0; this is echoed by the fact that 86 per cent of manufacturers
rank cloud computing as important for operations. As technology continues to evolve, we will see a rise in adoption rate within crucial industries. Mobile software for information-sensitive systems such as enterprise resource planning (ERP) allows manufacturers and employees to improve quality of service to customers by providing them with access to relevant information while increasing productivity, planning, forecasting and budgeting, at the touch of a button. THE MISSES OF 2019 While the manufacturing industry is undergoing many changes with the adoption of new technologies, it is important to address some of the missed opportunities and challenges within the African manufacturing industry. The misses of 2019 include: LOW ADOPTION OF AUTOMATION IN SOUTH AFRICA Compared to the rest of the world, the current adoption and impact of industry 4.0 on the African continent remains low. African manufacturers have fallen behind the curve of rapid advances in connectivity that makes advanced technologies possible. Africa has shied away from the adoption of technologies due to fears of job loss, a
popular misconception. 4IR will see further 133 million jobs created in place of the 75 million that will be displaced by 2022. KENYA PRODUCTIVITY REMAINS LOW According to the World Bank, a robust, diversified and globally competitive manufacturing sector can, without a doubt, contribute significantly to increasing the economic growth of the country. With most of Africa’s manufacturers operating under capacity, valuable production time is being lost, and with it, lost revenue. In Kenya engines typically run for 86 days a year, with 50 per cent only running three to five hours a week. If manufacturers increased this to 24 hours, they could easily achieve 12 months of production in just three months, according to a report by Syspro in conjunction with Strathmore University. The manufacturing sector in Kenya has not lived up to its full potential, with its growth trailing that of the overall economy, while its contribution to GDP and merchandise exports have stagnated. • About the author: Mark Wilson is the managing director for Syspro Africa.
Syspro – www.syspro.co.za
Getting Things Done: Our Recipe for Success Food Manufacturing ERP for Movers and Makers of the world. At SYSPRO, we support people who get things done – people like you. It’s why we’re committed to delivering specialist ERP software that can help you track allergens, streamline production across your entire supply chain, improve forecasting and reduce waste. Because we believe that the Movers and Makers of the world are the ones who move us forward. Learn more at www.syspro.com
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2020 Quarter 1 | Food Manufacturing Africa
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COMPANY FOCUS
Digitalise your plant with IO-Link
IO-Link is a standardised communication technology (IEC 61131-9) that shortens commissioning time and allows plug-play device exchange. This technology allows digital accessibility of basic devices.
SIMPLICITY IN THE FIELD ITH EVER-IMPROVING performance and functionalities, instrumentation in the field requires time and knowledge for their selection, sizing and commissioning. Simple operations are thus important for basic functionality sensors. These sensors in the field need to be installed and be able to run autonomously to keep the focus on the major production lines. Therefore, simplicity of installation and minimal maintenance are key.
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"IO-link is a standardised communication technology (IEC 61131-9) that shortens commissioning time and allows plug-play device exchange. This technology allows digital accessibility of basic devices"
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Key benefits of IO-link • Easy and efficient integration, e.g. by using standardised function blocks. • Ideal fit of Industrial Ethernet highend devices accompanied by basic IO-Link devices. • Reduced variety of plugs and cabling, substitution of DI/DO/PNP/NPN/ Pulse/0…10 V / 4…20 mA signals. • Reduced variety of sensors, e.g. configuration of switching points with IO-Link. • F ast commissioning and start-up, e.g. by standardised cabling and automated parameter settings. DIGITALISATION FOR ALL INSTRUMENTS Seamless integration of basic devices is necessary in a digital environment. Endress+ Hauser enables automation of plants with basic and cost-effective IO-Link devices. This allows customers to achieve operational efficiencies while reducing costs. Quite often, entry-level instrumentation is not considered because of their lack of compatibility with the rest of the instrumentation in the field. IOLink is a digital protocol that offers huge improvements in the implementation of basic sensors in the field. The time and cost of project
Food Manufacturing Africa | 2020 Quarter 1
Where hazardous approvals are not required, fit-for-purpose sensors are a good fit in your plant
implementation can be reduced significantly thanks to IO-Link’s open protocol. Each IO-Link device is connected to an IO-Link master that acts as a gateway to a fieldbus such as Ethernet/IP. Since IO-Link is not a fieldbus dependent system, it can be added to existing control systems at a minimum cost. Other advantages of IO-Link technology include the automatic transfer of parameters after a device replacement, as well as low wiring effort compared to conventional wiring. In confined spaces where direct wired communication can be critical, some instruments even feature wireless communication capabilities such as Bluetooth which is included in Endress+Hauser’s Picomag as an example. •
Endress+Hauser – www.endress.com
DAIRY FOOD
Texture control,
stabilisation and xanthan gum The estimated size of the global ice cream market is around 15 billion litres. Consumption patterns vary significantly between countries and regions.
