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OURFAVORITETHINGS
Our editors, writers and others come up with 10 lip-smacking new products we can’t live without. p22
INGREDIENTS MAKE DAIRY
MERRYp33
IMPROVINGFROZEN
FOODSPROCESSING p57
MOM BRANDS: MASTER
OF BAGS p71
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COVER STORY
DEPARTMENTS
VOLUME 73, NUMBER 11
22
33
NOVEMBER12
In memory of a true foodie.
Continue the GMO discussion.
Maximize a closed plant sale.
How concerned are consumers?
Hostess’ bankruptcy plan.
Ball Park burgers; low-cal Greek yogurt; ID gum; Sara Lee pound cakes; Campbell’s upscale soups; fl avored peanut butters from Planters.
22 OUR FAVORITE THINGS
Th is year’s list: Adonia frozen Greek yogurt, Fair Oaks Farms Core Power, General Mills Gluten Free Chex Apple Cinnamon, Hershey’s Simple Pleasures, Hostess Chocolate Crème Twinkies, IHOP At Home syrups, Roland fl avored quinoa, Stouff er’s Farmers’ Harvest Steam Meals-For-One, Vitalicious VitaPizza, Wells Blue Bunny cake-inspired ice creams.
FEATURES
33 PRODUCT DEVELOPMENT
Today’s dairy case is a vibrant and diverse category expanding with the help of whey proteins, new sweeteners and probiotics.
INGREDIENTS:
As frozen foods get more sophisticated, so do their manufacturing processes.
66 MRO:
Box-free cereal packaging yields green payoff s for MOM Brands.
20
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E D I TO R ’ S P L AT E
We held open this page and one of our news pages (p15) to report on what I thought would be the start of one of the most important issues the food
industry would face in 2013. While the outcome is not what I ex-pected, it’s a big issue nonetheless, and the failure of Proposition 37 should not be considered the end of discussion.
In addition to helping to return Barack Obama to the White House, California voters on Nov. 6 weighed in on the question of labeling of genetically modified foods (GMOs, for genetically modified organisms). Most people I talked to thought Prop 37 would pass, but it failed by about 53 percent to 47 percent. Lib-eral coastal cities seemed to vote in favor, but narrowly; the agri-cultural interior of the state voted heavily against it.
But that’s not the end of this story, nor should it be. The bigger issue is trust of the food industry, transparency and al-lowing consumers to make informed choices. In that regard, the Nov. 6 vote should not be an ending so much as a begin-ning, the start of an important and national discussion. The very fact that this issue created so much acrimony should be a sign that consumers are concerned and suspicious of the food industry. They need to be dialogued with, not dismissed.
There’s no sound science that GMO foods are harmful. But there’s not a lot science proving they’re safe either. The food industry has just taken that as a given, the old absence of proof to the contrary. That’s not a healthy way to connect with your customers.
Frankly, the consumers who really care already are shop-ping at Whole Foods, etc., and looking for “GMO free” la-bels. You won’t change their minds, but the great silent ma-jority needs to be put at ease.
If you recall, we devoted our February cover story, “The Food Industry Fights Back,” to issues for which the indus-try is unfairly attacked (www.FoodProcessing.com/arti-cles/2012/food-industry-fights-back.html). On obesity, food safety, “questionable” ingredients, the solution pretty much was the same: communication and transparency.
I see one of those “questionable” ingredients winning its war. Two years ago, high-fructose corn syrup was labeled the No. 1 cause of obesity in this country. And when consumer sentiment turned into a mini-trend, even food processors jumped on the bandwagon, proclaiming their reformulated products were now “HFCS-free!” While a lot of hasty defenses immediately went up
from some sectors of the business and certainly the suppliers of the sweetener, the Corn Refiners Assn. also started a campaign to educate consumers that HFCS is not sinister. It’s as much a factor in obesity as any other sugar – no more, no less. All calorie-containing sweeteners should be enjoyed in moderation.
Two years later, the campaign appears to be working. I sel-dom hear paranoid talk about HFCS anymore in food indus-try or consumer circles. CRA-sponsored research shows that reformulated products that touted “no HFCS” enjoyed no sales bump, and some food processors already have reversed themselves. More recent research indicates consumers no lon-ger care; maybe they never did. Science and logic prevailed.
Maybe the same can be done for GMOs. Frankly, maybe a label requirement wouldn’t have been so bad. Maybe con-sumers would have realized GMOs have been in the foods they’ve eaten for years, maybe even generations, with no ill effects. (That a lot of maybes; forgive me.)
There already was a good pro-GMO educational campaign in California. That kind of education needs to be kept up and spread across the country. And augmented with convincing sci-ence that GMOs do no harm. The GMO debate will not end in California. Opponents already are taking aim at other states. Washington, Connecticut and Vermont have been mentioned as possible battlegrounds, and the anti- forces are lobbying the FDA and President Obama. So, as we exhorted in February: be transparent, be communicative, be proactive. This is a fight that can be won. Moreover, it shouldn’t be considered a fight.
Sad newsI haven’t left much room for this final word. Diane Toops, our News & Trends Editor, died Oct. 31 following a brief ill-ness. Many of you got to know her in her 24 years in our em-ploy. At trade shows or through her column or online blog, she was a delightfully quirky and opinionated personality. Several of us at Food Processing and Putman Media reflect on her impact on p86. Please give it a read.
Dave Fusaro, Editor in ChiefE-mail: [email protected]
Failed Vote Doesn’t End GMO Debate
industry needs to get in front of this issue.
NOVEMBER
www.foodprocessing.com
In Memory of Julie Cappelletti-Lange, Vice President 1984-2012
EDITORIAL
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The other pre-election debate.
The great GMO debate If you’re a regular visitor to FoodProcessing.com, you likely noticed our coverage of California’s Proposition 37. We’ve carried several articles, many of them opinion pieces authored by attorneys. One article, “Proposition 37: Food Transparency or Increased Organic Food Sales?” (www.FoodProcessing.com/articles/2012/prop-37-transparency-or-organic.html), was particularly popular among our readers, no doubt because it posed a question that encouraged many members of the food industry to think about: What is purpose of the proposition?
We asked visitors to comment with their thoughts on Prop. 37. “As a manufacturer, how do you feel about California’s Proposition 37?” Below are the results.
and steroids. All of this eventually makes its way into our bodies causing breakdowns on a cellular level, which increases our risk for cancer,
to contrast with the scenarios being portrayed in this article.
puff piece trying to confuse consumers, which this time I don’t believe will work. Perhaps try looking at your own family and values before agreeing to write this drivel for a few $$$.”
-santo and other biotech giants have made a science of making bad science to promote their products and further their corporate agendas and have turned the public into unsuspecting guinea pigs for dangerous genetic experiments.”
they can remain healthy.”
And now for something a little lighterFood Funnies is our way of letting you take a break from all the serious stuff you deal with at work – by com-ing up with appropriate light-hearted captions for the cartoons we supply.
-
www.FoodProcessing.com/articles/2012/food-funny-november.html
Here’s October’s winner:
Congratulations to reader Predrag
Olymel Cornwall, for his winning caption: “We should avoid
having ‘bring-your-kids-to-work’ on Halloween”
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P OW E R L U N C H
Manufacturing food profitably has rarely been so challenging. The effects of fuel and ingredient in-flation, a consolidated retail sector and dynamic
consumer preferences all collide on the plant floor, where margins are thin and sustainable only though manufacturing efficiency and throughput. When either is threatened, a plant closing looms, and decisions are made on how best to recover dual value streams from plant and equipment now surplus.
Historically, those value recoveries involved two interest groups, often operating independently of the other: Plant op-erations dictated the fate of equipment and infrastructure, and corporate real estate managed what remained. And often what remained was a cannibalized asset, use- and value-impaired, suitable neither for food production nor a lesser industrial use.
What was a food plant has become a warehouse, or worse, indistinguishable from millions of square feet of competing vacancy. The better course, as described below, is an orches-trated approach, where corporate operations and real estate manage the sale of the “whole,” optimizing the chances it will exceed the narrow value of its pieces.
First, to realize this result, dueling interests must work in tandem, understanding the most appealing asset will be one that properly balances real and personal property. Too often the equipment “tail” wags the property “dog.” Seeking to re-cover easy values quickly, owners liquidate infrastructure to the detriment of property value and potential food occupan-cy. Specifically, in redeploying or liquidating refrigeration, steam, waste pre-treatment and bulk ingredient systems, owners dilute next-generation use, mitigate speed-to-market advantages and, in so doing, eviscerate property values.
Spontaneous equipment decisions may yield a quick val-ue recovery but they often compromise far greater property sums. A more informed path requires an honest dialogue among several parties: corporate operations, the corporate real estate department, an equipment liquidator (who is will-ing to concede infrastructure left behind may support a larger real estate recovery) and an industrial broker fluent in the nuances of food facility valuation and marketing. Neither of those last two capabilities is a commodity, so whom you
choose matters, as does the ability of both experts to appreci-ate the other’s role for the better interests of the client.
Second, once the property brokerage/equipment liquida-tion team is identified, value will be maximized when both parties operate in sync. Many commercial brokers fail to comprehend the role infrastructure has in defining use and value; likewise, many liquidators are inclined to pick clean the property bone, with no regard to what remains. One or the other might reap a windfall, but the loser most certainly is the corporate seller failing properly to manage the process.
The better approach would be to define what the most all-inclusive asset package might be; to include necessary infrastruc-ture and non-critical surplus equipment; and, over time and in response to market demand, allow the latter to be liquidated as the parties agree. By marketing the most complete asset package available, the seller maximizes the chances of a full value recovery.
Third, in cases of extreme property obsolescence, where age, ceiling heights, demising walls and condition prohibit functional next-generation food use, including non-critical equipment in the sale process may be the only means to gen-erate market interest quickly. Many distressed properties can be packaged to trade where the proceeds of liquidated equip-ment and metals salvage offset acquisition cost and carry risk.
Indeed, the demand for metals from emerging economies has pushed prices to the level where the salvage value of copper wire and stainless and structural steel may exceed any property value in-use. Admittedly, this class of emerging opportunistic “salvage” buyers has few CFOs doing hand-stands, but it does represent one solution to disposing of highly distressed proper-ties. The relevant question then becomes not “How much is it worth?” but “How many years will it take to sell?”
