IDM 8-9 September 2019

INTERNATIONAL IDM 8-9 September 2019

PROCESSING INGREDIENTS PACKAGING IT LOGISTICS www.international-dairy.com Unbenannt-3 1 19.08.19 14:25 Editorial ¦ IDM Seize opportunities when they open up

Substitutes promise enormous sales potential

You don't have to stand behind everything, you don't even have to understand everything that has developed in society – and thus also in eating patterns – or that is just beginning to emerge. But one should take note of the fact that the dairy markets are on the verge of revolution. Alternative products are increasingly replacing traditional dairy products. Here, completely new sales opportunities have long since opened up for milk processors, which they should use accordingly. Each company must decide for itself whether these opportunities are to be seized – and above all argue this internally.

According to Persistence Market Research, sales of vegan "cheeses" will grow by an average of 8.6% per year until 2028. Future Market Insights forecasts that global sales of alternative Roland Sossna dairy products will rise to US$24.6 billion by 2029, with a CAGR of 8.3%. Hexa Research Editor IDM expects the global market for vegan "yoghurt" to reach US$ 2.53 billion in 2015, with aver- International Dairy Magazine age growth of 16.4% per year. [email protected] international-dairy.com Even if there is some sales promotion for the usually expensive market studies behind such sometimes somewhat sensational forecasts, it is still big numbers that are offered here. Against the background of declining sales figures in some dairy submarkets, such as coffee cream, liquid milk or fruit yoghurt, the segment of alternative products offers itself to be processed by dairies. Who else would have so much know-how, capacity, experience in competitive markets, marketing power and quality philosophy to contribute to substitute production? And the milk processors also know that the products must taste good in the end. The market opportunities are therefore there. But whether they can be used depends on a number of factors. First of all, the orientation of a milk processor – for manufacturers of traditional, possibly protected mopro, there is hardly likely to be a way into the vegan/veg- etarian world. In addition, there is the question of whether a dairy has a strong brand that almost automatically has the association with milk and nothing else. Different products from such a house would simply not be credible. Existing brands can only be used if they already have a strong anchoring in the modern lifestyle, which is true of very few Mopro brands. So in many cases there is only one new foundation left, with all the known risks.

Hardly any consumer switches completely to vegan, most simply seek variety or want to consume animal products less often. And the worldwide milk market is anyway on growth course. So no one doesn‘t have to worry if parts of the dairy industry are also working the alternative field, says Roland Sossna.

8-9 2019 ¦ international-dairy.com · 3 IDM ¦ Content

26 Repeatable across multiple 30 Cooling tower optimi sites zation Packaging Technology/IT

16 Digitization of dairies Interview

28 Personalized nutrition 36 Fermented dairy powders 38 Once again a pioneer Interview Ingredients Site report

Columns:

7, 15, 19, 24, 47 Imprint 43, 44, 45 News 47 Preview IDM 10 2019 46 Suppliers guide

4 · 8-9 2019 ¦ international-dairy.com Content ¦ IDM

Editorial: 3 Seize opportunities when they open up

Cover Page: 32 The rewards of hygiene: higher cheese yield

High-performance packaging machines with inline Interview: sterilisation systems for all packaging materials for 14 Better and hygienic solutions a gently ﬁ lled product under aseptic conditions. 16 Digitization of dairies 28 Personalized nutrition

Site report: 38 Once again a pioneer

Country report: Form-Fill-Seal Machine 8 Investment in the African Dairy Industry » up to 200,000 cups/h » in-mould cup labelling device Market report: » machine integrated sleeving system 6 Global Market for Infant Formula and Dairy Ingredients 2019-2023 12 Animal protein sources prove more popular than plant protein sources 20 Trends and developments in the ice cream market

Technology/IT: 15 New control unit for D4 Series valves Cup Fill and Seal Machine 24 Fast lane service » up to 58,000 cups/h » fl exible and easy format change 30 Cooling tower optimization » simultaneous fi lling of different fl avours

EDA Column: 42 Shaping the EU Dairy Landscape

IDF Column: 40 IDF issues guidance to help determine milk fat purity

Bottle Fill and Seal Machine Ingredients: » up to 46,000 bottles/h 19 Solution for vegan and plant-based beverages » compact linear machine design 36 Fermented dairy powders » for glass and/or plastic bottles

Packaging: Finnah Packtec GmbH | Einsteinstraße 18 | D-48683 Ahaus 22 Complete lines for dairy products and spreadable fats info@ﬁ nnah-packtec.de | www.ﬁ nnah-packtec.de 26 Repeatable across multiple sites

8-9 2019 ¦ international-dairy.com · 5 IDM ¦ Market report 3A Business Consulting

Global Market for Infant Formula and Dairy Ingredients 2019-2023

he Infant Milk Formula (IMF) While baby food in total grew by market amounted to more 2% annually from 2013 to 2018 in than USD 54bn and 2.6 m volume, the infant formula volume – plus a large number of regional and MT in 2018. The growth of grew 3% annually. The infant formula local companies. Dairy companies sup- the market between 2013 volume is expected to grow slightly ply ingredients, base powders as well Tand 2018 averaged at 7% p.a. in value. stronger than total baby food volume as complete infant formulas for the IMF According to a new market anlaysis by towards 2023 at 2%. companies, and some dairy companies 3A Business Consulting, the market val- The infant formula industry is domi- also market IMF directly to consumers. ue is expected to further grow by 6% nated by four global companies – the Nestlé and Danone are key play- annually to reach approx. USD 73 bn 'Big Four' – (Nestlé, Danone, Mead ers in all 4 IMF categories while Reckitt and more than 2.85 m MT by 2023. Johnson/Reckitt Benckiser and Abbott) Benckiser and Abbott have their relative strength in the Formula-1 and Formu- la-2 product categories. Reckitt Benck- iser also has a particular strength in the special infant formula category. Besides from the "big four" the IMF market is fragmented with regional companies such as: Heilongjiang, Yili, Biostime, DMK, Sodiaal, Lactalis, Hipp, Hero, Frie- slandCampina, Arla, Heinz etc. The growth is mainly driven by Asia. Key driving forces for the IMF market include economic and population growth in emerging markets resulting in a larger middle class and an increasing number of women in the work force.

Future trends in IMF ingredient usage Infant formula manufacturers are constantly aiming at developing products as close to human milk as possible including the amino acids composition. Some research suggests that excessive protein intake in babies is likely to lead to obesi-

6 · 8-9 2019 ¦ international-dairy.com News ¦ IDM

Mould manufacturing COMEP was created in 1998 to focus on the design and manufacturing of moulds improved for PET bottles. Based in Salles-d’Angles, Sidel France, with more than 20 years of experience in this industry, COMEP produces Sidel has taken over Cognac Moules Em- over 4,000 moulds per year for custom- ballages Plastiques (COMEP), a French ers around the world. With around 60 producer and designer of moulds for PET, employees, they were a first mover in adding further strength to the group in the low blowing pressure technologies. the manufacturing of moulds and tooling. sidel.com

November 12 –14 PERFECT Hall 8 ty. This has led to some major IMF companies to advise lower minimum protein requirements and instead focus on the nutritional value of included proteins. SOLUTIONS In the future, the whey:casein ratio may further work to the advantage of whey proteins – staging IMF. DO NOT STOP Long-term infant formula manufacturers may favour high protein content US FROM WPC usage over demineralised whey CONTINUING TO powder. Such a development may ben- WORK ON OUR efit the use of lactose. Ingredients with proven science- IDEAS. backed bioactivity is of high interest e.g. lactoferrin, osteopontin, siallyllactose etc. The report focuses a lot on innovation in the IMF market, analysing trends, NPD and regional as well as global developments. 3A has identified a number of key future ingredients such as hydrolysed proteins, GOS, alpha-lactalbumin, lactoferrin, Milk Fat Globule Membrane (MFGM), milk phospholipids, sialic acid and sialyllac- tose, Igs, osteopontin, LC PUFA's, pro- biotics, FOS and HMO.

More information: 3A Business Consulting, Marselis Boulevard, DK-8000 Aarhus C, Denmark, As a leading innovator, we have one prime Phone: +45 70 21 00 98, Mobile: +45 40 18 48 35, characteristic: We are never satisﬁ ed.

Web: www.3abc.dk At KHS, we are thus always proud of what we have achieved – but we also immediately start to question it and think ahead. With the aim of constantly advancing and always improving – and of providing our customers with new, intelligent systems time and again. Which we then, of course, develop further. khs.com/products

khsIM5021_AZ_Markenkampagne_Podest_139x200_ICv2_2ml_englisch_BrauBeviale.indd 1 29.08.19 09:45 IDM ¦ Country report Investment in the African Dairy Industry

Profiles of the Leading Dairy Companies in Africa

Author: Brian McNulty, Brian McNulty and Associates. Brian McNulty has been researching dairy markets in Africa and the Middle East for twenty years. His extensive research and consulting experience in International dairy markets (with projects completed in forty seven countries including seventeen in Africa) provides a unique perspective on the African dairy industry. For full details of the report contact Brian McNulty and Associates at: [email protected]. The report is available from Research and Markets, www.researchandmarkets.com.

n recent years there has been significant investment in the African dairy industry particularly by international dairy companies. Collectively a relatively small number of companies have established an extensive dairy footprint across the continent. The twenty largest and most Iinfluential dairy companies in Africa have been identified and the development of their business on the continent is outlined in a significant new publication from Brian McNulty and Associates (www.bmna.ie). The twenty include eight of the world's largest dairy companies as well as the two largest carbonated drinks suppliers globally (both minority partners in significant African dairy businesses). The report is available from Research and Markets, www.researchandmarkets.com. The twenty companies – listed in Table 1 with an estimate of African food sales where known – have acquired existing producers as well as investing in new capacity to produce ready-to-consume dairy products. Danone for example, the most active investor in African dairy over the past decade has invested over €1.3 billion in Africa since 2012 alone. It now controls an extensive network of dairy processing plants with operations (or a share in those operations) in fourteen countries. As recently as 2005 its Af- rican presence was confined largely to Morocco, Tunisia, Algeria and South Africa (see Table 2). Such investments contribute to meeting Africa's growing demand for dairy products. Through their innovation, product development The report “Investment in the African Dairy Industry“ is and marketing expertise international companies have also highly recommended for all who are interested in the helped improve product availability and grow demand. Ta- African milk markets ble 3 shows the main dairy items produced or sold in Africa by company.

8 · 8-9 2019 ¦ international-dairy.com Country report ¦ IDM

Table 1: Africa's Leading Dairy Companies, 2016

Company Country Global Dairy Ranking 2015 Sales (€ million)2 European In Africa Nestlé Switzerland 1 n.a.3 Danone France 3 1,400 Lactalis France 2 1,155 FrieslandCampina Netherlands 6 6504 Fromageries Bel France 338 Ornua Ireland n.a. Arla Foods Denmark 7 1005 Savencia France 15 n.a. PZ Cussons (Nutricima) UK 73 Sodiaal France 13 n.a. African Total Sales Clover Industries Ltd South Africa 680 Promasidor South Africa 650 Juhayna Egypt 250 Arabian Food Industries – Domty Egypt 143 Obour Land Egypt 136 Arab Dairy Products Company Egypt 506 Other Companies In Africa Fonterra New Zealand 5 n.a. Coca-Cola United States n.a. Americana Kuwait 7567 IDJ (Almarai/PepsiCo) KSA/ US 173 Source: Brian McNulty and Associates

1 Ranking based on analysis by Rabobank 2 Sales for non-African companies are total sales in Africa and so include non-dairy; e.g. Danone water, Lactalis juice and a wide range of non- dairy foods from Nestlé. Only the African food sales are shown for PZ Cussons, the only company not exclusively involved in food and drink. 3 Africa Middle East sales approximately €4.9 billion 4 Estimate. WAMCO the Nigerian subsidiary has sales of €530 million 5 €90 million in Sub Sahara Africa plus an estimated €10 million in North Africa 6 Estimate 7 Of which Dairy estimated at €120 million