I
CE CREAM IS made up of a complex matrix of frozen foam, emulsified fat globules and suspended ice and lactose crystals. The matrix is highly susceptible to temperature variations. Reducing this sensitivity will help to maintain the quality of the ice cream during storage and improve shelf life. A significant improvement can be achieved by using hydrocolloids to bind water and thereby control the growth of ice crystals. Additionally, hydrocolloids can be used to modify the melting process and mouthfeel. According to market analysis of hydrocolloids used in ice cream, 13 per cent of approximately 14 000 total new ice creams launched (2012 to 2014) contain xanthan gum, while 75 per cent of the newly launched ice creams were milk-based. Xanthan gum is often used in combination with guar gum, locust bean gum and carrageenan, but pectin carboxymethylcellulose and tara gum are also used as stabilising agents.
The hydrocolloids derive from different origins: XG is obtained by bio-fermentation of glucose with Xanthomonas campestris; guar gum is an extract of endosperm from guar beans and LBG or carob is an extract from the seeds of the carob tree. Carrageenan derives from red algae, seaweed or Irish moss. Many hydrocolloids are approved for use in food, registered with the following E-numbers: XG (E415), GG (E412), LBG (E410), CMC (E466), TG (417), pectin (E440) and carrageenan (E407) – often without a defined upper limit, but to quantum satis. FUNCTIONALITY OF HYDROCOLLOIDS AND THEIR SYNERGISTIC EFFECTS When properly hydrated, hydrocolloids increase the viscosity of aqueous solutions. As with water-binding capabilities, the viscosities vary strongly between different hydrocolloids. The hydrocolloid solutions also show varying degrees of non-Newtonian behaviour and they are more
of less shear thinning. In comparison to the galactomannans GG, LBG and TG, XG provides by far the highest viscosity at lower shear rates and the most extreme shear thinning. XG is thus the superior stabiliser, whereas galactomannans provide more thickness and high shear rates. Combinations of xanthan and one or more the galactomannans are known to display synergistic behaviour. This means that the viscosity of the combination is higher than the sum of the viscosities of the individual components. Theory explains that this is due to a special cross-linking of molecules. Xanthan gum has a glucose backbone and every second glucose-unit is substituted with a side chain of mannosepyranosyl – glucuronic acid – acetyl mannose. GG has a mannose backbone with galactose roughly every second monomer. LGB has the same backbone with a galactose on every fourth monomer. The cross-linking effects vary depending
2020 Quarter 1 | Food Manufacturing Africa
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Functionality of hydrocolloids and their synergistic effects
DAIRY FOOD
When properly hydrated, hydrocolloids increase the viscosity of aqueous solutions. As with the water binding capacities, the viscosities vary strongly between different hydrocolloids. The hydrocolloid solutions also show varying degrees of non-Newtonian behaviour and they are more or less shear thinning. In comparison to the galactomannans GG, LBG and TG, XG provides by far the highest viscosity at lower shear rates and the most extreme shear thinning. XG is thus thethe superior stabiliser, whereas galactomannans on structure of the galactomannan. XG and provide more thickness at high shear rates.
GG combinations provide higher viscosity when Table 1: A typical ice cream composition Combinations of Xanthan and one or more of the galactomannans are known to display synergistic behaviour, which dissolved in cold water, whereas XG and LBG only means that the viscosity of the combination is higher than the sum of viscosities of the individual components. Theory INGREDIENT % react when solutions are heated. explains that this is due to a special cross-linking of the molecules.
The synergistic effect between XG and GG is quite Semi-skimmed milk 46.59 remarkable as has visible in picture 1. It shows shear Xanthan gum a glucose backbone andthe every second glucose-unit is substituted with a side chain of mannoseCream 31.00 pyranosyl – glucuronic – acetyl-mannose. curves of 0.5 per cent ofacid the pure products and aGG has a mannose backbone with a galactose roughly on every Sucrose 13.00 second monomer. LBG therate same with a galactose on every fourth monomer. The cross-linking effects combination of both. At ahas shear of backbone around 40/s, Skimmed milk powder vary depending on the structure of the galactomannan. XG and GG combinations already provide higher 4.60 viscosity the viscosities of XG and GG are approximately when dissolved in cold water, whereas XG and LBG only react the solutions are heated. Drywhen glucose syrup 4.00 equal. The viscosity of GG increases only slowly to Emulsifier 0.40 around one Pa.s effect at lower shear rates, whereas the remarkable as it is visible in picture 1, which shows the shear The synergistic between XG and GG is quite Flavour 0.25 viscosity of XG increases to 40 Pa.s. When using 0.5 curves for 0.5% of the pure products and a combination of both. At a shear rate of around 40/s, the viscosities of
Stabiliser 0.16 XGcent and of GG are approximately equal. Thexanthan viscosity of GG increases only slowly to around 1 Pa.s at low shear rates, per a blend containing 25 per cent whereas viscosity of XG 40 Pa.s. When using 0.5% of a blend containing 25% xanthan and 75% GG and 75 perthe cent GG (X1 G3), theincreases resultingtoshear curve Dry matter content 38.70 G3), the resulting shear curve is very comparable is(X1 very comparable to xanthan gum, however with a to xanthan gum, however with a significantly higher viscosity over the whole shear range. significantly higher viscosity over the whole have risen significantly. Even producers and shear range. retailers face problems continuously keeping ice cream at ideal storage conditions. Hydrocolloids are being used to limit the XG, GG and Blend in 1% NaCl after heating negative effects of temperature swings on the quality of the ice cream. These effects can be measured by determining the change in size and frequency of the ice crystals and air bubbles in samples of ice creams using scanning electron microscopy (SEM). Different ice creams were prepared following one recipe where they only the type and dosages of hydrocolloid was varied. Samples of the ice creams were stored at varying, but tightly controlled temperatures according to the protocol for the heat shock 0.5% XG test to mimic a prolonged storage period with 0.5% GG temperature swings. • Pictures 2 and 3 show the microstructure of an ice cream sample by SEM. This sample was stabilised with a standard 0.5% X1 compound containing LBG, GG and carrageenan at G3 a concentration of 0.16%.