In summary, a closed plant has many stakeholders: owners, employees, municipal providers. Displaced employees want new jobs, owners want to maximize surplus property values and equip-ment assets, and municipal providers want demand loads. Proper orchestration and marketing of the property, infrastructure and the equipment package yields the best results. When functional assets are able to be redeployed as such, it benefits corporate, labor and community stakeholders. And everyone wins.
Getting the Most From a Plant SaleWhen a plant closes, too many companies rush to sell off equipment, cannibalizing the value of the real estate.
By Jeffrey Counsell, CBRE Inc.
Jeffrey Counsell is senior vice president for brokerage services in the food facilities group of industrial real estate firm CBRE Inc.
(www.cbre.com/jeff.counsell). He can be reached at 312-861-7852 or [email protected].
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F O O D S A F E T Y
Even with frequent food safety outbreaks and recalls, concern levels about the safety of the U.S. food sup-ply remain relatively constant – although there are
temporary spikes when news of an outbreak occurs, accord-ing to The NPD Group (www.npd.com), a Chicago-based market research firm.
NPD’s Food Safety Monitor, which continually tracks consumer awareness and concern about food safety issues, shows that for the period from January through August 2012, on average, 60 percent of U.S. consumers were some-what or slightly concerned about the safety of the U.S. food supply, 25 percent were extremely or very concerned and 15 percent not concerned at all. The food safety concern levels in 2012 are on par with previous years.
On a biweekly basis, when the Food Safety Monitor sur-vey is conducted, there are fluctuations in the percentages of consumers who are not or are concerned about the safety of the U.S. food supply based on whether or not there is a food safety issue in the news, but the annual averages remain relatively constant.
Every other week a representative sample of approximate-ly 500 U.S. adults is asked a series of questions related to food safety, and NPD then issues the results in its monthly report.
The NPD Group Food Safety Monitor tracks consumer awareness and concern about food safety issues including salmonella, E. coli, mad cow disease, foot and mouth dis-ease, acrylamide, trans fats, mercury in fish, avian bird flu and listeria. Consumers also are surveyed about their eating intentions of foods, including fast food burgers, chicken, ham, steak, fish/seafood, breakfast cereals, butter, milk, cookies and more.
Since November 2007, the Food Safety Monitor survey includes this question: “How concerned are you about the safety of the U.S. food supply?” See the answers in the ac-companying table.
There are spikes and then a leveling off with specific food safety outbreaks, according to NPD. For example, this past summer, in July and August, there were outbreaks and
product recalls involving listeria contamination. In mid-July, a California-based onion plant recalled all onions pro-cessed at its plant because of listeria contamination. Since a wide variety of products use the plant’s chopped, slivered and peeled onions, there were subsequent recalls of ready-to-eat and ready-to-cook foods issued by supermarkets and manufacturers.
In mid-August, pre-sliced apples distributed by a New Jersey plant to fast-food and grocery chains across the coun-try were among packaged products being recalled due to pos-sible contamination with listeria bacteria.
Listeria is a bacteria that causes food poisoning and is especially dangerous to the elderly, people with weakened immune systems and pregnant women. Awareness of and concern about listeria peaked during the time the outbreaks were widely reported and then leveled off when the news subsided.
“The impact of a food recall on consumer attitudes and perceptions often depends on the amount of news coverage received, or the severity of the situation in terms of numbers sickened or dead as a result,” says Darren Seifer, NPD food and beverage industry analyst. “Recalls, unfortunately, have become more commonplace, but consumers are creatures of habit. It takes a lot for us to change what we eat.”
How Concerned Are Consumers?Shoppers are only slightly concerned about the safety of the U.S. food supply despite frequent food safety outbreaks, reports NPD.
The NPD Group (www.npd.com) provides consumer and retail information for a wide range of industries. The research firm has deep
roots in food and foodservice, helping clients to identify new business opportunities and guide product development, marketing,
sales, merchandising and other functions.
HOW CONCERNED ARE YOU ABOUT THE SAFETY OF THE U.S. FOOD SUPPLY? (% OF ADULTS WHO ARE…)
2010Average
2011Average
Jan-August 2012 Average
Extremely concerned 10 9 9
Very concerned 16 16 16
Somewhat concerned 29 28 29
Slightly concerned
Not at all concerned 14 15 15
Source: The NPD Group/Food Safety Monitor
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F I N A N C E
Hostess Bankruptcy Plan Imposed on UnionsDespite the largest union’s rejection, court orders wage cuts; five plants may close.
Hostess Brands Inc. on Oct. 11 filed a bankruptcy reorga-nization plan that will cut wages and benefits and freeze pensions for its employees and will give its recent owner/
investors zero for the cash they pumped into the company since 2009. Reports say the plan also includes the closing of five un-named plants.
The plan cuts at least $1.6 billion in debt (other media reports estimated it to eliminate $2-2.5 billion in unsecured claims). It also estimates an emergence from Chapter 11 bankruptcy pro-tection in January 2013 for the Irving, Texas-based baker. This is the second time in three years Hostess has been in bankruptcy reorganization.
Both union and non-union employees, totaling 19,000 full-time and part-time jobs, will take an 8 percent wage cut and will see only modest hikes in the coming years, as well as having their pension benefits frozen for at least two years. Healthcare and other benefits also will be cut.
Earlier in October, the same New York State Bankruptcy Court imposed the company’s plan on the Bakery, Confection-ery, Tobacco Workers and Grain Millers International Union, despite having 92 percent of the union members reject the pro-posal. At the time Hostess filed for bankruptcy protection (Jan. 11), the BCTGM union was the company’s largest unsecured creditor, with debts totaling $944.2 million. Hostess’ other large union, the International Brotherhood of Teamsters, narrowly ap-proved the contract modifications in September.
Greg Rayburn, Hostess CEO, earlier said the company might have to liquidate assets if all unions did not accept the reorganiza-tion proposal.
“Upon emergence, our union-represented employees will hold a 25 percent equity owner-ship, a $100 million interest-bearing note and have two seats on the board of directors,” said Ray-burn in a statement carried by Reuters.
The filing noted that investors, which had pumped more than $150 million into the com-pany since 2009, “will suffer a complete loss and receive nothing on account of these investments.”
“Demand for Hostess products has been very resilient, giving us a solid base to work from,” Rayburn said. “With a competitive cost structure and fresh capital at our disposal, we can begin to make the kinds of investments in our business that is essential to our future success.”
Hostess’ operating losses have increased while net revenues have declined over the past three years. The company reported a loss of $1.14 bil-lion in the 53 weeks ended June 2, compared to a loss of $341 million in the 52 weeks ended May 28, 2011, and a $138 million shortfall in the year ending May 29, 2010.
Sales for the 2012 fiscal year were $2,466.5 million, com-pared to $2,474 million in 2011 and $2,584.5 million in fiscal 2010. Revenues in fiscal 2004, before the bankruptcy filing, were nearly $3,468 million.
A hearing in Southern District of New York U.S. Bankruptcy Court is set for Nov. 29 to determine the adequacy of the reor-ganization plan.
IN THIS SECTIONOSI Group building overseasCampbell building biogas plant in OhioMonster Beverage sued for wrongful death
Industry News & Vision
Proposition 37, which would have required most foods and beverages made with genetically engineered ingre-dients to be labeled in California, appeared to have failed
by mid-day Nov. 7, the morning after the election.We reopened this page so we could bring you that report.
With more than 94 percent of the precincts reporting, the San Francisco Chronicle pronounced it defeated. Another media re-port from a few hours earlier had “no” votes at just more than 4 million to 3.5 million for “yes.”
We’ve done a fair amount of writing about it the past few
months, with even more conversation on our web site (www.FoodProcessing.com). Had it passed, California would have been the first state in the nation to pass such an initiative. For com-ments of visitors to our web site, see our On the Web column on p9.
“We said from the beginning that the more voters learned about Prop 37, the less they would like it,” said Kathy Fairbanks, a spokeswoman for the opposition quoted in the Chronicle story. “We didn’t think they would like the lawsuits, more bureaucracy, higher costs, loopholes and exemptions. It looks like they don’t.”
R E G U L ATO RY
Proposition 37 Defeated in California
E X PA N S I O N
SI Group, one of McDonald’s Corp.’s biggest (and lowest-profi le) suppliers, has been busy building overseas, putting up three plants this year in developing markets.
Vista Processed Foods Pvt. Ltd., a wholly owned member of the OSI Group, on Oct. 23 opened a frozen vegetable processing plant in northern India, in the state of Punjab. It’s Vista’s third facility in the country, after opening its second location in southern India, in Madanapalle near Bangalore, in January. Th e company’s fi rst plant opened in 1995 in Taloja, Navi Mumbai.
Th e Punjab facility will focus on producing value-added frozen vegetable products for quick-service restaurants (QSRs) and retail outlets for both the domestic and export markets (especially Middle East). Th is new plant makes Vista one of the largest value-added food companies in the country, supplying a variety of processed vegeta-bles, chicken, dairy and fresh produce items.
Located 155 miles north of New Delhi and 18 miles from Chan-digarh International Airport, the facility sits in India’s largest veg-etable production and consumption region. Th e facility also houses one of the country’s largest fresh vegetable processing lines, which is owned and operated by Pagro Frozen Foods Pvt. Ltd., long one of Vista’s key raw material vegetable suppliers.
Th e Madanapalle plant, opened in January, also will focus ini-tially on vegetable products for QSRs.
OSI Food Solutions Poland broke ground in September for a new production facility in Ostroda, Poland. Th e new beef processing plant will replace an older facility in the area.
“Th e production of hamburgers started in Ostroda in 1993. Today the hamburgers produced in the Polish plant are delivered to Poland, Sweden, Finland, Czech Republic, Slovakia and the Baltic states,” said John Gray, OSI Europe’s commercial director. Th e investment of €25 million ($32 million) will begin with phase one of the project, which in-cludes a three-story, 64,600-sq.-ft. processing and storage building. Th e plant is expected to be operational in the second quarter of 2013, with an estimated production capacity of approximately 25,000 tonnes (55 mil-lion lbs.), which could expand if customer volume requirements increase.
“OSI has been working alongside McDonald’s in Poland since the be-ginning, and with this investment we are creating the capacity to contin-ue to support growth well into the future,” said Phil Marsden, managing director for OSI Food Solutions Europe. “We see this plant as an impor-tant strategic investment in a country with a strong agricultural future.”
OSI Group is a $4.5 billion worldwide food supplier with head-quarters in the Chicago suburb of Aurora, Ill.