Investor Motivation the increased European milk output associated with the abo- Interest in Africa is based on strong growth in demand – and lition of EU production quotas in 2015. expectations for growth to continue. The main demand driv- ers include: Emerging Consumer Markets 1. Rising population (more mouths to feed); According to World Bank data annual per capita milk consump- 2. Urbanisation (facilitating access to consumers); tion in Africa is 37 litres, compared with the global average of 3. Economic growth and rising incomes (higher 'effective 104 litres. As incomes increase the diet of nutritionally deprived demand' i.e. consumer demand backed by an ability to consumers tends to improve, whether through eating more or afford dairy products). through a more balanced diet. Typically this involves consuming more and a greater variety of dairy products. And as incomes For European companies, which have been the most active rise further consumers switch to more sophisticated products. investors in Africa, the continent also provides an outlet for For example they may switch from unpasteurised raw milk, to

8-9 2019 ¦ international-dairy.com · 9 IDM ¦ Country report

Table 2: Danone: Manufacturing Presence in Africa, 2016

Country Company/Acquisition Sector Year

North Africa

Algeria Danone Djurdjura Fresh dairy products 2001

Trèfle Yoghurt 2015

Tunisia STIAL/SOCOGES Tunisian dairy market leader. 1997

Egypt Olait Yoghurt 2005

Halayeb Cheese 2016

Morocco Centrale Laitière Milk, yoghurt, cheese. 2001

East Africa

Kenya Brookside (40%) Long life milk, fresh dairy products, milk powder. 2014

Uganda Brookside - 51% of SAL Long life milk, fresh dairy products, milk powder. 2015

Rwanda Brookside - 51% of Inyange Industries Milk 2016

Ethiopia Brookside - 20% of Elemtu Dairy Milk 2013

West Africa

Nigeria Fan Milk International Yoghurt, ice cream, flavoured milk, drinking yo- 2013 ghurt and juice drinks Ghana 2013

Togo 2013

Côte d'Ivoire 2013

Senegal Laiterie Du Berger 2009

South Africa

South Africa Danone Southern Africa Fresh dairy products 1998

Source: Brian McNulty and Associates

processed and hygienically packaged milk; or from 'loose' milk Opportunities powder to hygienically packaged milk powder. Instead of mak- Rapid economic growth in Africa over the past two dec- ing fermented milk drinks at home, they may purchase factory ades has for the first time put consumer goods within the produced yoghurt and other fermented products. reach of millions of low-income households. The challenge The African Development Bank estimated the continent's for dairy and other food suppliers is to reach them with con- middle class in 2010 at 34.3% of Africa's population or 326 mil- veniently packaged products at prices they can afford. Thus lion people. Though widely quoted the definition used in arriv- for example: ing at this estimate has proven controversial, and many believe • For milk packers smaller volumes of milk (e.g. 100 or 200 middle class numbers were overestimated. A 2015 study by Pew ml) in low cost packaging (such as plastic bags) will be Research Centre concluded that just 6% of Africa's population more accessible to consumers than larger volumes and could be classified as middle income. Despite marketeers' in- more expensive packaging formats; terest in middle class numbers, opportunity for many compa- • For producers of yoghurt and other fermented dairy prod- nies lies at the bottom of the social or wealth pyramid. Often ucts plastic packaging is more affordable than cups, while perceived as not having purchasing power, aggregate buying long life products help overcome difficulties associated power of poor communities is significant and profit margins on with the continent's limited cold distribution chain; goods sold to poor consumers can be higher. Moreover provid- • Milk powder in small sachets is more accessible than in ing basic goods and services in poor communities can improve large cans or boxes, and fat filled milk powder more af- living standards while offering profitable business opportunities fordable than milk with animal fat; for suppliers. Thus for many companies targeting African mar- • And for processed cheese a single triangle will be more ac- kets the big opportunity is not the wealthy few or the emerging cessible to consumers for whom a full packet of triangles middle classes but rather the more numerous aspiring poor. is unaffordable.

10 · 8-9 2019 ¦ international-dairy.com How much does your software know about milk? Ours knows a good deal. VENITE A TROVARCI!

Industry-specific processes, integration The end-to-end solution encompasses of machines and systems, monitoring ERP, FACTORY ERP and MES. and reporting, traceability, quality And best-practice standards come as management and much more. The part of the package. CSB-System is the business Would you like to know exactly why software for the milk industry. industry leaders count on CSB?

www.csb.com IDM ¦ Market report

FMCG Gurus Comment

Animal protein sources prove more popular than plant protein sources

Author: Michael Hughes, Director of Insights, FMCG Gurus, phone: +44 203 372 4454 email: [email protected] Mike Hughes has over twelve years experience analyzing consumer trends across the food, drink and supplement industries. He has a particularly interest in challenging industry perceptions when it comes to the way consumers think and behave.

n recent years, much attention has and the growth of consumers looking plant protein is growing, animal-based been given to the growing popu- to cut down on intake of animal pro- sources of protein continue to be more larity of plant food and drink as duce. Indeed, such interest in protein popular amongst consumers. Moreo- a source of protein. This is some- is no longer restricted to people who ver, there are several barriers that the thing that can be attributed to engage in physical activity as everyday plant-based protein industry needs to Iconsumers taking a greater interest in consumers seek out high protein prod- address. protein in general. It can also be at- ucts to boost their general health and Dietary habits are changing across tributed to changing dietary habits, wellness. However, whilst demand for the globe. An FMCG Gurus survey of

10,000 consumers were surveyed in Q4 2018 (1,000 per country) in Australia, Brazil, Canada, China, France, Germany, Italy, Spain, UK and the US. For more info please contact FMCG Gurus at [email protected].

12 · 8-9 2019 ¦ international-dairy.com Market report ¦ IDM

10,000 consumers across ten coun- nutritious and 31% believe that plant ents that offer a health boost. This will tries conducted in Q4 2018 found that protein is more expensive. These are create opportunities for brands and 46% of consumers follow a diet based barriers that will have an impact on manufacturers of both animal protein around meat restriction or avoidance. willingness to incorporate plant-pro- and plant protein products. It is impor- A total of 3% of these consumers clas- tein sources into everyday diets. tant to remember however that irre- sify themselves as vegan, looking to The reality is that interest in pro- spective of the recent attention given avoid animal produce altogether. Ad- tein will continue to grow. This will be to plant protein, animal-based protein ditionally, 66% of consumers who eat driven by health-conscious consumers sources continue to be more popular meat say that they have looked to limit wanting products to contain ingredi- amongst consumers. their intake of meat in the last two IDM, Aseptik, 139 x 200 mm, en24-AZ238 08/19 years. When asked why there were reducing meat intake, health (32%) and concerns over animal welfare (26%) are the two top reasons cited. Whilst consumers are looking to cut back on meat, less than 10% state that they are actively trying to reduce their intake of dairy. These changing dietary habits are occurring at a time when a significant number of consumers are looking to increase their intake of protein. The survey for instance shows that 30% of consumers are looking to do this. These two factors are something that are driving the popularity of plant food and drink as a source of protein. Indeed, 42% of consumers say that they regularly turn to plant-based food and drink, with options as lentils, oatmeal and soy proving popular amongst consumers. However, whilst the plant-based protein market continues to grow – even amongst meat eaters – it is important not to over-estimate the appeal of plant protein. For instance, FMCG Gu- rus research shows that 61% of consumers across the globe say that they turn to meat products for protein. Ad- ditionally, 73% of consumers say that they turn to dairy products as a good way of boosting protein intake. This shows that meat and dairy sources of Performance, not risk protein are more popular amongst consumers. This can be attributed to meat Why do more than firms put their trust in the Contipure AseptBloc? Because it dependa- and dairy being staple dietary items in bly bottles both high- and low-acid products. many countries. Because it gives you exceptional resource- As well as meat and dairy as a economy. And because it works seven days at source of protein being more popular a stretch – without taking a single break. than plant protein, there are also barriers that exist when it comes to plant protein that the industry needs to address. For instance, 37% of consumers believe that plant-based protein is less www.krones.com tasty than animal protein. Additionally, 27% believe that plant protein is less

8-9 2019 ¦ international-dairy.com · 13

CC_en24-AZ238_08-19.indd 62 07.08.2019 10:52:39 IDM ¦ Interview Better and hygienic solutions

FAM now addressing cheese processors

elgium-based manufacturer flat surfaces or hidden corners and no process low to medium volumes of all tra- of cheese processing ma- electrical components, bolts or wires in ditional cheese varieties and cutshapes. chines, FAM, has developed a the product zone. We are a full solu- Motor and gearbox are completely out- range of new solutions. IDM tion provider starting from shredders, side of the product zone eliminating asked Guy Baeten, Strate- dicers, pre-cutters up to complete product build-up and heat generation. Bgic Business Development Manager at lines and technical service, knives and It is powered with a revolutionary de- FAM, about details. spareparts are very close by. Our strate- signed cutting head: the SureShred 16C. gic partnership with Deville Technolo- This high quality & high capacity cutting IDM: Why is FAM not yet very well gies is providing the opportunity to of- head offers an extremely hygienic design known in the cheese industry? fer full line solutions. and is USDA Dairy Accepted. As a result, For shredding of cheese the brand this shredder increases considerably ef- Baeten: FAM has been focusing primar- new and innovative FAM Centris 400C ficiency and yield. ily on vegetable and meat applications. centrifugal shredder is specifically de- But over the past 10 years, FAM has signed for cheese processors looking to IDM: What offers FAM to cheese developed unique, competitive and in- processors that are not organized novative machines, offering much better in bigger groups? and hygienic solutions for shredding and dicing of cheese in all varieties. The time Baeten: All customers are equal for is there to inform all cheese processors FAM. The machines are developed with and make them aware of these novelties. their needs in mind. For shredding and dicing, there are at least three different IDM: What makes FAM machines/ machine types, each covering small, lines special? medium and large volumes in stand- alone or line configuration. Baeten: The broad range of machines Together with local partners we of- to accommodate each of the different fer small, medium or large cheese pro- types of cheese processors for shredding cessors the best solutions. Next to our and dicing, each covering small, me- support activities, we have a range of dium and large volumes in stand-alone services to make the processor at ease or line configuration (see www.fam.be/ with our products like demonstrations, en/segment/cheese for all information). trials, application videos & reports Cheesography We offer three dicers with the FAM Hy- and expertise of working with cheese maks being USDA Dairy Accepted, four processors for various application and Cheesemaking technologies at its best, worldwide. shredders incl. the FAM Centris 400C cheese types. Hytec (USDA Dairy Accepted) and the Guy Baeten, Strategic Business Devel- A nice example of FAM commit- Euroblock shredder Deville FS40 (manual opment Manager at FAM: Over the past ment to smaller cheese processors and automatic) as well as all compo- 10 years, FAM has developed unique, is the mozzarella processing in Italy nents for a complete line setup , includ- competitive and innovative machines, where more than 100 processors have ing a variety of pre-cubers. offering much better and hygienic solu- adopted FAM as their solution partner The machines have a high level of tions for shredding and dicing of cheese for the dicing of mozzarella (see web- hygiene for the cheese industry: no in all varieties (photo: FAM) site www.fam.be/en/segment/cheese). sulbana.com 14 · 8-9 2019 ¦ international-dairy.com News ¦ IDM

New control unit for D4 Series valves SPX FLOW

SPX FLOW has released the new CU4plus control unit retrofitted to existing D4 installations. SPX FLOW ad- for its next generation APV/Waukesha Cherry Bur- ditionally offers a straightforward upgrade insert to rell D4 Series double seat mix proof valve. With fully change from the previous generation DA3+ to DA4 Se- integrated seat lift detection, the new control unit ries technology, which can now also incorporate the combined with the state-of-the-art D4 Series hygien- CU4plus control top. spx.com ic valve is one of the most sophisticated and reliable valve solutions available. The CU4plus control unit uses an innovative design with completely internal sensors to detect all critical valve positions, so the electronics are secure from damage during handling and washdown. For rapid commissioning, the unit incorporates the proven ‘Teach-in’ function, which enables reliable set-up of valve position and feedback with the push of just one button. Its high-resolution, integrated measuring system ensures accurate and reliable control, while an advanced toolkit provides the ability to monitor valve parameters including the number of open/close cycles, strokes, operating hours, feedback position trends and power status. Based on proven CU4 Series technology, the new control unit offers chemically resistant, high strength construction with ultra-bright LEDs for clear indication of valve position, power and solenoid activation. Its accurate and reliable control is provided by a high- resolution, contact-free measuring system. The CU4plus control unit uses an innovative design with The new control unit utilizes AS-i bus protocol and completely internal sensors to detect all critical valve posi- is suitable for all D4 Series valve types. It can also be tions (photo: SPX FLOW)