Picture 1: 1:The The viscosity viscosity of and a blend Picture ofxanthan, xanthan,guar guar and a blend
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Viscosity (Pa·s)
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0.1
0.01 0.01
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Shear Rate (’/s) Pictures
The synergistic effects vary depending on the hydrocolloids used and the medium production processes (e.g. heating steps). They offer food developers the opportunity to tailor the stability, thickness and mouthfeel of products. For ice cream production, manufacturers often use a stabiliser system, which is specifically tailored blends of different hydrocolloids, sometimes in combination with some emulsifiers. These combinations will obviously vary depending on whether the final products are dairy-based ice cream, sorbet or lollies. Specifically, for dairy-based ice creams, the blends may also contain a small fraction of carrageenan. This ingredient is very compatible with milk proteins and can develop a gel structure, even in low concentrations. Stabiliser blends are typically used in the range of 0.1 to 0.3 per cent of the total ice cream formulation. Table 1 shows a typical ice cream composition. The individual ingredients can vary widely. The total dry matter is mostly maintained in a rather narrow range as its variation can easily make the texture hard, crumbly or too cold. ICE CREAM HEAT SHOCK TEST AND STRUCTURE ANALYSIS Elevated temperatures may inflict irreversible damage to the delicate gas-liquid-solid structure.
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2: First day sample stored at -40°C test
*This is an abbreviated version of a white paper by Jungbunzlauer. For more Pictures 3: 14th day sample after heat shock information, please contact Savannah Fine Chemicals.
Consumers will not store the ice cream continuously at -20°C. It2 must takenthe from the freezer to be Pictures and 3beshow microstructure of an ice cream sample by SEM. This sample was stabilised with a standard compound containing LBG, GG and at a concentration of 0.16%. consumed and before any left-overs arecarrageenan returned Savannah Fine Chemicals – www.savannah.co.za to the freezer the temperature of the ice cream may Pictures 2: First day sample stored at -40°C test Pictures 3: 14th day sample after heat shock Table 1
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black spots: small air bubbles
greyish spots: ice crystals
liquid concentrate
Pictures 4 and 5 show the microstructure of an ice cream sample by SEM. This sample was stabilised with a compound containing XG, LBG in a ratio of 25:75 and a concentration of 0.16%. black spots: small bubbles greyish ice crystals liquid concentrate Pictures 4: First dayair sample stored at -40°C test spots:Pictures 5: 14th day sample after heat shock
Pictures 4 and 5 show the microstructure of an ice cream sample by SEM. This sample was stabilised with a compound containing XG, LBG in a ratio of 25:75 and a concentration of 0.16%. Pictures 4: First day sample stored at -40°C test
black spots: small air bubbles
Food Manufacturing Africa | 2020 Quarter 1
Pictures 5: 14th day sample after heat shock
greyish spots: ice crystals
liquid concentrate
The SEM pictures clearly show that the solid particles and air bubbles are on average smaller than 50 µm in both fresh ice cream samples (day 1). The range of diameters after hardening confirms previous studies that suggested a mean
DAIRY FOOD
Dairy foods’ inline insurance policy Contamination of a product with foreign objects is a permanent threat to the dairy sector. Its implications can be deeply unpleasant for consumers and manufacturers.