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Monster Beverage Corp., Corona, Calif., was named in wrongful death lawsuit in October by the parents of a 14-year-old girl who died of cardiac arrest af-ter drinking the firm’s namesake highly caffeinated energy drink. Parents of the late Anais Fournier filed the law-suit in the Superior Court of the state of California in Riverside. Anais, then 14, died on Dec. 23, 2011. According to media reports, she consumed a 24-oz. Monster Energy drink on Dec. 16, 2011, and another the next day. A few hours later, she went into cardiac arrest. The cause of death was listed as “cardiac ar-rhythmia due to caffeine toxicity com-plicating mitral valve regurgitation in the setting of Ehlers-Danlos syndrome.” Monster Beverage as of January 2012 is the new name for Hansen Natural Corp.
News reports out of Washington say the District of Columbia City Council is considering a ban on the sale of large, sugar-sweetened beverages sold in the District. That follows New York City’s September ban, championed by Mayor Michael Bloomberg.
MERGERS &ACQUISITIONSFlowers Foods Inc., Thomasville, Ga., in October said the U.S. Dept. of Justice approved an agreement under which Flowers will acquire certain assets and trademark licenses from BBU Inc. (Bim-bo Bakeries USA), a subsidiary of Grupo Bimbo S.A. B. de C.V. Flowers gets li-censes to the Sara Lee and Earthgrains brands for sliced breads, buns and rolls in the state of California and to the Earthgrains brand for a broad range of fresh bakery products in the Oklahoma City, Okla., market area. Financial terms were not disclosed.
B&G Foods Inc., Parsippany, N.J., has an agreement to acquire the New York Style and Old London brands from Chipita America Inc. for approximately $62.5 million in cash. The acquisition in-cludes a manufacturing facility in Yad-kinville, N.C., with approximately 250 employees.
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ampbell Soup Co., Camden, N.J., on Nov. 5 said it will create Ohio’s first commercial biogas power plant to gen-erate renewable electricity at its Napoleon, Ohio, pro-
duction plant. Campbell will divert 35-50 percent of the waste generated from its soup, sauce and beverage production away from Henry County landfills.
In addition to the Campbell waste, the anaerobic digester will process material from other area food processors, waste recyclers and local dairy farms. It will generate methane gas, which will be used to fuel turbines to replace about 25 percent of Campbell’s Napoleon facility’s annual electricity use. CH4 Biogas LLC is the technology provider and operator. A 15-year power purchase and services agreement will allow Campbell to use 100 percent of the electricity generated at a f lat cost.
“This new biogas technology will improve Campbell’s Na-poleon recycling rate to approximately 95 percent, reaching the company’s 2020 destination goal for the site early,” said Dave Stangis, Campbell’s vice president of public affairs and corporate responsibility.
“Th e use of biogas energy will reduce greenhouse gas emissions associated with the use of electricity in this facility by approximately
16,000 metric tons per year, or the equivalent of 3,000 cars.” The Napoleon Biogas plant will be located on more than seven
acres of land directly across from the Campbell site in Harrison Township. CH4 will design, own and operate the site, acting as stewards of the land, protecting the watershed and recycling and processing the organic waste in an environmentally sustainable way, a Campbell statement said. Other area industry and farming operations will also be able to use the facility, as the digester is designed to handle approximately 450 tons of mixed waste or-ganic material a day, leaving 60 percent available capacity.
Construction is under way and slated for completion in mid-2013. The project is financed by EKF (Eksport Kredit Fonden), the Danish state export credit agency, which will provide a debt guaranty on the financing and with investments from CH4 Bio-gas and BNB Napoleon Biogas.
The site is adjacent to a 60-acre, 9.8 MW solar system con-structed by BNB Renewable Energy Holdings for Campbell in 2011 that currently provides 15 percent of power for Campbell’s Napoleon facility. These efforts ref lect the company’s commit-ment to sustainable energy production in the areas of solar, wind and anaerobic digestion.
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Chiquita Brands International Inc., Charlotte, N.C., in October named Edward Lonergan president/CEO. He succeeds Fer-nando Aguirre, who previously announced plans to step down as chairman and president/CEO. Lonergan was president/CEO of Diversey Inc., a global provider of sustainable cleaning, sani-tation and hygiene solutions. In addition, Kerrii Anderson was named non-executive chairwoman of the board of directors.
JBS USA, Greeley, Colo., in September said Don Jackson will retire as CEO at the end of this year. Andre Nogueira, former JBS USA CFO and current CEO of JBS Australia, will become CEO of JBS USA eff ective Jan. 1, 2013. But Nogueira will have responsibility for both U.S. and Australia operations and will report directly to Wesley Batista, president and CEO of JBS global operations. Bill Rupp, in addition to his current role as president and COO of the JBS USA beef business, will assume leadership of the Australia business and report to Nogueira. Jackson will keep his seat on the board of Pilgrim’s Pride Corp. Parent JBS S.A. is based in Brazil.
ConAgra Foods Inc., Omaha, Neb., back in June named W. L. (Bill) Hutton as president of Consumer Foods Inter-national. He was vice president and general manager of
PepsiAmericas Inc., Poland/Baltics. Hutton also had prior assignments from PepsiCo in China and Canada.
Campbell Soup Co. on Oct. 31 hired its fi rst chief marketing offi cer. Michael Senackerib, 47, who worked for Campbell 16-20 years ago, returns after a varied career. Most recently he was senior vice president and CMO at Hertz Corp. Earlier he led Kraft’s $3.8 billion biscuit portfolio, global snacks sec-tor and the direct store delivery business and also served as executive vice president of Nabisco’s $1.2 billion salted snack
keting roles in Campbell’s U.S. soup business. He will report directly to Pres/CEO Denise Morrison.
Idahoan Foods LLC, Idaho Falls, Idaho, in September an-nounced the promotion of Drew Facer to president and chief operating offi cer. He was to executive vice president-retail. It’s the fi rst step in the succession plan led by CEO Gordon Lewis, who has advised the company’s board of governors that he will be retiring in September 2013. The board anticipates giving the CEO title to Facer when Lewis retires. Idahoan Foods makes packaged mashed potato and potato casseroles.
PEOPLE
ROLLOUTWe add new products to our web site throughout the month. Go to www.FoodProcessing.com and click on the New Products Resource Center along the top navigation bar.
-Mondelez Interna-
tionaliD Gum, -
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-General Mills Yoplait
Greek 100,
Hillshire Brands Co.,
Ball Park Flame Grilled Patties.
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PEANUT BUTTER FOR THE ADVENTUROUSPeanut butter just got a makeover, as Northfield, Ill.-based Kraft Foods Inc. rolls out Planters Nut-ritionpeanut butter. Created for adventure-seekers, the new line is the first national brand to add whole-some ingredients like bananas, granola, berries, rai-sins, cinnamon and nuts to its peanut butter.
Made with a peanut butter base, Planters Nut-rition peanut butter is nutrient dense and a good source of energy, providing 6-7g of protein per serving and at least five vitamins and minerals, de-pending on variety – Cinnamon Raisin Granola Nut,
Banana Granola Nut and Berry Nut. Made with real chunks of granola and dried fruit, Planters Nut-rition is a perfect combination that results in 0g of trans fat per serving and endless snack options. The good source of energy and delicious taste this mix provides will satisfy consumers ready to take on whichever adventure they choose to pursue.
“Planters Nut-rition peanut butter will change the way PB lovers think about their favorite staple,” says Jon Hall, brand manager. “Once fans get a taste of Nut-rition, we know they’ll be hooked. It’s time for all of us to expect more from peanut butter.”
Suggested retail price for a 12-oz. jar is $3.49-$3.99.
CAMPBELL GOES EPICUREAN Global. Bold. Gourmet. This is how Certified Master Chef Thomas Griffiths from Camden, N.J.-based Campbell Soup Co. describes the line-up of new soups that appeal to diverse palates and the demand for exciting flavors.
Six new Campbell’s Go! soups draw inspiration from global cuisines. Variet-ies include: Moroccan Style Chicken with Chickpeas; Coconut Curry with Chicken & Shiitake Mushrooms; Creamy Red Pepper with Smoked Gouda; Chicken & Quinoa with Poblano Chilies; Spicy Chorizo & Pulled Chicken with Black Beans; and Golden Lentil
with Madras Curry. Packaged in convenient, microwavable pouches, they are perfect for time-strapped 20-somethings.
Boldness extends to the Campbell’s Chunky brand, which is rolling out three new varieties: Jammin’ Jerk Chicken with Rice & Beans, Kickin’ Buffalo-Style Chicken and Chipotle Chicken & Corn Chowder.
Campbell’s iconic Condensed soups add Sun-Ripened Yellow Tomato, build-ing on the success of last year’s intro-duction of Harvest Orange Tomato soup. Says Mark Alexander, president, Campbell North America: “This is the new face and flavor of Campbell Soup Co.”
SARA LEE UPDATESITS POUND CAKES
On the frozen dessert side of its house, Hillshire Brands Co., Downers Grove, Ill., launches Sara Lee Lemon Pound Cake,the first new pound cake loaf from the brand in more than a decadey Hillshire also updates its famous Butter Pound Cake, which is now more moist. Based on research, consumers pre-fer the moister Butter Pound Cake,
which retains the same homemade taste as its predecessor.“Sara Lee brand produces America’s fa-
vorite frozen pound cake, and we’re in the
process of expanding upon its rich heritage by providing new and delicious varieties we hope will become household favorites,” says Kanika White, senior brand manager of Sara Lee Desserts. “Our new Lemon Pound Cake is a twist on an American classic – it tastes great alone or is delicious dressed up with fresh berries and a little whipped cream.”
The Sara Lee Pound Cake portfolio now consists of Lemon Pound Cake, But-ter Pound Cake and Light & Dreamy Pound Cake, as well as Pound Cake Slices, single-serve and pre-cut pound cake slices in Orig-inal and Double Chocolate. Suggested retail price for the regular size (10.75-oz.) is $3.99 and $5.39 for the family size (16-oz.).
OURFAVORITETHINGS 10 lip-smacking
new products we can’t live without.
This is one of our favorite projects of each year. We write about product introductions in every issue of Food Processing.Rollout and Food Biz Kids are devoted to them, and new
products pepper our features on product development and some-times even plant operations. But this is the only issue in which we put them on the cover.
Every year we survey our full-time editors, freelancer writers and others who help us out and ask them for the new products that have delighted them during the year, the ones they actually buy, repeat-edly, for themselves and their families.