Cheesography Cheesemaking technologies at its best, worldwide.

sulbana.com 8-9 2019 ¦ international-dairy.com · 15 IDM ¦ Interview Digitization of dairies

Transparency in real-time by linking data

It is essential to analyze the CURRENT state of the factory before the start of any project to increase the degree of integration (photo: CSB-System)

igitization has arrived in the know what is going on in the com- is only feasibly with an integrated ERP dairy industry. Just what pany at any given time. The managers system geared towards manufacturing, does this buzzword mean, of the different divisions can check the such as the one we produce. Our refer- and what are its implica- current state and initiate optimization ence customer Privatmolkerei Bechtel tions? IDM interviewed Mi- measures if needed. has pursued the approach of highly in- Dchael Tenbeitel, head of dairy industry tegrated data capture for years and has sales at CSB-System AG. IDM: This sounds like a great task … now become one of the most advanced dairies with regard to digitization. IDM: What does the term "digitiza- Tenbeitel: Yes, but you can start small. tion" mean specifically for dairies? Basically, every digitization step can yield IDM: What are the difficulties a com- some quick wins. Of course, ultimately pany can come across if they want Tenbeitel: In the process of digitiza- this is about gradually connecting the to achieve such a high degree of in- tion, the previous separation between existing data systems with the ERP so- tegration? commercial and technical systems is lution as the company's central nervous gradually removed. This means that system. In production, this comprises Tenbeitel: It is essential to analyze ERP data of the commercial processes process and control systems, packag- the CURRENT state of the factory be- such as sales, purchasing and producing machines, integrated scales and test fore the start of the project. If this is tion, QM, maintenance, and other data systems as well as warehouse systems. not known precisely, the concepts and from machine control systems and data From all these data, important informa- steps cannot be aimed exactly at the systems are linked with each other via tion can be established in concise dash- project targets. In addition, it is impor- interfaces so they can be utilized and boards. In addition, you can derive key tant to define the priorities. For sure, evaluated. This creates transparency in performance indicators on the overall one of the goals must be to reduce real time, executive management will equipment effectiveness. However, this costs, for example by utilizing produc-

16 · 8-9 2019 ¦ international-dairy.com Interview ¦ IDM

tion resources better, or by using ma- ty in production should be possible, production order, and it can only be terials (raw materials, packaging) in shouldn't it? based on batches or items. Further- an optimal manner. Furthermore, it is more, the data is not linked with the about increasing efficiency, enhancing Tenbeitel: Many process control sys- raw materials, auxiliary supplies and safety and improving quality. But in tems in the dairy production facilities operating materials from the ERP busi- many cases, you also need to check the by definition focus on controlling the ness processes (procurement and in- requirements of trade and of customers routes, usually capturing the mate- ventory) or other processes like pack- for semi-finished products, as well as rial flows with information on "When, ing. These are the components the final the legal requirements on production. where does it come from and where product is made of. The question there- Checking the technical feasibility with does it go to?". However, often the fore is how you can clearly document the installed equipment is a very impor- retrievable data is not linked with the processes so that data from the various tant point.

IDM: This raises the question of who could be a potential partner for a digitization project.

Tenbeitel: It is obvious that the partner must have considerable experience in the implementation of ERP projects in this industry. Such experience needs to be built up in a number of projects PALSGAARD DAIRY EMULSIFIERS & STABILISERS over several years, so that references should be available. Most of all, an industry-specific ERP solution must be available. The solution should comprise the implementation of continual best Smooth, creamy, practices as well as requests and sug- gestions by the customers, as is the case with CSB-System. What's more, we are always developing additional rich, silky solutions offering great benefits to our customers. Ideally, the supplier offers various ERP packages for different company sizes, as their requirements may differ considerably. A small regional dairy would focus on other aspects than a traditional medium-size company or the production plants of corporate Great dairy products are as simple as bringing together groups. We have taken account of strong technical know-how with an in-depth understanding these different needs in the functionality of our three software packages Ba- of what consumers want. sic ERP, Industry ERP and Factory. Finally, the IT system needs to be ex- Palsgaard is the world’s only full-service In our application centres around the world, pandable so it can grow with the company. For example, Züger Frischkäse AG emulsifier and stabiliser company. Dairy our teams of industry experts are ready to in Switzerland. They have evolved from products are one of our specialties, and our help you refine your existing products or a micro-business into a niche player custom-designed emulsifier and stabiliser develop new ones. with a staff 250 employees. Right from systems give you a range of advantages. For the start, their ERP system has played a instance, you can reduce dairy fat content Find out more at www.palsgaard.com/dairy fundamental role. It enabled them to without compromising a creamy mouth-feel keep their processes at the factory as lean as possible. – all while keeping costs low.

IDM: Once the digitization process BRINGING GOOD THINGS TOGETHER has been completed, full traceabili- IDM ¦ Interview

Michael Tenbeitel, head of dairy industry sales at CSB-System AG: In the process of digitization, the previous separation between commercial and technical systems is gradually removed (photo: CSB-System)

systems in use can be portrayed. Merg- on production and management. The are no transitions that would require re- ing the data of the ERP system (in par- compliance with the standards is veri- placing the entire system. As a result, our ticular from procurement) and of the fied in audits. With the CSB-System, all system can be used in the long term. control systems will enable full forward processes can be portrayed digitally. As and backward traceability. It also allows a result, audits can be performed en- IDM: How is CSB's development for you to trace valuable substances such tirely paperless, directly in the system. the dairy industry coming along, in as fat and protein. Where do losses your view? occur? Where is there a need for opti- IDM: Digitization thus requires a mization to improve the value added? considerable amount of investment Tenbeitel: Many dairies are currently You would even be able to answer stra- by the dairies. What about the fu- dealing with their digitization strategy, tegic corporate issues. ture-proofness of an ERP system? whether for current production expan- sions, in the context of new-build pro- IDM: A fully digitized dairy would Tenbeitel: I can only speak for ourselves. jects or in general as they are looking probably also benefit when it CSB-System has been updated and de- for an overall IT/ERP solution. We see comes to audits. veloped further for many years. For all the trend positive, also in light of our improvements past and present, the projects at Meierei Barmstedt eG and Tenbeitel: The trade as well as employ- CSB-System is upward compatible. Re- at Milchwerke Berchtesgadener Land ers for contract manufacturers and in- lease changes are easy and secure, from Chiemgau eG, which are currently in dustrial customers place heavy demands one version to the next. With us, there the implementation phases.

18 · 8-9 2019 ¦ international-dairy.com News ¦ IDM

Solution for vegan and plant-based beverages DuPont Nutrition & Biosciences

DuPont Nutrition & Biosciences an- GRINDSTED Gellan VEG 200 eases manufacturing of innovative plant-based nounced the debut of naturally and vegan beverages (photo: DuPont) sourced GRINDSTED Gellan VEG 200 stabilizer, enabling high performance results of innovative plant-based and vegan beverages. GRINDSTED Gellan VEG 200 – advanc- es plant-based and vegan beverages to fit the most demanding consumer expectations. Plant-based/vegan claim, health profile, clean label, premium taste and texture are the most desired features of innovative products in this category. GRINDSTED Gellan VEG 200 is suitable for a wide range of plant-sourced raw materials, has low protein reactivi- ty and high performance across a broad pH range. Added directly into the mix, Gellan VEG 200 delivers a stabilizing network throughout the shelf life to maintain a homogenous and stable final product. dupont.com “We are proud to launch a product that answers critical manufacturers’ needs – ease of formulation and production. Starting today, it’s available worldwide,” said Kirsten Braüner Nygaard, Business Development Man- ager, DuPont Nutrition & Biosciences.

About DuPont Nutrition & Biosciences DuPont Nutrition & Biosciences applies expert science to advance market-driven, healthy and sustainable solutions for the food, beverage, dietary supplement and pharmaceutical industries. We also use cutting-edge biotechnol- ogy across a range of markets to advance bio-based solutions to meet the needs of a growing population, while protecting our environment for future generations. We are innovative solvers who help our customers turn challenges into high-value business opportunities. For more information: www.dupontnutritionandhealth.com or www.biosciences.dupont.com IDM ¦ Market report Trends and developments in the ice cream market

Inter Ice 2019

rom 11 to 13 June, the international ice cream industry met at flavours for personal enjoyment or individually designed packaging. "This the German professional education institution ZDS in Solingen, shows clear communication of the product advantages on the packaging. Germany. The seminar, which was well attended by over 70 par- Manufacturers in the pints sector place much more emphasis on these ticipants, provided an overview of the latest developments in the than on other producers," says Küchler. Trends in the innovative pints seg- national and international ice cream markets. In addition to new ment include, for example, ice cream with ultra-filtered milk in the USA, Fingredients and trends, important developments in process technology as "healthy" ice cream, i.e. lots of protein, little fat and sugar, gluten-free, well as current strategies for calorie reduction were presented. etc. in Australia or ice cream made from local ingredients in New Zealand. According to Küchler, retailers are very willing to list small compa- Trends and developments nies. However, the market shares here are not yet so high that it causes Sascha Küchler, The Nielsen Company, explained that the retail ice problems for the big manufacturers. The fact is, however, that the trend cream category is a very seasonal and dynamic business. Due to the in the ice cream sector is also clearly towards more conscious consump- long and quite hot summer, the 2018 ice cream season was very suc- tion. Consumers would reflect their habits more and they would also be cessful in Germany and Central Europe. Ice cream consumption in Ger- willing to spend more on a corresponding product. many rose by 13.1 per cent to 532.5 million litres, in the Netherlands by 13.8 per cent to 88 million litres, in France by 6.3 per cent to 208.2 Opportunities of e-commerce million litres and in the UK by 7.2 per cent to 344.1 million litres. Rebecca Göckel, co-founder of Nomoo, is involved in the online sale of According to Küchler, the most exciting segment in terms of sales ice cream. Nomoo stands for "Free from Cow"; it is a vegan ice cream, and product development is the so-called pint segment (400 - 600 ml). but it is marketed as vegetable because the term vegan is rather deter- The largest market in this segment is currently the USA with 1.723 billion rent. The ice cream has also been available in the online shop since 1 euros. However, there is also solid growth in Europe, with the pint seg- April. Nomoo, which is offered in the trade for 5.99 euros/cup, costs ment in the UK increasing by 12.9 percent to EUR 302.1 million and in full 8 euros/cup in the on-line Shop. The dispatch takes place from 5 Germany by 33 percent to EUR 236.9 million. These formats are usually packing per carton, whereby the carton is isolated with special straw expensive and offer some potential for new experiments, such as special plates and filled with dry ice. So a cooling of 48 hours can be guar- anteed. So far the enterprise does not generate even one per cent of the conversion on-line, but sees enormous growth potential. "We can create a world online around our product and say much more about our brand," says Göckel. Mrs Göckel sees further advantages in the fact that activities can be measured and something about the target group is learned. Göckel: "This enables us to respond better to customer needs". Nomoo is currently testing various sales channels to be able to react more flexibly. "At the moment, ice cream online is just an add-on for us, but we want to create the infrastructure now if it means in the future that food will mainly be ordered online," says Göckel.

More than 70 participants informed themselves about the Startup latest developments on the national and international ice Guido Jörg, healthy planet, a company that has been producing organic cream markets (Photo: ZDS Solingen) ice cream since 2007, talked about how a start-up implements its ideas.