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OOD SAFETY IS enforced through a raft of regulations and legislation. Responsibility begins in the field and ends long after the point of sale. Contamination can occur at any of these points: from processing machinery, factories, transportation or through the addition of non-dairy ingredients. In the dairy industry, legal and reputational risk extends to processors, manufacturers and retailers who have a vested interest in keeping dairy products contaminant-free. For dairy producers that supply major retailers, the risk is particularly acute. Retailers may impose substantial fines or other penalties when contamination with a foreign object occurs. OPTIONS IN CONTAMINANT DETECTION There are a wide variety of options available, but two main technologies stand out: • Metal detection – used since the 1950s • X-ray technology – a more recent innovation and an excellent way to enhance technical performance to prevent foreign body contamination. Metal detecting machines have several advantages. They are established, reliable, easy to maintain, require low initial investment and are simple to install. For those smaller independent businesses, metal detection offers an ideal method of quality control. If a dairy product is contaminated with stones, glass, plastics or rubber, a metal detector will let the product go through. Detectors may also have problems finding metals according to its ferrous or non-ferrous nature. It is easier for these units to pick up a ferrous metal than a non-magnetic metal such as stainless steel. While a metal detector may find a ferrous metal particle of 1.5mm, a foreign body made of stainless steel may have to be three millimetres or greater to be detected by the same machine. Metal detectors can also detect problems with items packaged in metallised packs, such as foils for yoghurt pots or packages insulated with metallic materials. These limitations are significant in the dairy sector, where foreign objects often
reach foodstuffs from factory processes i.e. rubber seals falling from machines, or in products such as yoghurt with added fruit sections. Protective and foil packaging are also likely to increase as demand for long-shelf life products continues to grow. The question to ask then: how can the dairy industry improve on quality control offered by traditional metal detection systems? X-RAY TECHNOLOGY These systems measure the density of a product as it crosses the inspection area. It creates an image that is analysed to identify a foreign object. Like metal detection, X-ray technology can be applied during production; in bulk flow materials prior to packaging and to packaged retail goods before shipping. While X-ray won’t necessarily detect every possible contaminant, the technology does provide a wider detection spectrum than metal detectors and will pick up stone, glass, dense plastic/rubber and metal. It can pick up contaminants that have a greater density than water (1g/cm3). The technology is versatile and can assist in counting, weight estimation, detect fill levels, identify product flaws and ensure packaging integrity. PRIMARY PROCESSING OF CHEESE Many processes are required to produce cheese and each of these has a risk of adding foreign bodies. This normally occurs during processing i.e. rubber sealing ring failure from mixing equipment, pipework or metal from poorly adjusted cutting or blending processes. The high level of operator intervention during processing also carries foreign body risk. While rubber may be present in the block at this point, detection may not be possible due to the relatively low-density differential between the depth of the cheese block and the material requiring detection. At the primary phase, cheese must be checked for any metal contamination to protect the integrity of the cutting blades. Metal detectors are commonly used in this instance because of the large block size. A larger aperture metal detector is required, which reduces potential sensitivity.
This, coupled to the salt and moisture level in cheese, means detection limits are high - typically around 5.0mm or greater for stainless steel. Even a piece of metal of three to four millimetres will do significant damage if in contact with cutting blades. An X-ray, on the other hand, can provide detection down to 1.5 to two millimetres on the largest blocks and down to one millimetre in most cases. This provides a much higher level of protection. For operations producing grated cheese, the challenge is probably the greatest. The final product offers a high variable density as the strands overlap and combine with each other. Here the differential with metals is still large. Due to the lower height and overall density of the metal, detection levels achievable with X-ray are impressive and consistently below 1.0mm - below 0.6mm level in most cases. The varying nature of the product does mean that lower density contaminants are more difficult to detect. Rubber seals, having passed through the grating process are unlikely to be detected. SHOULD YOU INVEST IN TECHNOLOGY? Suppliers seeking to invest in quality control equipment must consider factors such as the nature and volume of their products, the nature of foreign body contamination, customer demand and contractual obligations. This should be offset against the perceived nature and impact of a contamination incident and the company’s tolerance of risk. Using X-ray technology to detect foreign bodies in dairy products can assure the quality of food produced, acting as an insurance policy against prosecution and brand damage. It can also give suppliers a real competitive edge. By using X-ray to exceed the standard demanded by customers, companies can demonstrate their commitment to quality while assuring potential clients they can cope with demanding specifications. •
Ishida’s range of X-ray systems
Ishida – www.ishida.com
2020 Quarter 1 | Food Manufacturing Africa
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FOOD SAFETY PRACTICES
Hygienic food production with pressure sensors and level switches Food production is a matter of trust, and hygiene is the number one priority in the manufacturing process. Success is determined by the reliability and efficiency that make flawless production possible – whether during bottling, container filling or CIP cleaning.