It’s not scientifi c or comprehensive, but it is fun. Th e only rules are that the items are nationally available and “new,” meaning intro-duced since July of 2011. Our list of faves this year:
We usually trot out that well worn phrase “new products are the lifeblood of the food industry.” Th at’s not entirely true, as quite a few processors make a nice living creating private label products, contract manufacturing for others or simply maintaining tried and true old
Oreo, it could provide nice returns on your investment.
product launches slowly recovering along with the economy. “In 2009 and early 2010, we saw new product introductions drop, due
director of innovation & insight.
“Dairy has shown strong increases in new product introductions
shown growth, driven in part by meals formulated for two people
decline may be due in part to the lack of 100-calorie pack type
which likely were driven by consumers choosing to cook more at home.”
chases. Following are the top 10 new products that Food Process-ing
long poll on our web site so you can tell us what are your favorite products of all time. We’ll give you 10 months to think about it.
specify. It should be interesting.
Wells Blue Bunny Cake-Inspired Ice CreamsLike having your cake a la mode
couple of years to become everyone’s go-to dessert when you want
ice cream but also several oth-
decadent enough, imagine
are all in what we used to call
Even newer, but only in pints, is
C OV E R S TO RY
We dedicate this month’s cover story to Diane Toops, our
THIS ONE’S FOR DI
NEW PRODUCT INTRODUCTIONS IN THE U.S.
Q1&2 2010
Q3&4 2010
Q1&2 2011
Q3&4 2011
Q1&2 2012
Jul-Oct 2012
9,910
Source: Mintel Group
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Cup O’ Coffee Cake. I’m not familiar with that last one, but I can say from first-hand experience all the others rely as much on the icing associated with each variety as the cake – and don’t forget the ice cream. They’re all dangerously good.
They were developed with TV baker Jef-frey “Duff” Goldman, owner of Baltimore’s Charm City Cakes and star of the Food Net-work’s Ace of Cakes. His name is co-branded onto each one. Wells Enterprises is a company I’ve been fond of for a long time, and they’re just the right size to take innovative chances like this. I’m eager to see what they come up with next. If it’s a line of Belgian beer-inspired ice creams, I’ve died and gone to heaven!
- Dave Fusaro, Editor in Chief
Hershey’s Simple Pleasures These new chocolates are simply wonderfulAccording to a recent survey of 1,000 women conducted by Hershey Co., 58 percent would love to savor their chocolate without guilt. Make that 1,001. I love chocolate and I love it even more when it feels healthier to consume.
Hershey, Pa.-based Hershey Co. launched Hershey’s Simple Pleasures this year, much to the delight of chocoholics everywhere. The creamy chocolates have crème-filled centers and contain 30 percent less fat than average milk chocolates. The Simple Pleasures line is also the first new brand from Hershey since 2007.
Available in three varieties – Milk Choco-late with Chocolate Crème, Dark Chocolate with Chocolate Crème, and Milk Chocolate with Vanilla Crème – they are individu-ally wrapped for easy portion control in a 24-count, 5.6-oz. stand-up bag. Each serving size, which includes six pieces (each about the size of a quarter), has 180 calories with 22g of sugar, compared to a Hershey bar which has 210 calories and 24g of sugar.
- Erin Erickson, Senior Digital Editor
Gluten Free Chex Apple CinnamonBig G goes G-freeMy favorite for the year is Gluten Free
Chex Apple Cinnamon cereal from Gen-eral Mills. With many friends adopting the gluten-free lifestyle, whether because of celiac disease or for general health reasons, these gluten-free cereals are timely. Tasty
C OV E R S TO RY
and not really smacking of a “health food” to those that do not have an issue, these products are easy to serve and pleasing to all. Th e ad-dition of Apple Cinnamon is a real plus, as it appeals to kids as well as adults and can be incorporated into recipes for additional options, such as a topping for crisps or ice cream. I am thinking gluten-free will ex-perience a heyday, then may fade as many
trends have. But for the present, Gluten Free Apple Cinna-mon Chex has a place in my pantry.
- Ann Juttelstad, Contributing Editor
Greek yogurt jumps into the freezerI love dairy products, and when I walk the ice cream aisle, anything new from Ciao Bella Gelato catches my eye. Ciao Bella’s Pistachio Gelato is among my favorite desserts ever.
So when the company announced in January it would cross-pollinate the excitement of Greek-style yogurt with its own frozen dessert prowess, you could bet the results would be spectacular. Th e
Adonia Greek Frozen Yo-gurt line, the fi rst of its kind, includes seven fl avors packaged in 14-oz. rounds, plus two fl avors of bars in four-packs. Each is fat-free, and carries 130 calories or less, with 5g protein for the bars and 9g per half-cup scoop. Th at protein load is the centerpiece of Greek yogurt’s game-changing popularity.
I recently enjoyed the Vanilla and Mango. Th e smooth texture falls somewhere between ice cream and sorbet, and the fl avors are bold, with a suggestion of tartness. Retail price in Chicago is $3.99.
- David Phillips, Plant Operations Editor
Lunch at your desk just got betterTh e frozen foods aisle is overrun with branded single-serve meals, each promising the best ethnic or chef-inspired creations and easi-est means of preparation. I regularly stock up on these easy lunch
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options to eat at my desk while writ-ing articles such as this. Happily, one of the latest trends in this category has given my once rubbery micro-wave entrées flavorful texture. The secret is steam.
Case in point: Stouffer’s Farm-ers’ Harvest Steam Meals-For-One, each of which is packaged in a “Steam Perfect Bag” to keep vegetables crisp, meats tender, pastas al dente and sauces rich, while offering the consumer a quick dining experience. Choose
from Chicken Florentine, Creamy Shrimp Scampi, Five Cheese Tortelloni, Garlic
Chicken and Cheesy Southwest-Style Chicken. Suggested retail price is $3.89. Your lunch hour will thank you.
- Deborah Cassell, Contributing Editor
I don’t care what you say; I like themI’m no health food fanatic (see my earlier pick, Wells Blue Bun-ny Cake-Inspired Ice Creams), so it’s no surprise I was smitten when Hostess Brands introduced Chocolate Crème Twinkies. The national baker tested them as a limited-edition offering in early 2011 (I think strawberry crème and banana also were explored in some test markets). After an overwhelmingly positive consumer response, it was clear adding chocolate to Twinkies was a recipe for delicious success, so they were made a permanent part of the portfolio earlier this year.
The iconic golden sponge cake has been delighting snackers since 1930, but it’s had surprisingly few brand extensions over the years. The little cakes get an unfair amount of derision – they are a post-er child for empty calories, detractors claim they’re sponge cakes filled with preservatives and there are suspicions they could survive a nuclear holocaust. But approximately 500 million Twinkies are baked every year, the product’s web site claims. That’s 1,369,863 Twinkies every day, 57,077 Twinkies every hour and 951 Twinkies every minute. And I’m not responsible for all of them. So they must
have their fans.Plus, there’s a busi-
ness story here. I really hope Hostess Brands can claw its way out of its second bankruptcy in three years. It will take more than choco-late Twinkies to re-establish this company, but they’re a start.
- Dave Fusaro, Editor in Chief
How good can a 190-calorie frozen pizza be?New York-based Vitalicious Inc. (www.vitalicious.com) made a name for itself by making whole-some muffins and muffin tops, then other nutritious baked sweets. This past summer, when the company stretched into a new category, microwavable frozen pizza, we had our doubts. Ques-tionable too was whether any company could produce a pizza with just 190 calories.
Multiple thoughts competed: “190 calories? Is that per slice?” And “the crust must be so thin it’s see-through, right?” And of course, “I bet the box tastes better!” But none of those turned out to be true.
VitaPizza is a 6-in. pizza, with a crust neither paper-thin nor heavy and thick, and there’s no skimping on the topping. The next thing you notice is, it’s not oily – no grease stains on the box, your hands, your shirt or in the microwave after you cook it (it only takes 4 minutes, too). The cheese and tomato has lots of good tomato flavor; the meat-less pepperoni makes clever use of soy-based meat analog for a “nice-a spicy” kick. All in all, it’s a tasty little number and it really is half the calories of its competitors.
Restaurant taste at the breakfast tableSunday is the one day my family sits down and enjoys the most important meal of the day. Like many American families with teenage children, the most popular item on our breakfast table is pancakes with syrup ... lots of delicious syrup. We’ve tested and tasted our fair share of syrups over the years, but IHOP’s At Home Syrups have become a favorite.
Glendale, Calif.-based International House of Pancakes launched IHOP at Home Syrups, this year. The full line of syrups features Original, Lite and Sugar Free, plus the restaurant chain’s signature syrups Rooty Tooty Fresh ’N Fruity Strawberry and Rooty Tooty Fresh ’N Fruity Blueberry varieties. They are available at retail only through Sorbee International LLC, which holds the licensing rights to produce and distribute IHOP at Home Syrups.
Suggested retail price for the Original, Lite and Sugar Free varieties
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(in 24-oz. bottles) is $3.99, and Rooty Tooty Fresh ’N Fruity Strawberry and Rooty Tooty Fresh ’N Fruity Blueberry varieties (in 12-oz. bottles) cost $2.99.
- Erin Erickson, Senior Digital Editor
Fair Oaks Farms Brands Core PowerMarketed as a recovery drink, I and the kids love themWho doesn’t love a milkshake? Well, this one is not frozen, but when served chilled direct from the refrigerator, it tastes just as great. Un-like other protein beverages in the market, new Core Power high-protein recovery drink from Chicago-based Fair Oak Farms Brands uses farm-fresh milk, not reconstituted dairy solids that can produce a chalky aftertaste. It’s that clean taste that has made Core Power a favorite in my household since its offi cial launch this past summer. Th e company’s unique cold-fi l-tration process yields fresh milk with increased amounts of protein in the same ratio natu-rally found in milk: 20 percent whey and 80 percent casein.
I personally prefer the Strawberry Banana Light version, which is sweetened with a touch of honey (like all the varieties), but keeps calories and sugar content low through the use of monk fruit juice concentrate and stevia leaf extract. I approve of these low-calorie natural sweeteners for my kids, too. Th ere’s also a light chocolate
variety that my 10-year-old is partial to as an after-school snack. Th e light versions contain 20g of protein per 11.5-oz. bottle, while the others, which come in Chocolate, Honey and Vanilla fl avors, contain 26g of protein. Th e protein satisfi es mid-afternoon munchies.