20 · 8-9 2019 ¦ international-dairy.com Market report ¦ IDM

The "rare sugar" allulose was the subject Rebecca Göckel, co-founder of Nomoo, is Michael vom Dorp, Cargill Germany, of Nathalie Vehlow, Savannah Ingredients involved in the online sale of ice cream showed the chances and risks of calorie (Photo: ZDS Solingen) (Photo: ZDS Solingen). and sugar reduction. (Photo: ZDS Solingen)

Similar to the "big ones", the company considers current trends, com- of the sugar manufacturer Pfeifer & Langen, develops so-called functional petitors and the international market in its product development. "Our carbohydrates, i.e. new sugar varieties with specific properties. Allulose is advantage is that we can produce very individual products that cannot be a reduced sugar produced from sugar beets. Compared to classic sugar, it produced by the industry due to their size," says Jörg. Marketing is also contains a residual calorie content of 0.2 kcal, which leads to a significant creative: Due to the rather limited financial budget, healthy planet pro- reduction in calories. Vehlow presented possible applications of allulose in duces special marketing products, so-called signatures. Jörg: "Although ice cream. Various basic recipes were developed in test series in which dif- these products are not necessarily bought, they are very well received in ferent types of allulose, fat content and fat were tested. A sensory evalu- the press". Jörg was somewhat more cautious than his previous speaker ation and a melt behaviour analysis were carried out. In comparison to when it came to online retailing; although this area had been examined, it standard ice cream with sucrose, various calorie-reduced milk ice cream had been classified as "not worthwhile". recipes with allulose could be developed. So far, allulose has not been ap- proved in the EU, but Vehlow expects approval for 2021. Calorie and sugar reduction Wilhelm Meyer zu Venne, Waffelfabrik Meyer zu Venne, presented various examples of sugar reduction in ice cream products. One possibility would be to adapt the wafer, i.e. a sugar-free rolled wafer. Malit is used here instead of sugar, which enables a calorie reduction of 10 percent, with Worldwide trading a declaration as "sugar-free" and only minor changes in taste. "But they can also go back to a pressed wafer instead of a rolled one. According to Tel: +31 348 460 009 Meyer zu Venne, this can save 18 percent sugar. Of course, there is also the [email protected] possibility to change the ice cream recipe, a topic Michael vom Dorp, Car- www.useddairyequipment.com gill Germany, dealt with in more detail. He made it clear that the pressure of legislation on sugar reduction is increasing all the time. "Some countries are about to introduce a sugar tax. A reduction paper is to be implemented in Germany," said vom Dorp. However, the speaker continued, it did not make much sense to reduce only the sugar content, but not the calorie content. He clarified that a sugar reduction does not result however inevi- tably in a calorie reduction. A reformulation, by playing with sugar kinds is in any case the wrong way. Vom Dorp pointed out that there are many possibilities, but the question is what is allowed and what works. For sugar reduction, the addition of starch should be reconsidered. "We must think Incl. recipes and technology more broadly again and also rethink old raw materials," said vom Dorp. Mads Wiene, DuPont Nutrition Biosciences, dealt with recipe design For Sale: Complete Dessert Line for calorie reduction. After an overview of the current EU legislation and Complete pudding, desserts and yoghurt the presentation of the various nutrition claims, the speaker presented var- processing, filling and cooling line ious recipes for calorie reduction – for the components fat, carbohydrates Production just stopped, and sugar. Wiene pointed out different ways to reduce fat, such as the located in the Netherlands use of emulsifiers, stabilizers or bulking agents, and finally discussed the Offer nr: 19-15-01 changes to the process (homogenization, freezer technology). For sugar reduction, various sugar alternatives, but also their possible disadvantages, were presented. Wiene came to the conclusion that the easiest way to Total line of process tanks, aeration and achieve calorie reduction was through fat. fruitmixing station, cup filling and packaging The "rare sugar" allulose was the topic of Nathalie Vehlow, Savannah machines Ingredients. The start-up, which was spun off from the Innovation Center

8-9 2019 ¦ international-dairy.com · 21 IDM ¦ Packaging Complete lines for dairy products and spreadable fats

5th international in-house exhibition at Trepko

repko, manufacturer of pack- that his company had long since devel- not only a good overview of the com- aging machines and complete oped into a full-range supplier offering pany's performance, but also some in- packaging lines, combined its a one-stop shop and does not change novations. For example, Trepko's new 5th in-house exhibition from hands every three years. Rather, Trepko OEE Monitoring System celebrated its 10 to 14 June with the 100th has grown with an average increase premiere. Here, data from running pro- Tanniversary of the plant in Gniezno, Po- of 15% over the past 20 years. Trepko ductions are made available in real time land. The site was taken over by Trepko does not address the width of fillable and are condensed into overviews of in 2000 and has since been significantly food at all, but focuses more or less on machine status and performance. At the modernised and expanded. IDM visited dairy and margarine. in-house exhibition, a screen gave an this year's worldwide largest practical insight into a running production at the exhibition for packaging technology. New OEE monitoring Polish dairy Jana. The OEE Monitoring Trepko owner Jesper Björn Hansen The in-house exhibition held every System is now available as a standard explained at the opening of the event three years in Gniezno,Poland, offered add-on for all Trepko machines.

Butter: Bag-in-Box Another innovation that Trepko presented live at the in-house trade fair was a bag-in-box filler for spreadable fats based on the 600 machine series for blocks weighing 5 to 25 kg. This machine can ensure quasi-continuous operation via two lanes. The outer cartons are erected by Automatic Case Erecting machine, the tube is produced from roll- stock by the Series 610 Bag-in-Box Mak- er & Inserter and placed in the carton. This is followed by weight filling in the 620 Weigh Filler with an accuracy of +/- 2% and the closure in a Series 630 unit. In opening the inhouse event, Agnieska Libner and Jesper Björn Hansen high- The entire machine is CIP-cleanable, the lighted the positive development that Trepko had over the past years filling nozzles are protected against drip-

22 · 8-9 2019 ¦ international-dairy.com Packaging ¦ IDM

One of the event's highlights was a Trepko showed the new high-speed complete line for packaging kefir with butter wrapper which has a capacity of additives in cups 220 pcs/min

speed and precision of the process sur- lection lines, tanks and deaerators to prised not only IDM's editorial staff. membrane filtration systems. The latter Other practical demonstrations in- were demonstrated live at the Trepko cluded a brick wrapper with an end-of- event. 2 % fat milk was triple concen- line solution and a yoghurt filling system trated (UF) in a mobile pilot plant, then Trepko presented a great number of with a capacity of 25,000 units per hour, cultures were added directly at the filler innovations at their 5th international in which the cups were placed in carton and "matured" in a fermentation tun- in-house exhibition trays and then automatically palletized. nel. The product was filled immediately Also on display was a Trepko 3000 series into cups. The process is repeatable high-capacity ultraclean bottle filler (up and, according to Mlekomat, provides ping, the piping is double-walled on the to 48,000 bottles/h) equipped with bot- shelf lives of up to 21 days. The batch product side and can be tempered so tle rinsing, filling unit and capper. The process can be designed continuously that condensation is avoided. The out- practical demonstrations, which were via two tanks and produces 1,300 kg put is 15 units/min. spread over an entire day, concluded fresh cheese from 5,000 kg raw mate- In addition to the 620 bag-in-box fill- with a Series 9000 thermoformer, which rial. As the whey proteins are retained, er, a new solution for the production of was designed for 25 g portion packs water binding is excellent. butter blocks weighing 10 kg was also with spreadable fat and outputs up to The Icelandic dairy Mjölkursammsa- demonstrated. It is based on the 851 10,800 units per hour. A full live produc- lan is setting up a licence business for and 852 machine series and can form tion of white cheese in brine directly in original skyr through its subsidiary 25 plates weighing up to 2 kg or 4 to 8 the pack is reported below. "isey". The licence package includes blocks weighing 5 - 10 kg per minute. A the culture (supplier is Chr. Hansen), butter wrapper with a capacity of 220 Supplementary information the technology and the complete pcs/min was also demonstrated. Traditionally, Trepko's in-house exhibi- documentation as well as marketing tion is not limited to providing informa- recommendations. Thise Mejeri is an Complete line for cups tion about its own program, but also isey partner in Denmark, Q Mejeri in One of the trade fair's highlights was invites cooperation partners to present Norway and Lactica produces original undoubtedly the demonstration of a highlights from their field. complete line for packaging kefir with Zentis reported, among other things, additives in cups. The line started with on the new concept called "Xtract", in a vertical mixer from Zentis, which was which colouring food extracts are ob- explained and controlled by its inventor tained in an osmosis process. The ex- Dr. Adam Glowacki. Dill and dyestuff tracts can be precisely adjusted to the were added to the matrix. Filling took required properties and are already place on a rotary filler that had only re- used in Zentis fruit preparations. In ad- cently been added to the Trepko port- dition, Zentis informed about the static folio. The sealed cups were fed directly mixer. It offers advantages for the rhe- to a Trepko 770 Series high-speed ma- ology of the end product and the mix- chine, where they were placed in car- ing result is superior to other processes. ton sleeves in a wrap-around process. Mlekomat provided information The interaction of the individual com- about its product range, which ex- Trepko's new OEE Monitoring System ponents worked excellently, and the tends from valve clusters, milk col- celebrated its premiere

8-9 2019 ¦ international-dairy.com · 23 IDM ¦ Packaging/News

Skyr in Russia. New licensing projects maintenance and troubleshooting on to the high-shear principle, delivering are being launched in Japan, Australia mobile devices. excellent results and are always fully and the UK. At the isey information The Danish company Limitech spe- CIP-compatible. They can be equipped stand, the product was available for cialises in the production of cookers with all possible options such as double tasting in several varieties – the qual- and mixers. The mixers work according jacket, vacuum, scrapers, etc. Cookers ity was so convincing that the editorial are available in sizes from 10 - 4,000 l, staff would describe the isey skyr as by the mixers are built with 60 - 6,000 l far the best on the market. capacity. Buffer tanks, UHT and CIP sys- Schneider Electric has been cooper- tems complete the Limitech range. ating with Trepko for some time. The Festo has automated the design of giant in the automation business has simple stacking processes. The custom- focused, among other things, on packer simply enters the path and desired aging. Schneider's software is installed working speed on the website and the in Trepko's complete lines so that there system delivers the result immediately. In is a continuous data flow without in- the field of compressed air technology, terfaces. This also makes it easier for the company strives to achieve the high- the programmers at Trepko to design est possible level of digitalisation. This the control of the lines. A new addi- year, Festo will be the first company in tion to Schneider Electric's portfolio is During a factory tour, participants its industry to put an AI into operation the use of AR. The machine operators of the event were introduced to the that can completely control compressed on site are provided with all necessary manufacturing excellence in Trepko's air processes. More information can be information for machine operation, Gniezno plant found at getdigitalnow.com.

Fast lane service GEA

Following a series of optimization ready began significantly reducing zational improvements, as well measures at its Center of Excel- the general repair times of its sepa- as the appointment of an Assess- lence (COE) in Oelde, GEA has al- rators. Infrastructure and organi- ment Coordinator, have enabled numerous synergies, resulting in inspection and repair times being reduced by up to 40% worldwide. For particularly urgent cases, GEA is now offering a Fast Lane Service, which enables affected separators to be repaired in less than 10 days, depending on the requirements. The Fast Lane offer is currently limited due to capacity and time considerations. For this reason, a small steering team will decide on the urgency of each repair based on diverse criteria. Once a repair is prioritized, the operational team takes over the order, managing the entire process which includes cooperating with the specialist de- partments as well as arranging for With its considerable reduction in repair times and optional Fast Lane offer, GEA the dispatch of parts and repaired has achieved an important improvement in its service which is a clear plus for machines – reducing overall lead customer satisfaction (photo: GEA) times by up to 80%. gea.com

24 · 8-9 2019 ¦ international-dairy.com

IDM ¦ Packaging Repeatable across multiple sites

Cama Group supplies a highly flexible and efficient packaging solution

Top loading RSC case machine

companies," Rocca explains. "Normally you would receive the order and then develop the ama Group commits significant fer the flexibility and agility that will help them machines to the customer's specifications, but pre-order engineering work to address contemporary business pressures. in this instance, we dedicated several months' create highly flexible and effi- worth of effort into engineering, design re- cient packaging solutions for a Repeatable packaging views and meetings in order to meet the very major upcoming product launch solution high expectations of the customer. All this was Cfrom leading multi-national confectionery In a recent project, Cama Group was ap- before the order had even been placed. company. proached by a leading international confec- "There is an advantage to this approach," For companies that operate across mul- tionery company, that wanted a packaging he continues, "as in the pre-development tiple sites and from different geographical solution that could be repeatable across mul- phase, you can address all the operational locations, standardisation of manufacturing tiple sites in multiple countries. "This was a requirements, such as features, product for- assets becomes a very attractive proposition, brand-new line and platform for an impor- mats, efficiency levels, and then, once all the especially if the same or similar products are tant upcoming product launch," explains factors have been successfully addressed, you being manufactured on the various sites. Alessandro Rocca, Sales Engineer Director press the metaphorical start button and com- Having a common machine, line, con- at Cama. "As it was a new product launch, mence with manufacture. I think it is fair to trol and software format delivers economies expectations were high… as were the pres- say that we are relatively unique in this aspect. across many operational facets, including sures on us to deliver a packaging solution There aren't many companies that would be spares, maintenance, upgrades, development that matched the customer's precise needs." willing to undertake this level of development work and, of course, site-to-site exchange of To ensure that the machines were right work without an order being confirmed. knowledge to promote best practice. first time, Cama agreed to flip the project "The customer came to us, not only be- But standardisation does not necessarily timetable and undertake significant engineer- cause of what we could supply," he adds, mean off-the shelf. Companies are still looking ing development prior to the order being "but also since we were an existing supplier. for bespoke machine and line solutions that of- placed. "This is quite unusual for packaging Their confidence in us was also boosted by the fact that we had more-generous-than-usual lead times in which to engineer the perfect solution. In terms of actual timeframes, the process lasted two years, with first contact for this project being in 2016. For 90% of our customers this would not be viable, with around seven months being the normal timeframe."