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HIS MAKES IT important for plant operators to rely fully on the measurement technology employed. Level and pressure sensors from Vega have made a name for themselves over many decades for reliability and longevity. Robust, versatile and easy to use: even under extreme conditions or strict regulations, these instruments provide important inputs for delivering greater plant safety and efficiency. COMPLETE SUPPLIER FOR LEVEL AND PRESSURE Vega completes its measurement technology portfolio for food production with two new compact instrument series, comprising of pressure sensors and level switches. The products, Vegabar and Vegapoint, prove that automation can be simple and highly efficient without compromising dependability, hygiene or accuracy. The new measuring instruments are perfectly tailored to standard applications that still demand the highest quality. Their standardised hygienic adapter system
Vegabar compact pressure sensors with switch function and Vegapoint capacitive level switches are tailored to standard applications
provides the flexibility needed to reduce and keep installation work and parts inventory at a minimum. The process fittings can be selected as needed and adapted to local requirements. 360° SWITCHING STATUS DISPLAY With all-round switch status display, all sensor states can be visually discerned from any direction. The colour of the illuminated ring, which can be customised from over 256 different colours remains clearly visible, even in daylight. The user can see if the measuring process is running, if the sensor is switched or if there is a possible malfunction in the process. INTELLIGENCE WITH IO-LINK There is a lot of sensor intelligence built into the new compact series: the standard IO-Link protocol ensures both a universal and particularly simple system of communication. This means the instruments have a standardised communication platform that enables seamless data transfer and simple system integration.
256 colours Individually selectable: Measurement in progress Sensor switching Process malfunction
EVERYTHING’S EASIER WITH WIRELESS The new Vegabar and Vegapoint instrument series can be easily read out and configured with a smartphone or tablet. Device setup and operation become considerably easier, especially in environments such as clean rooms, where physical access involves a lot of effort. Vegabar pressure sensors and Vegapoint level switches represent an important milestone for the company. Users have access to an entire range of level and pressure measurement technology from a single source. Hygiene-optimised instrument designs are extremely easy to install and an application-based combination of reliability, flexibility and reproducibility in the food production process. •
Vega - www.vega.com/food-industry.
We bring colour into view! Compact pressure sensors and switches with 360° custom-colour status display
www.vega.com/vegabar
AD-VEGABAR-Clamp_177x65+5_EN-ZA_ohne-Preis.indd 1
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Food Manufacturing Africa | 2020 Quarter 1
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FOOD SAFETY PRACTICES
Committed to
industry best practise No retailer or brand owner worth its salt will consider business with a supplier that cannot prove its certification to a global standard. Certification enables your business to implement change, improve management systems and build your future success.
numbers exercise. Small, medium and large organisations will require a system assessment that will ensure the application is appropriate for the business in question. SCHEDULE A TRAINING CALENDAR A breadth of learning options that meet market needs and delivered via a range of training modes will add defined value and solid outcomes to you and your business. MANAGE YOUR SUPPLY CHAIN COMPLIANCE You can ensure this through advanced software options, which help you track and monitor supply chain compliance to the relevant standards and requirements that dictate your organisation’s risk management system.
Food safety auditing and certification from NOSA
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RC Global Standards for Food Safety (BRC) is one such an example. BRC was first introduced in 1998 and is regarded as one of the benchmarks for best practice in the food industry. It has evolved into the framework on which many companies base their supplier assessment programmes. This has extended from just manufacturers of private branded products to ingredient manufacturers and co-packing operations. In certifying your organisation within this standard, you automatically meet the fundamental requirements associated with senior management participation; adoption of HACCP; a documented quality management system and control of your environmental standards, processes and personnel. FIVE BENEFITS OF CERTIFICATION Clarity: It contains well-defined requirements built within a clear certification process. Credibility: An experienced technical services team, with worldwide reach, offers peace of mind through continual customer support.
Collaboration and continuous improvement: Multiple technical experts and committees regularly review the standard to ensure continuous improvement and to ensure the standard remains current with food safety trends. Consistency: A global training infrastructure allows for localised, language-based training and auditing teams, with standardised audit reports with a global application functionality. Confidence: Through a robust performance, the standard’s monitoring assessment tools and transparent process of logging complaints help to maintain the rigorous requirements for auditors’ competence, qualifications and experience. Much like the happy ‘ending’ of every fairy tale this is in fact just the beginning. Your certification is the first milestone in your continued pursuit for business excellence. FIVE WAYS TO ENFORCE YOUR COMMITMENT TO INDUSTRY BEST PRACTICE • Enlist the services of exceptional auditors The right auditors will understand that applying a standard is not a paint-by-
• Enlist global support How best to apply a global standard than with an ongoing conversation between you and your global partners? By enlisting the help of a global certification leader, you will enable your organisation to grow and change through food safety programmes. Through the assistance of experts in the fields of quality; environment; aerospace; automotive; medical devices; health and safety, as well as many other industries are impacted. • Implement appropriate food safety programmes By observation of and alignment to the following food safety programmes you are making a clear statement of your commitment to food safety best practice: • ISO (e.g. 22000, 9001, 14001) • HACCP • GFSI Standards (BRC/SQF/IFS) • GlobalGap. For a full discussion around potential certification services, please contact NOSA Testing, Inspection and Certification (TIC). •
NOSA – www.nosa.co.za
2020 Quarter 1 | Food Manufacturing Africa
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ALCOHOLIC BEVERAGES
Membrane de-alcoholisation unit GEA's AromaPlus membrane de-alcoholisation unit was installed at the Laitilan Oy's brewery plant at the end of 2019
for alcohol-free beer
There are several different methods for producing de-alcoholised or non-alcoholic beer. Laitilan Wirvoitusjuomatehdas Oy (Laitilan) brewery in Finland knew it wanted to avoid wort-like flavours and achieve the best results when it came to taste and quality.