Core Power comes in recyclable plastic bottles and is aseptically packaged so it can be distributed – and stored at home – in a shelf-stable environment until chilled before consumption. I am in Chicago where Core Power made its initial launch. Coca-Cola Re-freshments recognizes the potential of Core Power and recently added it to its distribution system so that the rest of America can enjoy.
- Donna Berry, Dairy & Food Communications Inc. and past contributor
Roland Flavored QuinoaWhen all you can do is boil a pot of waterAmerican Roland Food Corp. hits all the right notes with its quick and easy Flavored Quinoa. Easier than Easy Mac and deli-ciously healthy, these gluten-free quinoa dishes can complement practically every-thing from meat, chicken and fi sh to the lowly lentil, and also be sublimely satisfying by themselves as all-in-one-bowl meals.
Consumers yearn for meals that fall into one of three categories: quick, delicious or healthy. Th e Roland quinoa line-up satisfi es all three and more. Made from nutritious An-dean quinoa – rich in fi ber and amino acids and valued for its high protein and mineral content – they require nothing more than a pot of boiling water and 15 minutes to sim-
mer. Containing only ingredients like garlic, onion, tomato, carrots, celery and sea salt, the Roasted Garlic, Garden Vegetable, Lemon Curry, Toasted Sesame Ginger and Mediterranean Quinoa are all just what the doctor or-dered for dieters and athletes everywhere. Even more com-pelling: Th e United Nations’ Food and Agricultural Orga-nization has declared 2013 to be “Th e International Year of the Quinoa.”
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IngredientsThat KeepDairy GrowingToday’s dairy case is a vibrant and diverse category expanding with the help of whey proteins, new sweeteners and probiotics.By Stuart L. Cantor, Ph.D., Contributing Editor
Dairy is having a banner decade. Following a slump in consump-tion, 2011 saw sales of yogurt, in-
cluding frozen products and beverages, surpass $6 billion. And the ice cream and frozen novelty market saw retail sales of nearly $11 billion.
The impressive growth was driven in large part by sales of Greek yogurts, as well as products aimed at kids (such as Dannon Co.’s Danimals). Mintel Group Ltd. (www.mintel.com) estimates sales for the category in 2012 will total nearly $7 billion, a 9 percent increase from the year before.
While manufacturers of dairy products are enjoying these big trends, they’re mindful of the ingredients needed to sup-port them. Consumers are more knowledgeable (and criti-cal) than ever, and chalky, weepy yogurt or tasteless, rubbery cheese is not tolerated. But processors are benefiting from an arsenal of new, improved and emerging ingredients that will help dairy foods and beverages maintain their status as healthful choices and indulgent treats.
“Consumers are looking for higher quality natural prod-ucts with a high protein content, and whey protein is an excellent source for this,” notes Jeff Banes, applied technol-ogy manager for Grande Custom Ingredients Group (www.grandecig.com), Lomira, Wis. “Dairy ingredients, whey in particular, help formulators develop unique products with an excellent mix of quality and flavor, high protein content over-all nutrient density and trusted natural ingredients.”
Whey proteins have proven important in formulating dairy products as well as on their own as ingredients for forti-fying food products, such as bars. There are three main types of whey proteins: whey protein concentrate (WPC), ranging from 35-80 percent protein; whey protein isolate (WPI) at 90
percent protein; and whey protein hydrolysate (WPH) which is an 80 percent protein enzymatically broken into smaller pieces called peptides.
“Whey proteins display clean flavor, excellent solubility and heat stability properties,” says Gwen Bargetzi, director of marketing for Hilmar Ingredients Inc. (www.hilmarin-gredients.com), Hilmar, Calif. “Whey proteins are soluble across a wide pH range [from 2.5 to as high as 8.0] and can be used to fortify liquids without causing sedimentation. Because of its isoelectric point [pH where the protein car-ries no charge], only whey proteins are stable under low pH [acidic] conditions.”
Whey proteins also are highly heat stable and can withstand ultra-high temperature retorting or pasteuriza-tion. Bargetzi adds that Hilmar has developed a functional
P R O D U C T D E V E LO P M E N T
Yogurt powders can give products such as coatings, dips, candies,
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Whey proteins are trending well for their health benefits, too. Whey proteins and other dairy products are helpful to athletes because they are high in the branched-chain amino acids (BCAA) leucine, isoleucine and valine, believed to protect muscle tissue against breakdown during heavy exercise. In fact, whey protein contains the highest concentration of BCAAs available from any protein source. In addition, the BCAAs in whey protein take longer to burn, providing a longer-lasting source of energy.
This muscle advantage is also impor-tant for seniors. An adult’s need for protein doesn’t decline with age, yet many seniors do not get enough protein, leading to muscle wasting. “Foods made with whey protein can help meet the needs of this population, as whey is particularly easy for seniors to di-gest,” sums Bargetzi.
Triple-duty fibersGums, starches and fibers used for stabilizing and texturizing dairy products do double duty as fat and sugar replacers in low fat and/or low sugar products. Ingredient developers have cre-ated a wide range of components that not only taste great but are great for you.
Most of those ingredients add a third benefit: fibers and fiberlike starch fractions that function as prebiotics. They stimulate beneficial bacteria in the gastrointestinal tract and chemical reactions in the cellular lining of the digestive system.
Global Industry Analysts Inc. forecasts the U.S. market for prebiotics will surpass $225 million by 2015, while European sales are expected to top $1 billion by then. Inu-lin or fructooligosaccharides (FOS) offer both consumers and food processors many benefits. Besides the digestive health benefits of these dietary fibers, consumers also desire products that they can enjoy while reducing
their caloric, fat and sugar consumption at the same time.
Oligosaccharides — carbohydrate poly-mers of 3-20 or so glucose units — are water-soluble, neutral in taste and mildly sweet, typically 30-60 percent of the sweetness of sucrose. At 1.5 kcal/g, they are suitable for low-calorie diet foods as a bulking agent that enhances other flavors. Longer-chain oligo-saccharides have applications as fat replacers.
“Adding prebiotics such as inulin and oligofructose to a balanced and healthy diet can help to achieve the added health ben-efits from fiber-enriched foods,” notes Wim Caers, senior nutrition manager for Beneo-Institute (www.beneo.com), Leuven, Bel-gium.
The health benefits of inulin, derived from chicory root, include stimulation of beneficial probiotic colon bacteria such as Lactobacillus and Bifidobacterium bifidus. In addition to gastrointestinal benefits, it
With good doses of both dairy (including whey
protein isolates) and fruit, smoothies have become a
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also helps increase calcium absorption and adds slight sweetness with low cariogenicity.
“Inulin is well known as a fat replacer in the dairy industry and al-lows for the development of low-fat foods while maintaining the sensory and textural characteristics of their full-fat counterparts,” says Rudy Wouters, vice-president of Beneo’s Technology Center. “The inulin par-ticles, formed by applying shear to a food product, are similar in size to fat droplets, resulting in similar mouthfeel and creaminess attributes.”
Beneo offers a wide range of inulin products with differing tech-nical specifications for solubility, particle size distribution, dispers-ibility and process and storage stability, dependent on the desired benefits (e.g., fiber claim, sugar or fat reduction, shelf life, etc.). A “good source” (2.5g fiber/serving) or an “excellent source” (5g fiber/serving) are commonly used inclusion levels.
While inulin can be used in either the white mass or fruit prep for yogurts, it is susceptible to hydrolysis in acidic conditions around pH 3.5 and lower. The degree of hydrolysis will depend on the tempera-ture and duration of exposure to the acidic environment.
“Yogurts have a pH of 4.0 to 4.6 and are stored refrigerated for 21-30 days, so degradation is not a concern,” states Carol Lowry, senior applications scientist for Cargill Health and Nutrition Inc. (www.cargill.com), Minneapolis. “When inulin is used in the fruit prep,
again an acidic environment, water activity is low enough that fructan degradation is not a concern.”
Through thick and thinThe various organoleptic functions of fat can be very hard to mimic. Addi-tionally, when the fat content is drasti-cally lowered, the perception of acidity and/or bitterness is heightened. This necessitates a careful reformulation of the product so those undesirable tastes can be masked or balanced.
Large starch polymers of repeat-ing glucose units linked together in either linear (amylose) or branched (amylopectin) structures deliver several key properties in dairy appli-cations. In low fat yogurts, starches can be used to rebuild the texture and creamy perception lost upon removal of fat. They are often used in combination with other stabilizers such as guar and locust bean gum to prevent ice crystallization and to impart mouthfeel and body to ice cream and frozen desserts, and are effective in controlling melt.
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Th e linear amylose provides less viscos-ity in hot pastes but upon cooling re-sets to a more rigid gel structure. Amylopectin gives higher hot viscosity, and upon cool-ing gives a fl uid, longer texture rather than
the short gel structure of amylose. Native starches contain varying amounts of these two structures. Specialized varieties of na-tive starches have been developed for high amylose content or with almost no amylose
(waxy starches).If hydrated granules are subjected to too
much heat or shear, the granules fragment. When this occurs, amylose polymers will then re-associate and release water (synere-sis, or “weeping”). Subsequently, an unac-ceptable, rigid, opaque gel or crystalline structure forms, via retrogradation. How-ever, chemical modifi cations of the starch, such as cross-linking, stabilize granule structure to withstand more heat and/or shear processing.
Starches also help dairy manufacturers off er more cost-eff ective products. “Mul-tiple stabilizers can be replaced to off er a shorter ingredient label, and the nutrition profi le of dairy foods can be improved by replacing fat and cream,” says Erhan Yildiz, business scientist for dairy applications at Ingredion Inc. (www.ingredion.com), for-merly Corn Products and National Starch, Westchester, Ill.
Pre-gelatinized starches have been de-veloped that can be hydrated under room temperature conditions. Maltodextrins, for example, are produced by cooking starch and using acid and or enzymes to hydrolyze large polymers to smaller poly-mer lengths. “In low-viscosity products, maltodextrins provide less viscosity than other starches and can be used at higher levels to build solids and to give a good mouthfeel,” says Adam Berzins, principal food scientist at Ingredion. “Th ey’re also cold-water soluble and provide smooth, short textures required for fat mimetics in reduced-fat products, and can also func-tion as sugar replacers.