Focus on flexibility and fast changeover The main features demanded of the line – which comprised an IF318 tray packer coupled Tray top loading machine to an IF294 case packer – were flexibility and

26 · 8-9 2019 ¦ international-dairy.com Packaging ¦ IDM

Pick & Place Robot

fast changeover. "We worked a lot in reducing savings. And it was during this phase that we downtime for changeover," Rocca expands, discovered that many standard features could "using significant levels of automation; includ- be improved, too." ing features that were new to us. In the devel- The line developed by Cama utilised a Rock- opment phase we explored many new ways well Automation control platform, with part of performing changeover more rapidly, with of the engineering effort devoted to migrat- a constant eye on future plans and upgrades, ing over from another supplier. Thanks to this without adversely affecting flexibility. control platform the customer can now exploit "We decided that the new platform enhanced connectivity and Industry 4.0 levels of should have five or six possibilities for change- data generation and exchange. over," Rocca elaborates, "but in the end the "Cama offers an incredibly high level of cus- customer only adopted two of the ideas. This Chewing Gum samples tomisation," Rocca explains. "Our award-win- was not perceived as a loss on our part, how- ning modular Monobloc architecture delivers ever, as the technology we developed is al- impressive efficiency and flexibility too, coupled, most certainly going to be deployed in future looked at the automation of processes that in this instance, to a throughput of 100 trays projects. Our two development teams worked were normally manual, and found ways of per minute, from an in-feed of 500 products. together very closely, combining our engineer- shaving minutes off the procedures, which Using advanced, in-house-developed robotic ing knowledge towards a common goal. We over time would add up to significant time forming and loading we can deliver 99% efficiency. The development work has also resulted in very quick automatic changeover – less than 15 minutes – with all changeable parts having RFID tags." Cama's IF series Monobloc-based machines are seeing a positive reaction from many different markets, due to their flexibility, positive handling and high efficiency levels. Thanks to highly capable robotics and advanced automation solutions, they are Industry 4.0 ready and will comfortably fit into any smart-manufacturing environment. This project is a prime example where engineering design, customer support and technology have worked in synergy, resulting in a solution that will see a global roll-out for a worldwide product launch. And with a standardised solution, the end user will realise Easy change over multiple benefits, not just those in terms of operational performance.

8-9 2019 ¦ international-dairy.com · 27 IDM ¦ Interview Personalized nutrition

Nothing less than the future of nutrition

oday, no trade show, conference or symposium is complete without shining a spotlight on personalized nutrition. But what's behind this topic? Is it a feasible future concept or just the result of modern-day hype? IDM – International Dairy Magazine spoke with Prof. Dr Chris- Ttian Sina, nutrition-medical scientist at the University of Lübeck and an expert in the field of personalized nutrition.

IDM: Prof. Sina, how do you define personalized nutrition?

Sina: Personalized nutrition is a diet that's tailored to the specific needs of the individual. In the broadest sense, it's nothing new. How I tolerate food is singular to me; so, even the use of lactose- free milk is a rudimentary form of personalized nutrition. With the rise of genetic profiling, we have reached the next level. In the meantime, other methods such as microbiome research and me- tabolomic analyses are complementing the DNA-based methods. And, the use of artificial intelligence is ushering in a fourth stage of development now, Personalized Nutrition 4.0, so to speak.

IDM: Why has this trend come to the table in recent years?

Sina: I don't even want to call it a trend. The concept of individually adapted, data-based and objective nutrition is, in my opinion, no less than the future of nutrition. It's an extremely complex issue: foods contain numerous potentially bioactive nutrients for which no clear dose-response relationship is known. Precision medicine has taught us how differently people react to drugs and molecular analytics enables us to identify the optimal therapy for a patient. Thanks to technical progress, we are now able to link health data – such as the results of continuous blood glucose monitoring – with food data for the first time. This is allowing us to develop algorithms that help us to identify the optimal form of nutrition for each individual. Personalized nutrition can thus prevent diseases,

(photo: AdobeStock) support pharmacological therapies and improve chronic ailments.

28 · 8-9 2019 ¦ international-dairy.com Interview ¦ IDM

IDM: Are there any target groups for whom personalized nutrition is particularly relevant?

Sina: A sensor-based personalized diet, such as the one we developed in the "MillionFriends" program, is primarily aimed at the overweight or obese … and all those who want to learn about their own metabolic reactions to food. The program is based on a microbial stool analysis and a two-week period of continuous Prof. Dr Christian Sina, blood glucose measurement. With these results, a few adjustments nutrition-medical to the individual's daily diet can achieve a significant and long-term scientist: We need to weight reduction. take new approaches In my opinion, however, personalization will be the new stand- (photo: NewtritionX.) ard in the future of nutrition and affect each and every one of us. Unstable blood sugar metabolism, for example, is thought to IDM: What does this mean in particular for the dairy sector? promote a whole range of diseases, including age-related diabetes, high blood pressure, various chronic skin diseases and migraines. Sina: Basically, products that promote intestinal health and the di- I expect that in the next 2–3 years, the first products – based on versity of the bacterial ecosystem are very helpful. According to self-learning, predictive algorithms – will be ready for mass market current research, a reduced range of intestinal micro-organisms is launch. a decisive indicator of many diseases. The goal is therefore not to populate our intestines with one specific strain or species, but with IDM: You mentioned the topic of individual metabolic reac- as many genera as possible. In the dairy segment, I'm thinking of tions: How does this manifest itself? probiotic products and fermented foods such as kefir, which can be used for personalized purposes. Sina: Our diet plays an important role in the progression of dis- But, we have to go one step further for personalized nutri- eases such as diabetes mellitus type 2 or obesity. However, the risk tion … because what's considered to be healthy for some does of developing such a disease differs from person to person. For a not necessarily apply to others. A one-size-fits-it-all product long time, genetic predisposition was regarded as decisive for this needs to be replaced by a superfood that's tailored to the in- variance. New findings, however, have established a connection dividual's nutritional requirements and metabolism. This could between the composition of the intestinal microbiome and meta- be a yoghurt with a blood sugar regulating ingredient or the bolic health. The postprandial glucose response (how blood sugar ready-made muesli that ensures a balanced postprandial glucose levels stabilize after a meal) is very well documented. After eating response by way of its high protein or fat content. the same food, the glucose concentration rises differently in each person. IDM: Why should everyone look at their diet individually?

IDM: Personalized nutrition is a major research project of Sina: To counter the pandemic dimensions of obesity and other yours: What insights did you gain and how can they support lifestyle diseases, we need to take new approaches. For me, the industry in product development? personalized nutrition is the logical development of current scientific research and the ideal alternative to conventional diet Sina: Based on data derived from more than 1000 participants, programs, which only lead to long-lasting weight loss in about we've set up a predictive model for nutri types. This means that 15% of participants. By making minor adjustments of an indi- we've clustered people whose metabolism reacts very similarly to vidual's diet, I can define a metabolism-optimized nutrition plan food into distinct groups. For these clusters, we can make propos- that's not based on renunciation and, therefore, ensures long- als for a so-called "stratified diet" that takes respective disease risk term success. into account to provide a health-promoting effect. With this model, food manufacturers can create products that complement a personalized dietary recommendation and help to About NewtritionX. optimize the end-user's own metabolism or avoid unfavorable metabolic situations. We are currently working with food produc- What is the future of nutrition? How can we combat prosperity ers, for example, to develop bioactive foods that can reduce blood diseases in the long-term and is personalized nutrition ready for sugar levels in the long-term. practical use? This will be discussed by experts from science, One example is products with a modified fat or protein con- technology and the food industry at the innovation summit tent. Our studies show that the protein and/or fat content of a NewtritionX. on 6 October in Cologne. After the successful de- meal positively influences the postprandial blood sugar response of but last year, the industry network foodRegio e.V. is, in coopera- 86% of all test participants. This is just one of the ways that food tion with Anuga, once again addressing the entire spectrum of producers could adapt their product portfolios in an economically personalized nutrition in a single event and providing excellent viable manner and subsequently offer their customers a product networking opportunities (www.newtritionx.com/en/home). that is tailor-made to their health needs.

8-9 2019 ¦ international-dairy.com · 29 IDM ¦ Technology/IT Cooling tower optimization

ABB

Upgrading cooling tower systems can lead to major savings (photo: ABB)

ood and beverage production requires a large range of Furthermore, the motors help optimize cooling towers by re- temperatures. This means that plants must have effective ducing noise pollution and as the motor is reversable allows for cooling systems to deal with the excess heat. Removing the fans to be used to prevent freezing during the colder months the excess heat from the system requires a cooling tower, of the year. Adding extra functions like this means that the high- however, traditional designs require frequent mainte- er efficiency of permanent magnetic motors, especially at partial Fnance. Here Darcy Simonis, food and beverage group vice presi- loads, in tandem with the drive’s variable speed control ensure dent at ABB, explains how to optimize cooling towers. fast running of the fans at the required speed saving energy, re-

Food and beverage manufacturers understand that the indus- ducing CO2 footprint and lowering running costs. try is becoming a constant production environment, especially with Permanent magnetic motors from ABB can also be installed the expansion of technologies like cold supply chains. Businesses, with ACS880-01 industrial drives that are built with cooling therefore, require equipment that can work constantly. However, tower application control programs. This allows the drive to when producing for long periods of time machines tend to over- adjust the speed of the motors to match the process demand, heat, meaning that to become a constantly working operation further increasing energy savings while lowering wear and tear cooling systems must also work twenty-four hours a day. rates. Meaning that cooling towers will be able run for longer Heating, cooling and pasteurizing are all common steps in while further reducing the amount of maintenance required food and beverage. Each one of these steps either directly or in- during its lifetime. directly produces large quantities of heat. Managing this heat is a Overall, upgrading cooling tower systems can lead to major sav- priority, because otherwise equipment may be damaged through ings and create a platform for constant production that can help overheating. As such, it is important to have a cooling system that drive business growth. is reliable, requires minimal maintenance and can extract heat at Traditional cooling sys- a sufficient rate. tems, especially cooling fan motors are no longer How to optimize cooling up to par with the require- Traditional fans generally use 1,500 rpm induction motors that ments from the system. connect to a driveshaft that connects to a gearbox, the gearbox Optimizing them through then connects to the fan. This makes the system prone to break- the introduction of new downs as there are many moving parts, also gearbox maintenance technology is the only way is time consuming and, due to the environment, oil leaks are com- to improve production. mon. To combat this modern cooling fans need motors that can be mounted directly onto the fan, while being able to resist the Darcy Simonis, food conditions within the cooling tower. and beverage group Many of these traditional motors can be replaced with more vice president at ABB: efficient permanent magnetic motors that can be directly in- Traditional fan motors stalled onto the fan. This reduces the amount of parts in the can be re-placed with system, limiting the risk of breakdowns. They are also compact more efficient perma- compared to traditional cooling tower motors, reducing the nent magnetic motors space required by the system. (photo: ABB)