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N INDEPENDENT brewery in operation since 1995, Laitilan has grown to become Finland’s fourth-largest brewery. Its Kukko beer is the world’s first full-malt beer to receive the international gluten-free product trademark in 2005. The brewery produces speciality beers, ciders, sparkling wine, soft drinks, waters and long drinks – which totalled more than 20 million litres in 2019. DEALCOHOLISATION WITH REVERSE OSMOSIS During a separator installation at the brewery in 2017, plant manager Tommi Suutari asked GEA about possible solutions for beer de-alcoholisation. GEA had just developed and launched a new process using membrane filtration. Built on GEA's membrane filtration technology, AromaPlus works via reverse osmosis (RO). This allows alcohol and water to move through while retaining essential ingredients that contribute to aroma, colour and turbidity. The system achieves the required alcohol-free percentage of 0.5 per cent – down to 0.05 per cent.
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Several brewing frontrunners have chosen AromaPlus as it delivers in terms of cost and excellent tasting results. COLD PROCESSING RETAINS FLAVOURS The cold process with membrane filtration has less impact on beer flavour and aroma is maintained when compared to dealcoholisation methods, which rely on thermal processes. After a visit to one of the first producers of dealcoholised beer using the AromaPlus, the Schönbuch brewery in Stuttgart, Laitilan was convinced. GEA product manager Ralf Scheiber explains, ‘We put a lot of effort in developing the new AromaPlus process. We’re seeing that demand for non-alcoholic beer is increasing. Our solution has been well-received and is very much appreciated by breweries and consumers.’
Food Manufacturing Africa | 2020 Quarter 1
UNIT DESIGN AND LAYOUT The de-alcoholisation unit is mounted on a frame and comes ready for installation. It includes the filtration modules fitted with the special AromaPlus reverse osmosis membranes. The system features pumps for media transport or for providing the required system pressure, internal piping and a CIP dosing unit are installed next to the unit. It also features control technology for semiautomated operation. In addition to the process, the controller also manages cleaning-in-place (CIP) of the system to ensure proper operation and reliable cleaning of membranes. The modern GEA AromaPlus units have a standardised layout. Depending on size, they are designed for batch processing from approximately 50 hectoliters to more than 600 hectoliters per day. GEA also offers larger dealcoholisation units for continuous processing of more than 50 hectoliters per hour. The brewery's de-alcoholisation plant was installed at the end of 2019 with the new products launching early 2020. ‘We're looking forward to starting up with the new products, and we believe that the new equipment will be working hard from the beginning of the year,’ concludes brewmaster Ville Vilen. •
GEA – www.gea.com
ALCOHOLIC BEVERAGES
Complete can line for greater capacity and preserved beer quality
Bali Hai Brewery, situated in Indonesia, approached Sidel to install a new canning line. The aim was to secure a higher production capacity while maintaining the quality of its premium beers.
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ESIGNED AND SUPPLIED by Sidel, the line runs at up to 33 000 cans per hour for the 330ml format, twice as fast as the former line. It features a very compact layout - in line with the brewery’s space constraints. Bali Hai Brewery Indonesia has been developing and distributing a distinctive range of beer brands for the national and international markets since 1975. ‘Currently, our products are sold in more than twenty countries, including Russia, Singapore, Thailand, Japan, Korea and New Zealand,
and in different regions of Africa. We are committed to maintaining the consistent taste and quality of our beers,’ explains Daniel To, technical director at Bali Hai. With a domestic market share of 3.2 per cent in 2018, the family-owned company is the fourth largest domestic brewery. It offers a portfolio that speaks to consumers’ preference for local and premium beer brands. These include Bali Hai Premium, Draft Beer, El Diablo Original and Panther Black. Regardless of strong Indonesian regulations to control alcoholic
drink consumption, the beer segment in the country is showing a positive trajectory. It is set to register at seven per cent total volume CAGR to reach 324 million litres by 2023. To keep up with this growth, Bali Hai decided to invest in a large-scale project. Their journey started when the facility underwent a major renovation and automation of its brewhouse and cellar area in 2013. Many of these processes were still performed manually. The brewery also decided to upgrade its canning line, managing 330ml and 500ml formats to fit their needs for higher efficiency. Sidel stepped in with its expertise in line design
2020 Quarter 1 | Food Manufacturing Africa
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ALCOHOLIC BEVERAGES 1, 2, 3, 4: The complete canning line system has a capacity of up to 29 000 cans per hour in the 500ml format and 33 000 cans in the 330ml size