Water-soluble gums or hydrocolloids can bind up to 100 times their weight in water and increase freeze-thaw stabil-ity with almost no syneresis. Gums are also high in soluble dietary fi ber, about
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85 percent. Other hydrocolloids used for thickening dairy-based drinks and yogurts include guar gum, carboxymethylcellulose (CMC), carrageenan, xanthan gum and pectin.
Pectin is appealing as an all-natural gelling agent for fruit-based preparations used in yogurt and is also ideal to help sta-bilize the casein micelles from separating in acidifi ed dairy-based beverages. “For a
yogurt-based drink, a high-ester pectin is generally the best option” says Drew Wun-derly, senior applications technologist-dairy for DuPont Nutrition and Health (www.danisco.com), New Century, Kan.
“Other gums, such as xanthan and CMC, mask casein separation by build-ing viscosity,” he continues. “Above a pH of 4.6, the protein is negatively charged. However, below a pH of 4.6, the protein is positively charged and the pectin is nega-tively charged. Th is creates bonds between the protein and pectin and enhances the shelfl ife stability of the beverage.” For more neutral pH beverages, Wunderly suggests a combination of carrageenan, locust bean gum, guar and starch.
To prevent syneresis in yogurts, gelatin, starch, pectin and/or agar can be added. For fruit-on-the-bottom yogurts, a blend of starch/pectin or gelatin/pectin also works well, adds Wunderly. In the push for kosher status or a more “natural” label, manufactur-ers are starting to use pectin, native starches and carrageenans.
For hard-pack ice cream, emulsifi ers such as mono- and diglycerides are key to achieving a high overrun. “To prevent fast melting or dripping, mono- and diglycerides help destabilize fat particles, causing them to agglomerate,” continues Wunderly. “Carra-geenan and locust bean gum are important hydrocolloids for good melting/dripping characteristics. To limit ice crystal forma-tion, locust bean gum, guar and CMC work very well through water-migration control.”
Botanical bountyZero-cal botanical sweeteners and nutraceu-ticals are making solid headway into dairy products. Stevia, the zero-calorie, high-intensity sweetener from a South American shrub, which saw rapid growth in use in clear beverages, is now fi nding its way into
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dairy products. Originally plagued with a slight licorice-like aftertaste, improved pu-rifi cation techniques and precise combining with other sweeteners substantially mitigat-ed that drawback.
In addition to being an early U.S. suppli-er of stevia (under the Good&Sweet brand) Blue California (www.bluecal-ingredients.com), Rancho Santa Margarita, Calif., more recently introduced Blue Sweet, a sweetener made from luo han guo, also known as monk fruit. “Luo han guo extract is an all-natural, GRAS, white powder 300 times sweeter than sugar,” explains Cecilia McCollum, executive vice president of Blue California.
Tate & Lyle (www.tateandlyle.com), Decatur, Ill., has similar high hopes for its monk fruit sweetener, Purefruit. At around 200 times the sweetness of sugar and with exceptional stability, Purefruit is suitable for a wide range of food and beverage applica-tions. “Knowing that sweetness comes from
fruit instantly conveys great taste, natural and wholesomeness, all very appealing prod-uct qualities,” says a spokesperson.
“Other ingredients that can be easily incorporated into dairy-based beverages be-cause of their high water solubility are an-tioxidants,” says Rodger Jonas, director of national sales for P.L. Th omas & Co. Inc. (www.plthomas.com), Morristown, N.J. Th e company has a considerable portfolio of natural fruit, vegetable and other functional botanical nutraceuticals.
For example, its P40p contains high levels of antioxidants and natural compounds that reduce the cell damage typically created by free radicals during the natural biological process of oxidation. Its FruitOx antioxidant is composed of a clinically supported blend of fruit extracts and concentrates with high oxygen radical-absorbance capacity. Th ese extracts contain a spectrum of natural fl avonoids and polyphe-nols that provide a diverse antioxidant profi le and biological activity, according to Jonas.
In savory dairy products, meeting de-mands of sophisticated palates is the watch-word. “Dairy fl avors will play a vital role in the creation of products that meet consumer expectations for health and wellness by add-ing fl avor in the absence of added salt or fat,” says Karen Grenus, senior food scientist for Edlong Dairy Flavors Inc. (www.edlong.com), Elk Grove Village, Ill.
Th e company, about to enter its century year of creating dairy ingredients, currently is devel-oping more subtle fl avors derived from trends such as sheepsmilk and artisanal stylings.
“[Th ese] dairy fl avors allow manufactur-ers to keep pace with an increasingly diverse ethnic consumer base, providing fl avor pro-fi les unique to specifi c regions,” she says. Grenus also notes how the use of dairy fl a-vors to deliver a signature profi le will “pro-vide stable profi ts against a fl uctuating dairy commodity market.”
Anne Druschitz, corporate research chef for Edlong, agrees. “Specialty cheese fl avors, like gouda, asiago and parmesan, provide an opportunity to off er customers premium fl avor profi les while keeping the bottom line in check. Plus, dairy fl avors can help foods taste indulgent without the negative health impacts of added fats and excessive calories. Th is lets the consumer have a positive eating experience without compromising wellness goals.”
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The New Oils
lthough most consumers have learned that the par-ticulars of dietary lipid sources are a far more com-plex subject than the “all fat is bad” trope that used
to rule, they still cast an occasionally wary eye at oils. At minimum, they are demanding oils work harder on multiple levels. Ingredient makers are employing technical prowess to fulfill those demands.
One of the newer products in this category is high-oleic acid canola oil, which joins palm oil as a growing industry favorite. Oleic acid is the fatty acid that is dominant in ol-ive oil, a staple food in the Mediterranean diet. Early studies found that foods rich in oleic acid tend to lower LDL choles-terol without lowering HDL cholesterol, thus reducing risk factors for heart disease. More recently, a study published in the Journal of Internal Medicine reported that rapeseed oil (canola oil), when substituted for dairy fats in the diets of subjects with high cholesterol, lowered blood cholesterol and triglycerides.
Fatty acids are the carbon chains that make up fats and oils and give them their specific properties. Three fatty acids make up one fat (triglyceride) molecule.
There are two broad categories of fatty acids, saturated and unsaturated. Saturated fatty acids are “saturated” with hydrogen. Unsaturated fatty acids are not. That’s because in unsaturated fatty acids one or more pairs of carbon atoms
are linked together with a double bond, which naturally ex-cludes some hydrogen.
The double-bonded carbon atoms make the fatty acid chain bend, decreasing the melting point of the fat, allow-ing it to remain liquid at a lower temperature, depending upon the number of double bonds. Unsaturated fatty acids can have one or more double bonds and thus are termed monounsaturated or polyunsaturated. Oleic acid is the common name for a monounsaturated fatty acid that is dominant not only in olive oil but also in avocados, maca-damia nuts, almonds, pecans, hazelnuts, pistachios, pea-nuts and cashews.
In the body, having many double bonds in the fatty acids of the cells and tissues helps organisms adapt to cold weather. That’s good for the plant or animal, but not so good for processed foods, especially baked goods. The more double bonds in a fatty acid, the more it is suscep-tible to oxidation or rancidity, which translates into com-promises in taste and smell. Oils rich in saturated and monounsaturated fatty acids are more stable than fats rich in polyunsaturated fatty acids – i.e., the omega-6 and omega-3 classes of fatty acids.
Stability depends on the total distribution of fatty ac-ids in the oil. An oil may be rich in monounsaturated fatty acids and at the same time carry significant amounts
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of polyunsaturated fatty acids as part of the mix, making them a poor choice for stability. Lack of stability does not mean that the oil is unhealthy. Certainly omega-3 fatty acids are healthy, and it’s to our advantage to increase their presence in our diet. They are however quite volatile and will spoil faster in certain applications where shelf life is critical to the economic success of the product.
All those double bonds have another disadvantage when it comes to processed foods: Since they aff ect the melting point of the fats, they can compromise the texture of the fi nal processed product, leaving it less crispy or fl aky.
When it comes to selecting a suitable oil formulation that meets the stability test, smoke point is a critical factor. Th is is the tempera-ture at which the oil begins to break down and the fatty acids are released from the fat molecule. Th is aff ects the quality of the fi nished product. Oils with a high smoke point include avocado and saffl ower oils, with smoke points of more than 500ºF.
Refi ning oils tends to increase the smoke point temperature. For example, unrefi ned soybean oil has a smoke point of 320ºF, while semi-refi ned oil is 350°F, and the refi ned oil breaks down at 460ºF. Total saturated fatty acids also make a diff erence. Classic refi ned canola oil has a smoke point of 400ºF, while the high-oleic canola oil has a smoke temperature of 475ºF.
High-oleic oil is any oil that is high in monounsaturated fats. Olive and canola oil are naturally high in monounsaturated fat, but they are also high in polyunsaturated fats, which reduces sta-bility. High-oleic canola oil is thus marketed as a high-stability oil suitable for applications involving high temperatures, such as baking and frying.
Bunge North America (www.bungenorthamerica.com), St. Louis, markets its Nutra-Clear as a high-stability canola oil, rich in oleic acid, low in linolenic acid, specifi cally developed for exten-sive deep frying. Nutra-Clear is non-hydrogenated, low in satu-rated fatty acids and trans fatty acid-free. It can be used in a wide range of applications other than deep frying, including as a salad, ingredient, spray or griddle oil. It’s highly stable and off ers mini-mal fl avor transfer.
Richardson International (www.richardson.ca), Winnipeg, Man-itoba, markets its Pure high-oleic, low-linolenic omega-9 canola oil as “Canola Harvest.” It’s suitable for high heat exposure and longer shelfl ife applications. It is non-hydrogenated, trans fat-free and also has high stability properties and a high smoke point – an ideal frying oil. Naturally stable properties make this suitable for spray applica-tions and shelf-stable packaged goods, such as, croutons, crackers, cereals, snacks and potato chips. It has the lowest saturated fat level of any culinary oil.
Scientists have developed plants bred to be high in monoun-saturated fats and low in polyunsaturated fats so they can be used in products that need to be shelf stable. High-oleic canola oil is the most recent of these products. Th e process of creating stable oils for food processing diff ers from hydrogenation in that the double bonds are bred out of the oils rather than destroyed by chemical treatment. Th at means these newer oils can be marketed as naturally healthy.
I N G R E D I E N T S
There’s a reason our dairy flavors are pleasing to the pallet.
© The Edlong Corporation 2012
Frank: Edlong Shipping Specialist since 2008
Specialties: Shipping with pride; ensuring that every order is carefully packaged, labeled and shrink-wrapped; negotiating with carriers to save customers time and money; pleading with drivers to make one more pick-up; always giving 100%.