30 · 8-9 2019 ¦ international-dairy.com Meet the suppliers that matter

3-5 December 2019 Villepinte Parc des Expositions, Paris, France JOIN US IN PARIS www.fi-europe.eu IDM ¦ Cover page The rewards of hygiene: higher cheese yield

INTERNATIONAL IDM 8-9 September 2019

PROCESSING INGREDIENTS PACKAGING IT LOGISTICS Ultra-clean from the cow to the packaging Part 1 www.international-dairy.com

he use of over-pressure tech- dairy can work with this microbiology. The spot in the process chain. They react with nology with milking equip- problem are non-lactic spores and viruses aftercare measures, with cyclical disinfec- ment eradicates clostridia and from the ambient plant, air- and water- tion of the technical components and de- pseudomonas. Both bacteria borne germs. These are mainly protein- contamination of the products through species substantially influence and fat separators and can even suppress bactofugation, pasteurization and ultra- Tthe quality and flavour of dairy products. helpful bacteria. They adversely affect high temperature processing. These have A German-Israeli process now tackles the milk quality." Dr Josef Hüfner, head of known and adverse side effects. start of a potential contamination chain the Milchwirtschaftliches Institut Hüfner due to this bacteria on milking equip- in Hergatz in the Allgäu, highlights hy- Prevention not aftercare ment. Test series in the Allgäu region and giene issues as a vulnerability of process- An efficient – and easily retrofittable – in Mecklenburg Lakeland deliver convincing milk products. These issues affect the preventive measure, which stops any ing results. milking technology in agriculture and the unspecified microbiology from interfer- "Spores, which a healthy cow transfers process technology in the dairies. Produc- ing with the food product, so facilitat- from the udder to the milk, are actually ers and reputable machine- and plant ing milk purification downstream, was helpful for milk and cheese production. A manufacturers are familiar with this weak on trial in Germany in Karbow in Meck- lenburg Western Pomerania and at the Häfele plant near Wangen, Allgäu. The East German readings were evaluated by dairy company DMK Group at its labo- ratories in Neubrandenburg, while the Allgäu readings were verified by the lab Dr. Hüfner GmbH. Josef Hüfner author- ized "IDM" to review his report. His first comment was, "I was even surprised by the results." The reports from Hergatz, Neu- brandenburg and from a trial at a farm in Israel all confirm the same result: the Sterivent process is highly efficient at eradicating germs. The German-Israeli company Fischerplanning from Netan- ya near Tel Aviv launched the method on the market several years ago and has now patented it (Deutsches Patent- und Markenamt No. 102015116333) for sterile milking with sterile air. This Test in Karbow/Mecklenburg-Western Pomerania, Germany closes the final loophole in a hygieniza-

32 · 8-9 2019 ¦ international-dairy.com Cover page ¦ IDM tion chain from the cow to the packaging. The over-pressure filters and air technology prevent almost every exterior germ from getting into the milk product.

New role for proven technology The solution with the patent-protected description "milking plant, milking equipment and teat rubber and related operating procedures" refers in practice to a development that introduces pressurized air to the vacuum on the teat cup of the milking equipment. The compression is above the vacuum of about 40 mbar of the vacuum pump. The oerflowing air cushinon seals the teat cups securely against contaminat- analysis. To compare the results, at the ured less than 100 CfU/ml in the "Fischer ed air from the cowshed. Sterile pres- invitation of the DMK Deutsches Milch milk". This was compared with between surized air supplies the Sterivent filter Kontor, Fischerplanning also set up a 3,000 and 7,000 CfU/ml per cow for the plant, which has a good reputation in vacuum extraction with and without milking process without sterilized air. In the food and beverages industry, from Sterivent technology on the farm owned Hergatz, using the conventional process, Japan to the US and at Coca Cola, Nes- by the Karbow Agrargenossenschaft e. a bacteria group was concentrated with tle, Emmi and Müller Milk. It supplies G. in Karbow/Meckenlenburg Western the extremely undesirable pseudomonas up to 500 m3 hourly of sterile air for Pomerania. The evaluation of the re- of 900 after the first day up to 37,000 on permanent over-pressure of about 20 sults was based on the bacterial count the fifth day. On the other hand, after five mbar to the intermediate tanks and in the cow’s milk straight after milking days the bacterial count of pseudomonas storage tanks. Only clean air gets in into an airtight, sealed container. was less than 10 CfU for the tanks with from the exterior through leakages, for The results could not be more convinc- Fischer milk. Similar results were also ob- instance, in the seals of the bolted fit- ing. In Israel, the lab technicians meas- tained for other species. tings and valves, but contaminated air cannot flow in from outside. Fischerplanning has now designed a complete ultra-clean chain almost direct to the consumer. Basically, the production of milk and cheese products presents a contamination risk at five stages: the cow, the milking technology with cooling tank, transport, raw milk and process tanks, bottling and packaging. As mentioned, the company already put in place measures to ensure sterile processing in the dairy and in production facilities of the drinks industry. The Sterivent principle certainly protects from external airborne germs. However, it obviously fails to purify milk supplies that already contain spores and bacteria. The research department analyzed preventive measures for milking at the livestock farm. Sterivent filter unit for 500 m3/h overpressure sterile air. Connected load approx. 0.2 kW. The air cleaners in a stainless-steel housing (stainless steel 304) consist of Best results a pre-filter, a blower and the sterile filter (Hepa filter). Prefilter: class G3 according Fischerplanning installed a test facil- to DIN EN 779. Sterile filter: active surface 5.5 m2. Air velocity 1.5 cm/s. Separation ity on the Häfele farm near Hergatz; it efficiency 99.997 %. Fire protection class: F 1. Cascade connection of several units commissioned the Milchwirtschaftliches possible. Prepared for connection to the process control system. Below right in the Institut Hüfner to prepare the scientific picture the container for the milk milked with germ-free air.

8-9 2019 ¦ international-dairy.com · 33 IDM ¦ Cover page

Aggressors for milk and cheese The analytical values surprised Josef Hüfner. In his view, the new milking process with sterilized, particle-free air has substantial benefits for milk quality. "Firstly, primarily these two bacteria, the pseudomonas and the bacterial spores, the clostridia, negatively influence the smell, flavour and longevity of cheese and milk. I don’t want these bacteria near raw milk. On the one hand, due to health concerns. On the other hand, the cheese doesn’t mature and the storage time of consumers milk is reduced. This is caused by the bacteria, particularly the pseudomonas, and also the heat-resistant enzymes of these bacteria. This has less of an effect on products that immediately leave Excerpt from Häfele-Hof results (Source: MIH) the shelves in Lidl and Aldi, but the major export market, for instance, to the indirectly introduced bacteriophage, shock, which affects the warm equip- Middle East, requires UHT-milk with a the growing viruses, can spoil the en- ment, the air inside contracts. The result- longer minimum expiry date of up to tire cheese production so that it has to ing negative pressure counteracts the half-a-year or even a year. Milk pow- be rejected. cleaning task. Contaminants are brought der can also turn sour due to foreign into the food again due to leakages in enzymes." Sterile air to cool the plant the seals and connections. This contami- The Sterivent process filters out, What measures can be taken against nation path affects the entire dairy tech- among other things, the clostridia – waterborne germs? Instead of rinsing nology as well as milking machinery. Ster- environmental bacteria that are found cleaned pipes and surfaces with cold wa- ile air should replace fresh water for the everywhere. Eliminating the second ter, use hot water and then sterile air to entire cooling chain, regardless of which main bacteria, the pseudomonas, re- cool the equipment. Gentle cooling of the part of the chain. quires moderate modification of the plant equipment with sterile air avoids The institute director agrees: "Purified process technology. These waterborne the second negative effect of the cold and disinfected pipes should no longer bacteria, which are harmful in milk, water procedure: due to the temperature be rinsed with mains water – this would are introduced in the water for rinsing destroy the disinfection measures already the pipes, tanks, transport vehicles and put in place. However, if I use sterile air machines. They implant themselves in to seal the system and for cleaning or certain pockets and dead lines and start cooling, nothing else can get into the breeding. Disinfection procedures (like plant and equipment. Something like peracetic acid) only have limited effec- this should be integrated into the milking tiveness. On the one hand, this bacteria technique. I could imagine that optimiz- group is relatively resistant to disinfect- ing the cleaning process is cost-neutral. ants, on the other hand the bacteria Basically, it should not be allowed that "hide" in crevices, behind seals and so milk, which I milk in the bucket, is bet- forth. Hüfner also remarks, "Incidental- ter than milk in a cooling tank and rinsed ly, I cannot take measures against the with cold water. Dairies should require clostridia with hot water, because there the use of this technology in the milking are thermophilic groups of these bacte- process. Spores are a survival form for the ria that even survive at 120 °C and 140 bacteria. The microbes adapt to the disin- °C. The crucial factor is for both these fection process. At Weihenstephan, they aggressors not to get into the system realized that spores contribute to a clean- in the first place." The pseudomonas ing problem." species like diluted, moist and mainly cold conditions. These bacteria are part In part 2 of this article, cheese yield, risk of normal drinking or process water. In factors as well as factors that still need the worst case, these bacteria and the Stable air germ counts proof will be in the focus.

34 · 8-9 2019 ¦ international-dairy.com FoodFood ingredients ingredients ingredients is is is comingcoming to to toAmerica! America!America! YourYour trusted trusted trusted route route route to thetoto the theF&B F&B market.F&B market. market.

17-1817-18 October October 2019 2019 MandalayMandalay Bay, Bay,Las Vegas, Las Vegas, USA USA JOINJOIN US17-18 INUS LAS IN October LAS VEGAS VEGAS 2019 www.www.figlobal.com/northamericafiglobal.com/northamerica Mandalay Bay, Las Vegas, USA JOIN US IN LAS VEGAS www.figlobal.com/northamerica IDM ¦ Ingredients Fermented dairy powders

Marrying two major trends: fermentation & convenience

btained through a natu- publications. However, the fermenta- well-informed about the influence of ral process and combin- tion of various foods has been used for their diet and lifestyle choices on their ing both a unique tangy thousands of years, and researchers even overall wellness; therefore, actively seek- flavor and potential health found evidence of milk fermentation dat- ing foods that will help them stave off benefits, fermented foods ing as far back as the Neolithic era. So, some of their current health challenges. Oare experiencing renewed interest from why the sudden rise in popularity? By now, most of them recognize the consumers; being mentioned as one of Undeniably, modern consumers are importance of digestive health. Con- 2019's top food trends by many trade both increasingly health-conscious and sumers understand that a healthy gut is (photo: Epi Ingredients)

36 · 8-9 2019 ¦ international-dairy.com Ingredients ¦ IDM

the foundation of overall wellness and goes as far as supporting a healthy immune system. With that in mind, they are naturally attracted towards products, such as fermented foods, that are not only touted to affect digestive health positively but also alleged to promote heart health, strengthen the immune system and even help reduce symptoms of depression. Although originally designed to preserve food and extend shelf life, fermentation appeals to modern consumers for many reasons: from its dis- tinctive taste to producing 'clean label' products as well as delivering added health benefits thanks to the good bacteria contained in the finished product. Whether it be yogurt, kimchi, sauer- kraut, tempeh or other matrices, when it comes to fermented foods, most of them still require refrigeration; a feature that does not bode well with consumers' increasingly busy lifestyles and their ongo- ing quest for healthy, convenient, "on- the-go" options that also taste good.