and engineering, deriving from a longstanding heritage in complete solutions for beer. 360° SUPPORT ROOTED IN COMPLETE BEER LINE EXPERTISE ‘The floor space available at our plant is limited. We needed a very compact solution that did not compromise on efficiency and flexibility,’ To explains. The project started with the search for the right location within the site, always considering the need for additional capacity. ‘We were initially planning a line that could deliver 24 000 cans per hour (cph) for the 500ml format. We trusted in Sidel’s engineers and went for a complete line that can reach up to 29 000cph, thereby securing high capacity production for years to come,’ he notes. There were several important reasons for the Indonesian brewer to put its confidence for such a large-scale revamping in Sidel. ‘We appreciated the local service support and the time that the team took to understand and analyse our requirements. Thanks to their highly competent and responsive engineers, the installation of the line were completed in a short period,’ To enthuses. ‘Bali Hai can run the new canning line in three shifts, while the old one only allowed for a maximum of two.’ PROVEN FILLING AND PASTEURISING SYSTEMS FOR FULL CONTROL The complete canning line includes 13 different machines, laid out in six larger production modules: the de-palletiser, filler and seamer, pasteuriser, dryers, shrinkwrapper, tray shrink-wrapper plus conveying systems. Bali Hai’s goal of protecting beer quality was achieved through the integration of two specific solutions in the line: the latest Sidel volumetric electronic filler for cans and the PAMA pasteuriser. When explaining the rationale behind the choice of the filler, Blegog Sugiono, packaging manager at Bali Hai, highlights, ‘We opted for Sidel's filling technology because of the very low total oxygen pick-up. This ensures high product quality. We use volumetric technology to guarantee that our cans are filled to the correct capacity, and there is no product waste.’ The PAMA pasteuriser features Sidel’s unique Prince Plus software. It offers ideal control of the pasteurisation unit (PU) and was specifically tailored to Bali Hai’s requirements. ‘We decided to install this system to have a constant level of quality and consistent taste across our beers. We could cool down the can temperature at the outfeed of the pasteuriser, thereby eliminating the risk of unstable quality. With the latest technology, we can narrowly adjust and control the PU following the specified
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settings for a fully controlled beer taste,’ Blegog enthuses. By maximising the size of the pasteuriser, Bali Hai can also welcome future production increases.
“The complete canning line includes 13 different machines, laid out in six larger production modules: the de-palletiser, filler and seamer, pasteuriser, dryers, shrink-wrapper, tray shrink-wrapper plus conveying systems”
FLEXIBLE AND COMPACT TO HANDLE A WIDE VARIETY OF SKUS The canning line runs twice as fast as the brewer’s old line. The output became three times bigger, growing from 500 to 1 450 trays per hour. With two different can formats (330ml and 500ml); nine different recipes and various secondary packaging options, the number of SKUs handled by Bali Hai’s canning line lies at 18. This required a high level of flexibility at the secondary packaging stage. The brewery also decided to shift from RSC cases to film for economic benefits. To do this, they installed a Sidel EvoFilm Access. This is a seamless shrink-wrapping solution for low to medium speed applications. They wanted to widen the secondary packaging solutions offered to customers, including multipacks. Blegog comments, ‘With the new line, we have a sophisticated tray and film solution that we can apply to produce
Food Manufacturing Africa | 2020 Quarter 1
various packing alternatives. For example, four- or six-packs wrapped on one tray containing a total of 24 cans can run on one solution. If multipacks are not requested, products can bypass the tray and film packer directly to the shrink-wrapping system.’ A modular design concept allows for a broad array of configurations and options. EvoFilm Access offers expanded flexibility. ‘We added some tailor-made options to fit Bali Hai’s needs,’ Stéphane Séné, key account manager at Sidel explains. ‘A design to cost approach has been applied to deliver the best quality-price-performance ratio available on the market for shrink-wrapping at speeds of up to 60 cycles per minute. We also implemented a simple conveying solution to feed the shrink-wrapper.' The customer could save factory floor space, which is now dedicated to warehouse purposes. 'We removed the need for a divider by orienting the lanes of cans differently. Customers can now manage eight pack configurations easily and efficiently. The system can manage both packs and loose cans,’ he adds. The ease of operations brought by Sidel’s end-of-line solution became instantly clear when, after its integration, no specific training of the customers’ operators was required. ‘By operating Sidel solutions in our brewery, we expect to fulfil market demands while providing excellent quality products. We are very satisfied with the performance of the recently installed complete line. We believe the best beer is produced by the most qualified people and packaged with the best machinery. For that, Sidel is the solution,’ Daniel concludes proudly. •
Sidel – www.sidel.com
PACKAGING AUTOMATION
Artificial intelligence at the edge
Cloud computing is defined as the storage, management and analysis of data saved remotely on a server. Although invaluable in many instances, is it always the best solution for the production line? Food Manufacturing spoke to Victor Marques country general manager of Omron Industrial Automation to find out.