Motto: “I prepare every shipment as if it was going to my mom.”
Weight control methods are generally a matter of accounting — tracking the calories coming in and trying to increase the calories going out. But nuts have knack for cracking the shell of this paradigm.By Mark Anthony, Ph.D., Technical Editor
The basic equation for weight management is rooted in the Newtonian Laws of Th ermodynamics: You can’t create or destroy energy, you can only change its
form. In the nutrition world, this is translated as “calories in = calories out.”
Many diet enthusiasts hate this very notion. In fact, some decry that accounting for calories is old fashioned and out of date, that it’s fats or carbohydrates that make us fat. “Calories are not all created equal!” they cry. While such a declaration is intended to sound visionary, it plays off an interesting ca-veat to the generality of the equation: Humans are not walk-ing calorimeters.
It’s not groundbreaking to point out that a 2,000-calorie diet of doughnuts is signifi cantly diff erent from a 2,000-calo-rie balanced diet. Defi ciencies matter in living things. Let’s face it, calorimeters do not require nutrients; their only job is combustion, which does not result in thinking or movement, growing, exercising or fi ghting off disease.
Th is is where research has shown that nuts can make a sig-nifi cant diff erence. Th ough peanuts and tree nuts are energy-dense, supplying most of their calories as fat, there are multi-ple factors justifying the results from epidemiological studies that consuming several ounces of nuts daily can be inversely
associated with obesity. Nuts in moderation can contribute to healthy weight management and even weight loss.
Several diff erent mechanisms explain this. Th e fats and protein content of nuts make them particularly high in sa-tiety value. Th ey reduce overall calorie consumption by al-lowing one to feel more satisfi ed with less, and over a longer period of time, compared to consumption of either high-pro-tein or high-carbohydrate diets. Basically, they can discour-age overeating.
Nuts are also complex foods rich in fi ber and very dense. Th is might aff ect energy absorption, limiting it somewhat so that a measurable percentage of the energy is not absorbed. Th en there’s the thermic eff ect of food: Consumption of nuts is thought to increase resting energy expenditure, essentially helping you burn calories while at rest.
According to the article “Impact of peanuts and tree nuts on body weight and health weight loss in adults,” published in 2008 in the Journal of Nutrition, it is estimated that be-tween 55-75 percent of the energy (calories) contributed by nuts to the overall diet is compensated by lower subsequent energy intake.
Most nuts contain substantial amounts of soluble fi ber, which tends to slow the movement of food through the
I NGRED IENTS
A Nutty Good Diet
FOODPROCESSING.COM
digestive tract, while also providing bulk and a satiety-inducing sense of “fullness.” As sources of protein and rich in unsaturated fats, the composition of nuts is a combination that can delay stomach empty-ing. Some nuts have a very dense structure and require a lot of chew-ing – even the mere act of chewing burns calories, while naturally nutrient-dense foods stimulate a variety of hormones that signal the body to sense that sense of satiety.
Specifically, cholecystokinin, a hormone synthesized in the cells of the small intestine and secreted in the duodenum, stimulates the release of fat-digesting enzymes from the pancreas and bile from the gallbladder to emulsify dietary fat. This hormone acts as a hunger suppressant, along with ghrelin, a hormone secreted by the stomach, that tells us we’ve eaten enough.
As mentioned, consumption of nuts is believed to increase the resting metabolic rate, a factor known as the thermic effect of food. The process of chewing is a factor in allowing our digestive enzymes to access the protein, fat, carbohydrates and other nutrients (such as minerals and phytochemicals) from nuts. In “Mastication of al-monds: Effects of lipid bioaccessibility, appetite, and hormone re-sponse,” published in 2009 in the American Journal of Clinical Nu-trition, the authors demonstrated that the ability to chew nuts is a limiting factor when considering the amount of energy we obtain from the fat.
The calorie value of nuts is only an estimate of potential energy, assuming complete digestion. This means that when eating nuts, more than most foods, a significant amount of energy is lost to the process of digestion than in many foods.
Nuts as seeds for the growing plant contain a variety of micro-nutrients in addition to the protein, fat and carbohydrate, a factor which affects both satiety and overall health. Pistachios, for example, have received attention for their potential to improve blood lipid pro-files and reduce the risk of heart disease. But, they are also powerful sources of micronutrients and phytochemicals that can affect inflam-mation and antioxidant protection.
In a study published earlier this year in Nutrition Reviews, “Pis-tachio nuts: Composition and potential health benefits,” pistachios are cited as one of the richest sources of phytochemicals in the nut family. They are the only nut with significant xanthophyll carotenoid content. Another major pistachio carotenoid is lutein, known for po-tential protection against macular degeneration. Lutein could also help reduce oxidation of small-particle-size LDL, a risk factor for heart disease.
One unique method by which pistachios may aid dieting relates to presentation. Two studies published last year in the journal Ap-petite revealed that the visual cues of the empty pistachio shells accu-mulating on the table help to remind people of their intake, leading to the consumption of fewer calories. Also, the extra time needed to shell the nuts and the extra volume perceived when slowly consum-ing in-shell pistachios resulted in subjects consuming an amazing 40 percent fewer calories compared to subjects consuming pistachio kernels. The same fullness and satiety was reported.
There are many ways in which fat-rich, calorie-dense nuts in moderation can aid in successful weight management. And there is no need to break laws of thermodynamics – only the laws of fad diets.
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Scientific evidence suggests, but does not prove, that eating 1.5 ounces per day of most nuts, such as almonds, as part of a diet low in saturated fat and cholesterol may reduce the risk of heart disease.
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A Return to Simpler Times … and
BeverageFlavorsInnovations in beverage flavors give consumers the chance to savor updated fruit- and cocktail-based drinks.By Deborah Cassell, Contributing Editor
Forget everything we’ve written lately about superfruits and exotic ethnic flavors. With leaves and temperatures dropping, consumer tastes in beverages are turning to familiar domestic
fruits – with or without alcohol. Maybe politics or the economy are factors, too.
“Consumers are seeking safety and comfort in response to the volatility of the economy and current political landscape of an elec-tion year,” says Jim Shephard, director of R&D and innovation at Indianapolis-based Sensient Flavors LLC (www.sensientflavors.com).
“There is a rising [interest] in local varietals of American produce, fruits coming from local producers and traditional or heirloom variet-ies,” Shephard continues. Sensient has responded by launching a range of natural from-the-named-source apple varietal flavors. They are Braeburn (crisp, sweet and aromatic, with juicy notes), Crispin/Mutsu (a sweet honey profile), Fuji (super sweet with crisp notes), Gala (a mildly sweet, vanilla-like flavor profile), Golden Delicious (mellow with subtle sweet notes), Granny Smith (extremely tart, with juicy notes), Honeycrisp (a complex apple flavor profile, with balanced sweet and tart notes), Jona-than (a classic apple flavor profile with balanced sweet and sharp notes), McIntosh (sweet and refreshing, with an acidity and vinous profile) and Red Delicious (a characteristically sweet apple with mild aromatics).
“Domestic fruit flavors are finding their way back into beverages as consumers look toward local and sustainable ingredients,” agrees Stephanie Weil, product manager for Wild Flavors (www.wildflavors.com), Erlanger, Ky. “Consumers are also looking for simplicity, so using varietal or regional names, rather than a blend of fruits, creates a simpler yet interesting profile.”
While consumers love the familiar, adding a varietal orange or a touch of mint to grapefruit intrigues those eager to try new things, Weil notes. Wild’s Farmstand Favorites library contains such flavors as heirloom to-mato, wild strawberry and peppery peach. And its new Ethnic Fusion line combines familiar favorites with global inspirations, yielding Strawberry African Ginger, Moroccan Melon and Shanghai Lime offerings.
Shephard also notes all this interest in fruit flavors plays to con-sumers’ concerns about their health and well-being.
Virginia Dare (www.virginiadare.com), too, is touting new fruit flavors based on the knowledge that consumers are gravitating toward products that are familiar, local and labeled “natural,” says Anton Angelich, group vice president of marketing for the Brooklyn, N.Y., company. He’s also seeing a shift toward the use of fewer and simpler-sounding ingredients.
“In this age of global food security concerns and locavore and sustainability interest, many consumers are turning away from exotic superfruits from distant lands and seeking more familiar domestic-sourced healthy fruits, such as blueberry, raspberry, blackberry, elder-berry, cranberry, etc.,” he explains.
“An apple is not an apple is not an apple,” he says, citing the “new, improved and better-tasting apple varieties” now in stores. Virginia Dare has created “true-to-fruit flavors” based on this produce trend.
F L AVO R O F T H E M O N T H
While noteworthy beverage applications include flavored vodkas, malt beverages, fla-vored waters, functional teas and ready-to-drink coffees, Virginia Dare also has seen rapid growth in ready-to-drink teas and cof-
fees. So the company has created a propri-etary brewed tea concentrate incorporating tea flavor and top notes. Fruit flavors add pleasant fusion tastes, and sweeteners such as stevia lend calorie control.
Sensient also is seeing a resurgence of “classic cocktails with a twist,” Shephard says. The company’s contemporary takes include Shikuwasu Gimlet, a citrus fruit native to Ja-pan that boasts a bright and sour taste. Red Delicious Apple Manhattan couples the sweet and aromatic red delicious apple with the traditional cocktail. Grapefruit Basil Mojito lends bright citrus and sweet basil notes to the Puerto Rican import. Peach Jalapeño Mar-garita brings those earthy and hot flavors to the citrus cocktail. Ginger Shrub, originally used to preserve fruit by combining fruit, vin-egar, sugar and other ingredients, that can be used in various cocktail creations.
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’TIS THE SEASON
Natural red that rocketsExberry shade Rocket Red powder is a bright and rich red powder ideal for savory applica-tions, such as seasoning mixes. As every food and beverage ingredient becomes increas-ingly scrutinized, finding versatile, clean label colors you can feel good about can be difficult. All Exberry natural colors are made exclusively from fruits and vegetables, pro-cessed physically with water and are GMO-free and kosher
L-carnitine burns fatCarnipure is the vendor’s branded L-carni-tine, a nutrient produced in the body and found in some dietary sources and which plays a critical role in fat and energy metabo-lism. It shuttles long-chain fatty acids into the cells’ mitochondria where they are bro-ken down for energy generation. Extensive research shows that supplementary Carni-pure can play a supportive role in many areas of health, including recovery from exercise, weight management and healthy aging.