Innovative ingredients Committed to driving innovation and supporting food, beverage and nutrition manufacturers in the development Epi Ingredients has developed a range of premium fermented powders (photo: of finished products that resonate with Epi Ingredients) consumers' needs, Epi Ingredients developed a range of premium fermented On-trend concepts indulgent!", explains Mathieu Lucot, powders (yogurt powder, quark powder In an effort to go one step further to help Marketing Manager at Epi Ingredients. and fermented milk powder) with differ- their customers, Epi Ingredients vowed Next was SoBenefik, a protein-packed entiating features such as, among oth- to develop, over the years, a series of on- yogurt concept featuring EPIPROT 60UL, a ers, the presence of live and active cul- trend concepts designed to inspire man- native milk protein concentrate produced tures. Leveraging decades of expertise in ufacturers while showcasing the unique directly from fresh milk through an ultra- the transformation of milk, the company characteristics of its ingredients. low heat process allowing for minimal was able to fine-tune a unique manu- Their first concept, award-winning denaturation and optimal functional & facturing process allowing them to dry SoFlexi, is a powdered mix that allows nutritional properties. SoBenefik contains blends of milk and live cultures, keeping consumers to create fresh yogurt-tasting 8% protein, live cultures, and a rich, ex- the cultures alive throughout the process snacks at their convenience. Whether tra-creamy texture while being low-fat. and into the finished powder. they are in the mood for a drinking yo- With fermentation being one of the These dry yogurt ingredients are gurt, some ice cream, or an acid drink, major trends this year, the company is the perfect fit for new developments they can indulge almost instantly thanks working on expanding its range of fer- carrying the healthful halo of yogurt, to SoFlexi! It was specifically created to mented ingredients and also plans to delivering the same live cultures and demonstrate possible applications of EP- launch a new revolutionary concept fea- nutrition as their traditional counter- ILAC fermented powders. turing some of its Epilac fermented pow- parts but without some of the hurdles "With our EPILAC fermented powders… all of which will be unveiled later of fresh yogurt. They are also naturally ders, we can support manufacturers in this year at Food Ingredients Europe. perfectly adapted to regions where the development of both shelf-stable and Stay tuned! harsh climate conditions might hinder fresh products designed to cater to con- milk production or pose a challenge sumers who are always pressed for time For more information visit: when it comes to preserving fresh milk and looking for convenient, "on-the-go" www.epi-ingredients.com

(photo: Epi Ingredients) or refrigerated products. snack options that are both healthy and www.twitter.com/Epi_Ingredients

8-9 2019 ¦ international-dairy.com · 37 IDM ¦ Site report

Once again a pioneer

Palsgaard's production is CO2-neutral from now on

he Danish manufacturer of emulsifiers and stabilizers Palsgaard has reached a particularly ambitious target earlier than planned: the company's six global production sites are now all carbon-neutral, despite their very energy-intensive production. IDM took a look around. Palsgaard, set its goal of CO -free production in 2010, but its jour- T 2 ney started already in 2005 after Birger Brix, then Group CEO of the Schou Foundation that owns the company, had captured the effects of climate change with his own eyes on a trip to Greenland. Since then, a lot has happened to make the company a pioneer in sustainability. In addition to producing ingredients, the Palsgaard Estate also cultivates 800 hectares of arable land (cereals, lawn seeds). The straw produced

was the starting point for Palsgaard's CO2 neutral-production which it used to replace heavy oil in 2005 in the generation of heat energy for Palsgaard's offices and factory buildings. Biogas as an energy source and green electricity from Scandinavian hydropower were added later. In addition, extensive investments were made in energy-saving technology Burning straw for hot water generation marked the start of and process optimisation as well as the conversion of lighting to LED.

Palsgaard's journey to CO2 neutrality Overall, tangible changes such as energy optimisations and switching to

38 · 8-9 2019 ¦ international-dairy.com Site report ¦ IDM

renewable energy sources, account for around two thirds of total CO2 neutrally produced" ingredients, the sustainability of which is also man- reductions. Palsgaard still compensates for the remaining third by pur- ifested by the fact that the raw materials, mostly palm oil, come from chasing official UN carbon credits to offset emissions. According to An- sustainable cultivation and are certified accordingly. The purchase of ders Brix, who today heads the Schou Foundation, this will only be done RSPO-certified palm oil costs Palsgaard an extra € 1.5 million per year. until green energy becomes available at all six production sites on four There are several reasons why Palsgaard was able to become CO2- continents. The Dutch plant is already working completely without CO2 neutral at all. On the one hand, the Schou Foundation pursues a long- emissions on the basis of wind-energy and a photovoltaic installation. term approach and does not have to worry about short-term profits. On the other hand, Palsgaard acts as a supplier who above all offers know- Further expansion will also be sustainable how to customers. The company, which is regarded as the inventor of

All in all, Palsgaard has reduced its CO2 emissions by 56,175 tonnes in modern plant-based food emulsifiers, maintains several application cen- the nine years since 2010. This corresponds to the emissions of almost tres worldwide in which development is carried out for the addressed in- 4,900 average European households. But the company does not want dustries – dairies, ice cream manufacturers, the confectionery and bakery to stop there. Due to a steadily growing business, production capacities industries. The dairy and ice cream department in Juelsminde, with its at the main plant in Juelsminde, Denmark, are now to be doubled by excellently equipped pilot plant, is in a position to provide customers with 2023. This, explains Managing Director Jakob Thøisen, will be done, targeted support in product development and recipe optimisation. while retaining carbon-neutral production. Palsgaard is currently in the Even in uncertain times, Thøisen mentions Brexit and global trade planning phase for a large solar power plant right next to the factory conflicts in particular, the company can continue to pursue its sustainabil- site, which will supply the additional production. Thøisen's approach is ity strategy unwaveringly. Here, too, the that every year in the relevant six to seven months far more electricity company‘s foundation structure acts as a is generated than is consumed, so that it is fed into the grid. In times stabilising factor despite all the difficulties when solar power is scarce, Palsgaard will then buy in green electricity in the market. and thus, in the bottom line, obtain a largely self-sufficient supply. Palsgaard Managing Director Jakob Know-how as the basis Thøisen: R&D in emulsifiers and

As Thøisen points out, Palsgaard began the road to CO2-free produc- stabilizers focuses very strongly on tion when the discussion about climate change was less urgent than it modifications of existing solutions. is today. The initiative that led to the current status was, of course, also Establishing a completely new associated with savings in various areas. But customers are now also emulsifier for the food sector is asking for sustainable ingredients against the background that climate challenging in view of today's regu- has become the dominant topic. Palsgaard can now supply "carbon- latory approval requirements.

8-9 2019 ¦ international-dairy.com · 39 IDM ¦ IDF Column IDF issues guidance to help determine milk fat purity

Report provides much needed guidance to those involved

in the testing of milk and dairy products

Author: Aurélie Dubois-Lozier, Science and Standards Programme Manager, International Dairy Federation

ilkfat is an important com- Standard ISO 17678|IDF 202 Milk and Milk tists and non-scientists involved in the testing ponent of milk and most Products – Determination of the milkfat pu- of milk and dairy products. dairy products. In addition rity by gas chromatography, was developed It is anticipated that the publication will to having a nutritional im- by international standards organisation ISO, assist both those who desire to test milkfat pact, it also provides nu- in partnership with the International Dairy purity and those who need a general under- Mmerous benefits to food products including Federation (IDF). The standard, a revision of standing to interpret the results the method flavour enhancement and desirable mouth- which was recently published, is designed to produces, thus helping to ensure the quality feel. In addition, milkfat has numerous health accommodate regional, seasonal and feed of dairy products produced globally. It is fur- benefits: in the human diet it is an important variations in authentic milkfat composition. ther hoped that greater knowledge of the source of bioactive fatty acid conjugated lin- Recognising a need for the IDF/ISO stand- testing of milkfat purity and its advantages oleic acid (CLA), which is claimed to exhibit ard to be easily interpreted by a wider range of could lead to the replacement of some of several health benefits including anticarcino- dairy and food professionals, in August 2019, the older test methods used in some re- genic, antiatherogenic, immunomodulating IDF released its Bulletin 499/2019: Guidance gional regulations, increasing harmonisa- and anti-obesity effects. However, the high on the practical application of IDF/ISO stand- tion. Both IDF Bulletin 499/2019 and IDF/ price of milkfat means that it is susceptible ard on the determination of milkfat purity. ISO standard ISO 17678|IDF 202 are avail- to replacement by other animal fats or veg- The new publication provides guidance on the able on the IDF website www.fil-idf.org, etable oils. Non-reporting of lower-quality practical application of the IDF/ISO standard along with a wide range of dairy sector ingredients risks the quality and nutritional and is designed to accommodate regional, publications and information on the sector. profile of dairy products and subsequently seasonal and feed variations in authentic milk- their reputation with consumers. fat composition. IDF Bulletin 499/2019 pro- About IDF Unsurprisingly, the dairy sector is often vides supplementary background information Helping nourish the world required to prove the authenticity of its prod- and guidance on the determination of milkfat with safe and sustainable dairy uct against potential adulteration with other purity, providing much needed guidance and The IDF is the leading source of scientific oils or fats. In order to do this, International important additional direction to both scien- and technical expertise for all stakehold-

40 · 8-9 2019 ¦ international-dairy.com IDF Column ¦ IDM

ers of the dairy chain. Since 1903, IDF has provided a mechanism for the dairy sector to reach global consensus on how to help feed the world with safe and sustainable dairy products. A recognized international authority in the development of science-based standards for the dairy sector, IDF has an important role to play in ensuring the right policies, standards, practices and regulations are in place to ensure the world’s dairy products are safe and sustainable.

About ISO ISO is an independent, non-governmental international organization with a mem- bership of 164 national standards bodies. Through its members, it brings together experts to share knowledge and develop voluntary, consensus-based, market relevant International Standards that support innovation and provide solutions to global challenges.

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Newsletter_EA.indd 1 12.01.16 14:24 IDM ¦ Column ‘Shaping the EU Dairy Landscape’

EDA/ASSIFONTE ANNUAL CONVENTION 2019

16 – 19 October 2019, Vienna, Austria

he 2019 edition of the EDA Annual Convention will sail under the motto of ‘Shaping the European Dairy Landscape’. With a new European Parlia- ment and a new European Commission that will take office in just a few weeks from now, the Brus- Tsels institutional set-up is completely renewed. In these times of political changes, this landmark event for the European dairy industry will be a timely opportunity to be at the fore- front of political debates. Shaping the European Dairy Landscape is more than just a title: this is our statement and our mission. From a Dairy perspective, we are ready to work together with the next Eu- ropean Commission, focussing on the ecological transformation of our continent, on a better inclusion of rural areas in the European project, on a Single Market that is fit for our 21st century and on the consoli- dation of our trade environment. Our European Dairy Platform on Friday 18 October will feature dairy and policy-making experts from Eu- rope and beyond. Our EDA President Michel Nalet will chair the 1st Ses- sion “Our ambi- tion by 2024”, hosting MEP Nor- bert Lins (chair of

42 · 8-9 2019 ¦ international-dairy.com Column/News ¦ IDM

Strengthening the Latin American business Emmi

Surlat, the existing Emmi company in Chile, is merg- million in 2018 and has reported growth in a challenging with competitor Quillayes to form Quillayes Surlat. ing market environment over the past three years. The newly founded company will be the number four Quillayes produces cheese, yogurt, butter and cream in the Chilean dairy market. Emmi subsidiary Kaiku will in Victoria (southern Chile) and Calera de Tango (close hold a majority stake of 51.5 %. The acquisition is sub- to Santiago). It has developed a solid market position, ject to approval by the local competition authorities. especially in the cheese market, and particularly with In 2018 Quillayes generated sales of some CLP 50,000 fresh and soft cheese and speciality cheeses, but is also million. Surlat recorded net sales of around CLP 70,000 well established in other segments and in distribut- ing imported branded goods. Quillayes is a long-established brand with high recognition, which is one reason why its name is used first in the new company the European Parliament’s Committee on Agriculture and name. Surlat’s key segments are UHT milk and other Rural Development), Giuseppe Ambrosi (CEO Ambrosi spa dairy products, particularly in the lactose-free area. and President of ASSOLATTE) as well as Josef Braunshofer (CEO Berglandmilch). We will dive into the expectations of the European Parliament for the legislative term 2019 – 2024 and debate on how we want our dairy landscape to look like in 2024 and beyond. Session 2 focussing on "What’s driving global dairy?" and chaired by Ingo Müller (CEO of DMK) will feature H.E. Dr David Walker (NZ Permanent Representative at WTO in Geneva), François Salamon (CEO Schreiberfoods Europe) and Prof. Dr. Marin Bozic (University of Minnesota, USA) … an opportunity to discuss amongst others the developments of No.1 specialist the international trade arena. in reconditioned Session 3 will be moderated by Hélène Simonin (EDA Di- rectory for Food, Environment and Health) and will raise the dairy machines question “Where to position dairy in today’s consumer, B2B and retail world?” together with Dr. Jaap Petraeus (Direc- Milk tor Sustainability, Royal FrieslandCampina), Dr. Michael Blass Yogurt (AMA-Marketing), Boyan Neytchev (Bel groupe GM Central Butter and East Europe) and Dr. Andreas Steidl (REWE Austria). In parallel, on Thursday 17 October, our 2019 break-out Margarine sessions will focus on two essentials topics for our dairy success in Europe and beyond. In the first session moderated by Processed cheese Philippe Diercxsens (Environment Manager, Danone) we will Cheese debate on how to feed the World with Sustainable Dairy, together with Prof. Jürgen König (University of Vienna), Jane 2.000 machines Muncke (Food Packaging Forum, Zürich / Vetropack), Daniel in stock Lehner (ALPLA-Group), Heike Schiffler (Tetra Pak). Session 2 Warranty moderated by EDA Chair of the Trade & Economics Cmte. Fast delivery times Wim Kloosterboer (Royal FrieslandCampina) will focus on the Global Dairy Market Intelligence Landscape, with Angelo Low investment Rossi (CLAL, Italy), Prof. Dr. Marin Bozic (University of Min- Complete projects nesota, USA) and Prof. Holger D. Thiele (ife, Kiel, Germany). On behalf of EDA President Michel Nalet, Assifonte Presi- dent Ludwig Rupp and VÖM President Helmut Petschar, we are looking forward to seeing you in Vienna on 16-19 Oc-  +31(0)348-558080  [email protected] tober 2019 for this landmark event! All information about the programme, registrations and venue is available on the www.lekkerkerker.nl conference website: www.eda2019.eu/en/welcome.