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NOTHER PROMISING ALTERNATIVE is edge computing. This system enables data storage, applications and analysis to be carried out at the edge of a machine. Lines and devices are monitored and real time sensors and data at machine level can be processed in microseconds. A machine’s condition can be monitored in real time, but data volume is limited. Data processing at the edge enables an immediate response. Industrial manufacturers need to think carefully before deciding which of these two options will be the most effective. They must consider the recent arrival of solutions involving artificial intelligence
(AI) and machine learning (ML). Although AI offers some great benefits, care needs to be exercised before incorporating it into industrial applications WHAT’S YOUR PROBLEM? The biggest challenge companies face is that they often can’t identify the problem they want to solve. The solution is to start collecting and cleaning data first, before thinking about introducing AI. You can then obtain information from the data and start visualising this in a smart way. Basic data science will help your company to start realising a range of benefits. A lot of existing data isn’t suitable for
analysis, however. If you’re thinking about AI, you must think in a broader sense about data science - what and how much data you need. You will require a substantial amount if you want to reach the right conclusions. You can apply AI at various levels, depending on the problem you want to solve. If you want to compare the performance of two factories, you can gather the data and put it into the cloud (inside or outside your enterprise) and compare, analyse and draw conclusions. The main challenge remains: what problem do you want to solve? Do you need to look at a lot of data? If you want to compare a large amount of data from 20 factories, this is where AI in the cloud can play a key role. If
2020 Quarter 1 | Food Manufacturing Africa
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PACKAGING AUTOMATION
you need an immediate reaction on a bottling line for example to avoid downtime, you should consider a solution with AI at the edge. ACCESS AND MAKE THE BEST USE OF YOUR DATA Machines within a factory are a potential source of valuable data. How can a manufacturing plant make the most effective use of this data, especially when introducing AI to enhance its capabilities? The key questions that need to be addressed are: •D ata - Do I have enough – and if so, which is the most relevant and how will it be used? • I nfrastructure - How much will the set-up cost? •O utcomes - What problem do I need to solve and what increase in efficiency can be achieved using cloud or edge computing?
"Edge computing within an industrial manufacturing environment looks at the actual process within the machine"
Some manufacturing facilities might decide to send all data to the cloud. Large IT companies are promoting the cloud as a solution to everything. It isn’t a complete panacea however, as it doesn’t show or respond in real time to what is happening in the machines. This is one reason why Omron decided to focus on this area. The company has been developing tools to help the human brain to cope with the challenges of what is happening inside the machines – along with details of downwards analysis and pattern recognition.
Edge computing within an industrial manufacturing environment looks at the actual process within the machine. Real time data processing at the edge enables an immediate response to an abnormal situation in a process. With AI at the edge, manufacturers can control complexity and security. With edge computing, data and computing resources are located close to the machines. This enables users to gain real time information about the efficiency of different aspects of their industrial automation system. This means that they can access intelligence within the machine, which in turn enables a deep analysis to be carried out. This information is scalable and measurable and enables the factory to achieve a significant increase in its overall equipment effectiveness (OEE). Manufacturing companies are starting to recognise that AI can make a major contribution to their profitability by increasing their OEE. This, in turn, will lead to greater productivity and lower costs. Omron’s AI Controller has some preprogrammed tools that can help with simple cases of preventative maintenance. Using advanced mathematics, it can detect a problem or a deterioration in part of the equipment before a machine breaks down. With complicated machines and problems which involve detailed use of AI, you will need specialists with advanced skills (such as data
scientists and software engineers) to extract maximum value from this new technology. ISSUE 3: HOW SECURE IS YOUR DATA? Using the cloud can cause problems in terms of security, particularly in relation to compliance with the latest IEC 62243 cybersecurity standards. These are becoming very important in industrial situations, and relate to the security, safety and integrity of the components and systems used within industrial automation programmes. In contrast, edge computing within the factory provides another level of security, as the data resides within the machines. The whole industrial automation process can be secured using solutions such as intruder detection, video monitoring and access control systems. In a traditional machine control environment, it has been impossible to programme a machine to recognise microsecond skill patterns. Potentially all machines have this information, but until recently it has been ignored. The introduction of AI solutions at the edge inside the machine provides you with tools that enable you to look at that data. Advances in technology mean that you can have machine control equipment that will process data and recognise patterns within it. • Omron – www.industrial.omron.co.za
Superior image sensing speed and precision FH Series
• High-precision object detection • Ultra-high-speed searching • Flexible functionalities to provide high compatibility with manufacturing machines
Would you like to know more? +27 (0)11 579 2600 info.sa@eu.omron.com industrial.omron.co.za fh_series_177x65_ad_enza_01.indd 1
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