8-9 2019 ¦ international-dairy.com · 43 IDM ¦ News

NIZO Dairy Conference New stabilising systems Top quality scientific conference Hydrosol

NIZO will hold the upcoming 11th NIZO Dairy Confer- The new stabiliser system range Stabiprime MFD by ence on Milk Protein Functionality in Papendal, Neth- Hydrosol consists of carefully selected hydrocolloids. erlands on October 8-11. These stabilising systems are soluble in water as well The conference aims to combine the most recent sci- as in sweet whey. They are easy to use, and make entific developments in milk protein functionality. It it economical to produce milk mixed beverages. In will provide a unique opportunity for experts from aca- addition to the proven system with carrageenan, demia, the dairy and food industry to interact and ap- Hydrosol also offers a gellan alternative, Stabiprime ply their knowledge and latest research findings to the MFDG. Its advantage is that it enables milk beverage design and manufacture of novel and improved foods filling even at high temperatures, up to 40°C. The and dairy ingredients. The conference will bring to- main property of Stabiprime MFDC with carrageenan gether experts from the fields of dairy science and tech- is that it lets manufacturers make stable products nology, processing, chemistry, physics, sensory, health without high-pressure homogenisation, preventing and nutritional sciences. nizodairyconference.com sedimentation even with cocoa. hydrosol.de

Exploring innovative solutions for sustainable dairy wastewater management IDF

IDF has released a publication that explores pioneering wastewater treatments in dairy processing. Owing to its composition and organic matter content, biologi- cal treatments are preferred and currently, activated (photo: Hydrosol) sludge is one of the most used processes. This treatment, completed by other unitary operations, achieves the quality levels required for the discharge. However, dairy wastewater presents further interest- ing possibilities. Its unique composition can support reuse. Some dairy plants already use these technologies energy production and its treatment, under some con- and the feedback received has been positive. Developed ditions, allows for the recovery of water for its reuse. by the Federation’s action team on innovative practices The new International Dairy Federation (IDF) publica- for eco-friendly dairy technologies, the publication in- tion represents a guide that professionals can consult to cludes examples from Canada, France, Germany, Ireland, improve the treatment and valorisation of wastewater Italy, Japan, Sweden and India, giving a broad overview produced on site or identify a state-of-the-art technol- of the latest technologies available in this area. ogy in the event that a treatment plant requires replacement. The production of this guide helps deliver on the The publication is available in the IDF E-Shop: dairy sector’s commitment to the adoption of sustain- www.store.fil-idf.org able practices throughout the dairy chain, ensuring that best expertise and resources are available to the entire dairy supply chain with regard to wastewater processing and treatment options. Different technologies are currently available to treat wastewater produced through dairy processing. These include anaerobic reactors to treat carbon pollution and produce biogas, membrane bioreactors and membrane filtration for treating and producing water for

44 · 8-9 2019 ¦ international-dairy.com Nuremberg, Germany | 12 – 14 November Improved responsiveness Standard-Knapp is joining the End of Line Packaging Experts Good conversations.

EoL Packaging Experts (EoL) has acquired Standard- Knapp (S-K) based in Portland, US. The acquisition Good business. represents a fit with EoL‘s strategic plan of being a market leader in the provision of end-of-line packaging solutions for the food and beverage industry. Standard-Knapp and A+F that also belongs to EoL both provide a strong basis representing the full value chain with new machine sales, engineering, manufacturing and an own service organization. The merger creates a globally active industry leader for end-of-line packaging machines and systems with an established presence in America and in Europe. The product portfolio is fully focused on custom- ized high speed end-o-line packaging machines and 100% complementary. This will enable EoL to ex- pand with both product portfolios to the U.S. and European market. Furthermore, the worldwide sales and service organizations can be utilized by both companies. Group-wide competence centers like the A+F digital packaging competence center, the S-K shrink wrapping competence center or the A+F palletizing competence center will enable the EoL group to fully utilize its technological competence. standard-knapp.com

Acquisition of Merlett Group braubeviale.de Continental

Continental has reached an agreement with Merlett Group, based in Daverio, Italy, on the purchase of its flexible hose business. With this acquisition, Con- tinental is expanding its material expertise beyond CONNECT WITH rubber, particularly with regard to high-performance thermoplastics technologies and solutions. At the THE FUTURE same time Continental is diversifying its product Over 1,000 exhibitors and more than 40,000 trade visitors portfolio and broadening its regional presence, espe- all have exactly one goal in mind: To drive progress for the cially in Europe. Merlett Group was founded in 1952 by the Tam- beverage production of tomorrow, so that new solutions borini family and is now one of the leading European can be used to market better products. manufacturers of flexible plastics hoses. It designs, Sound exciting? Find out more: manufactures and distributes hoses for the agricul- braubeviale.de/next ture, industrial, construction, transport and food industries. The company operates two well-equipped production sites in Italy (Daverio, Varano Borghi) and one in Rancate, Switzerland. continental.com

Brau19_108x280_EN_International_DIARY_magazine_HERST.indd 1 26.08.19 09:32 IDM ¦ Supplier directory

Cheese cutting machines Cheese technology Separation

holac Maschinenbau GmbH ALPMA Alpenland Maschinenbau GmbH Flottweg SE Am Rotbühl 5 Alpenstrasse 39 – 43 Industriestraße 6-8 89564 Nattheim, Germany 83543 Rott am Inn, Germany 84137 Vilsbiburg, Germany Phone: +49 (0)7321 964 50 Phone: +49 (0)8039 401 0 Phone: +49 8741 301 0 Fax: +49 (0)7321 964 55 0 Fax: +49 (0)8039 401 396 Fax: +49 8741 301 300 Email: [email protected] Email: [email protected] Email: [email protected] Web: www.holac.de Web: www.alpma.de Web: www.flottweg.com

Ingredients Software

TREIF Maschinenbau GmbH Toni-Reifenhäuser-Str. 1 57641 Oberlahr, Germany Chr. Hansen GmbH Phone: +49 (0)26 85/944-0 Große Drakenburger Str. 93-97 Fax: +49 (0)26 85/1025 31582 Nienburg, Germany Email: [email protected] Phone: +49 (0) 5021 963 0 Web: www.treif.com Fax: +49 (0) 5021 963 109 Email: [email protected] Web: www.chr-hansen.com

Reconditioned dairy equipment

Weber Maschinenbau GmbH Günther-Weber-Straße 3 35236 Breidenbach, Deutschland Telefon: +49 (0) 6465-918-0 Telefax: +49 (0) 6465-918-1100 E-Mail: [email protected] Web: www.weberweb.com Lekkerkerker Dairy & Food Equipment Handelsweg 2 3411 NZ Lopik, the Netherlands Phone: +31-348-5580 80 Fax: +31-348-5548 94 Email: [email protected] Web: www.lekkerkerker.nl

find hot news from the suppliers‘ industry at the IDM Website

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46 · 8-9 2019 ¦ international-dairy.com Preview IDM 10 2019 & Imprint ¦ IDM (photo: E+H) Bosch) (photo: Standardized process instrumentation Flexible, precise, easy to clean and retrofit Technology/IT Packaging (photo: J. BULLA) (photo: KHS) Exopolysaccharides from lactic acid bacteria The Facilitator Ingredients Packaging

Imprint

Publisher: Publisher’s International representative: B&L MedienGesellschaft mbH & Co. KG Hilden, Verlagsniederlassung Bad Breisig, dc media services, David Cox, 21 Goodwin Road, Rochester, Kent ME3 8HR, UK, Zehnerstr. 22 b, 53498 Bad Breisig/Germany, Fax: +49 (0) 26 33/45 40 99, Phone: +44 845 393 1574, Email: [email protected] Internet: www.international-dairy.com Subscriptions: Object Manager: B&L MedienGesellschaft mbH & Co. KG, Office Munich, Ridlerstr. 37, Burkhard Endemann, Direct line: +49 (0) 26 33/45 40-16, 80673 Munich/Germany Email: [email protected] Sales manager: Patrick Dornacher, Direct line: +49 (0) 89/3 70 60-3 71 Editor: Email: [email protected] Roland Sossna (responsible), Office Dülmen/Germany, IDM International Dairy Magazine is published eight times a year Direct line: +49 (0) 25 90/94 37 20, Cell phone: +49 (0) 1 70/4 18 59 54, (January, February, April, June, August, September, November). Annual subscription Email: [email protected] rate: € 86.00 incl. postage Subscr. in Germany: € 70.00 incl. postage + VAT Office Dorsten: Anja Hoffrichter, [email protected], Single copy: € 16.00 incl. postage Orders from Germany add VAT Cell phone: +49 (0) 178 233 0047 Bank details: Commerzbank AG, Hilden; Food Ingredients: IBAN: DE58 3004 0000 0652 2007 00; SWIFT-BIC.: COBADEFFXXX Max Schächtele, Mengener Str. 2, 79112 Freiburg im Breisgau, Germany, Cover page: Direct line: +49 (0) 76 64/61 30-96, Cell phone: +49 (0) 172 357 0386, Email: [email protected] F.F FISCHER PLANNING LTD.

Correspondents: Print: Ferda Oran, Middle East, [email protected]; Jack O´Brien, USA/Canada, Radin print d.o.o., Gospodarska 9, 10431 Sveta Nedelja, Croatia [email protected]; Joanna Novak, CEE, [email protected]; The magazine is printed on chlorine-free paper. Tatyana Antonenko, CIS, [email protected]; Mario Schacher, Economically involved in the legal sense of. § 9 Abs. 4 LMG Rh.-Pf.: South America, [email protected]; Brian Norwood, Australasia & Pacific, B&L MedienGesellschaft mbH & Co. KG, Verlagsniederlassung Bad Breisig, [email protected]; Chris Walkland, UK & Ireland, [email protected]; Zehnerstraße 22b 53498 Bad Breisig. Bent Oestergaard, Scandinavia, OCon ApS, [email protected], Economically involved in the legal sense of § 9 (4) LMG Rh.-Pf.: Owner of B&L Claudia Vasquez Alarcon, Spain/Portugal, [email protected] Medien-Gesellschaft mbH & Co. KG D-40724 Hilden (shares in brackets): Graphics, layout and production: Renate Schmidt (38.8 %), community of heirs Ulla Werbeck (31.2 %) Nikolai Janz, Direct line: + 49 (0) 26 33/45 40-25, Email: [email protected] General Manager of B&L MedienGesellschaft mbH & Co. KG: Harry Lietzenmayer Advertising Manager: Heike Turowski, Office Marl/Germany, Direct line: +49 (0) 23 65/38 97 46 Fax: +49 (0) 23 65/38 97 47, Cell phone +49 (0) 1 51/22 64 62 59, Email: [email protected]

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