Sparkling sweet treatTreattSweet Extra 9856 and TreattSweet Sparkling 9857 are new flavors that enable manufacturers to improve the sweet taste profile in a number of flavor compositions and applications. They were specifically de-veloped to work in combination with high-intensity sweeteners such as stevia. The non-caloric blends of all-natural essences smoothe out the sweetness profile and un-desirable lingering characteristics associated with some high-intensity sweeteners. Tre-attSweet Extra 9856 has been formulated to provide flavorists with a low-odor alterna-tive, providing less aroma intensity at levels
of 100 ppm upwards. TreattSweet Sparkling 9857 tackles issues associated with carbon-ation, acidulants and sugar in low-calorie beverages, especially at low pH and at re-duced sugar levels (7º Brix or lower).
Saffron extractSatiereal is a proprietary extract of saffron stigmas (Crocus sativus L.) that enhances the activity of the neurotransmitter serotonin, influencing satiety, appetite, mood and be-haviors relating to snacking. A GRAS food ingredient with a long history of safe con-sumption, it is featured in a range of prod-ucts designed to support a healthy weight, including supplements, gums, functional foods, snacks, smoothies and more.
Clean label ingredientsPenPure is taking aim at the growing demand for clean label ingredients with its portfolio of clean label starches. These are not chemi-cally treated and are familiar to consumers when listed in the ingredient statement. Of-fered in a wide variety of formulations with
potato, corn, rice and tapioca bases, the line offers multiple functional benefits in appli-cations ranging from soups to tortillas. This portfolio is composed of cook-up and instant viscosity starches, as well as starch gels.
Something to cluck aboutWix-Fresh ingredient systems are designed for use with poultry products. The all-nat-ural line, available in liquid and dry forms, can improve flavor, reduce sodium and ex-tend poultry shelflife. The line includes: RSS reduced sodium system; Wix-Fresh Mimic to reduce off-notes associated with listeria growth inhibitors; Wix-Fresh Max improves poultry products’ natural flavor and color; MimicMax for masking off-notes plus the benefit of an antioxidant; Miner, which re-duces the feathery dark notes often found in fresh whole-muscle and ground poultry; MinerMax, to promote the inherent flavor integrity of poultry plus an antioxidant; Wix-Fresh Umami for enhancing and bal-ancing natural food flavors; OatMax, to nat-urally enhance shelflife and water binding; and MDR, which extends shelflife in fresh and ready-to-eat further processed poultry.
Moving in for the krillThe omega-3 category is saturated and ev-eryone is competing for the same custom-ers. However within the category, krill oil is experiencing 40 percent growth as many consumers are trading up for a more effi-cient form of omega-3s. Consider krill as the source of your next omega-3 product.
Combat high egg pricesThe Nutrilac range of egg replacers is manu-factured from fractionated whey proteins. They are not only less expensive than eggs, but they are also lower in calories, saturated fat and cholesterol. They have a longer shelf life – up to 18 months – and they produce great-tasting end products. The company calculates that a cake manufacturer using 750 tonnes of liquid egg a year could save
FOODPROCESSING.COM
around $125,000 annually by switching to 50 percent egg replacers.Arla Foods IngredientsViby, Denmark; +45 89 38 10 00www.arlafoodsingredients.com
Flavor speaks GreekNatural Yogurt-Type Flavor #1412104 is a liquid with a sweet, creamy and milky pro-file. It can offset the bitterness and cost of popular Greek yogurt, and performs well in frozen desserts, salad dressings, sauces and puddings. This highly concentrated, oil-soluble liquid is non-dairy, Kosher Pareve certified, non-GM, and whole foods- and organic-compliant. Edlong Dairy Flavors; Elk Grove Village, Ill.888-698-2783; www.edlong.com
Catechins and theaflavins for menAssuriTEA Men’s Health is a proprietary formula of catechins and theaflavins that sup-ports urological health – a top health concern for older men. With age, men are more at risk of an enlarged prostate; in some cases this results in unpleasant or bothersome symp-toms commonly known as lower urinary tract symptoms (LUTS). This ingredient can be taken to improve general urinary health, so men can enjoy an active lifestyle and main-tain their quality of life. It’s 100 percent wa-ter extracted and therefore does not contain harsh solvents and chemical residues and is backed by clinical trial results.Kemin; Des Moines, Iowa515-559-5121; www.kemin.com
We add new ingredients and equip-ment to our web site on a nearly daily basis. Find them two ways at www.FoodProcessing.com. Either type what-ever term you’re looking for (extruders, starches, etc.) into our search bar or go to the gray tabs at the top of our home page; the fifth one over is “Products,” and within that “Search products.”
MORE ON THE WEB
INGREDIENT SUPPLIER GUIDECOMPANY PHONE WEB
SugarsAdvanced Ingredients Inc. 888-238-4647 www.advancedingredients.comBeta Pure Foods 831-685-6565 www.betapure.comCargill Food Ingredients-Sweeteners 800-227-4455 wwww.cargill.com/food/sweetenersCenterChem Inc. 203-822-9800 www.centerchem.comCrosby Molasses Co. Ltd. 506-634-1724 www.crosbys.comDawn Food Products Inc. 800-248-1144 www.dawnfoods.comDomino Specialty Ingredients 800-446-9763 www.dominospecialtyingredients.comGold Medal Products Co. 800-543-0862 www.gmpopcorn.comGolden Barrel 800-327-4406 www.goldenbarrel.comImperial Sugar Co. 800-727-8427 www.imperialsugarcompany.comIndiana Sugars 630-986-9150 www.sugars.comMalt Products Corp. 800-526-0180 www.maltproducts.comMid-Eastern Molasses Co. 404-378-2056 www.mideastern-molasses.comNational Honey Board 303-776-2337 www.honey.comPrinova 630-868-0300 www.prinovagroup.com Tate & Lyle 800-526-5728 www.tateandlyle.comUnited Sugars Corp. 952-896-0131 www.unitedsugars.com
SweetenersADM 800-637-5843 www.adm.comAHD International 404-233-4022 http://ahdintl.comAlfa Chem 800-375-6869 www.alfachem1.comAjinomoto Co. 201-292-3200 www.ajinomoto-usa.comArnhem Group 908-709-4045 www.arnhemgroup.comBaldwin Richardson Foods Co. 866-644-2732 www.brfoods.comBlue California 949-635-1991 www.bluecal-ingredients.comBriess Malt & Ingredients Co. 902-849-7711 www.briess.comBunge North America 314.292.2000 www.bunge.comCalifornia Raisin Marketing Board 559-248-0287 www.calraisins.orgCargill Food Ingredients-Sweeteners 800-227-4455 www.cargill.com/food/sweetenersCorn Products U.S. 800-443-2746 www.cornproductsus.comDanisco USA Inc. 800-255-6837 www.danisco.comDomino Specialty Ingredients 800-446-9763 www.dominospecialtyingredients.comGLG Life Tech Corp. 604-641-1368 www.glglifetech.comIngredion 708-551-2600 www.ingredion.com/usNutraCea 602-522-3000 www.nutracea.comNutrinova, Celanese Corp. 972-443-8532 www.nutrinova.comOrganic Nectars 845-246-0506 www.organicnectars.comOrganic Planet 415-765-5925 www.organic-planet.comPrinova 630-868-0300 www.prinovagroup.comPureCircle USA 630-361-0374 www.purecircle.comSensus America LLC 646-452-6144 www.sensus.usStevia Brands Inc. 310-455-9876 www.steviva.comSweet Green Fields 360-483-4555 www.sweetgreenfields.comTate & Lyle 800-526-5728 www.tateandlyle.comUnited Sugars Corp. 952-896-0131 www.unitedsugars.comUnivar USA 425-889-3400 www.univarusa.comU.S. Niutang Chemical Inc. 714.993.6885 www.niutang.comWild Flavors Inc. 859-283-4052 www.wildflavors.comWisdom Natural Brands 800-899-9908 www.sweetleaf.comWixon Inc. 800-841-5304 www.wixon.com
SyrupsAssured Organics Inc. 914-428-6800 www.assuredorganics.comBaldwin Richardson Foods Co. 866-644-2732 www.brfoods.comBriess Malt & Ingredients Co. 902-849-7711 www.briess.comCalifornia Custom Fruits & Flavors Inc. 877-588-0056 www.ccff.comCargill Food Ingredients-Sweeteners 800-227-4455 www.cargill.com/food/sweetenersCiranda Organic Ingredients 715-386-1737 www.ciranda.comCitadelle Maple SyrupProducers’ Cooperative 819-362-3241 www.citadelle-camp.coopDomino Specialty Ingredients 800-446-9763 www.dominospecialtyingredients.comGolden Barrel 800-327-4406 www.goldenbarrel.comInternational Molasses Corp Ltd. 800-526-0180 www.maltproducts.comMalt Products Corp. 800-526-0180 www.maltproducts.comMid-Eastern Molasses Co. 404-378-2056 www.mideastern-molasses.comNational Fruit Flavor Co. 800-966-1123 www.nationalfruitflavor.comOrganic Nectars 845-246-0506 www.organicnectars.comOrganic Planet 415-765-5925 www.organic-planet.comPrinova 630-868-0300 www.prinovagroup.comSweet Ovations LLC 800-280-9387 www.sweetovations.comTova Industries LLC 502-267-7333 www.tovaindustries.com
© Key Technology 2011
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Refrigerated and frozen foods have always offered con-venience, but in recent years the freezer and cooler aisles also have come to mean variety, gourmet, or-
ganic or natural. While creating entrees co-branded with restaurant chains, simple to complicated breakfast items or easy-to-prepare hors d’oeuvres, processors must maintain tight control over a broad array of ingredients and processes.
In the frozen food arena in particular, the bar has been raised on quality and flavor, while operations personnel are continually pressured toward higher levels of hygiene and productivity. To some extent, refrigerated and frozen food manufacturers are finding new solutions to challenges both old and new.
From fryer to freezerFrom a technical standpoint, the most profound change in the last decade has been the move toward more inline freezing, and away from a dependence on slower cold room freezing. The most crucial change from a processing strategy standpoint has been the focus on hygiene and ensuring that freezing equipment meets ev-er-stringent food safety requirements, says Paul Osterstrom, vice
president of sales support for GEA Refrigeration Canada (www.gea-refrigeration.com), Richmond, British Columbia (formerly Aerofreeze). Sometimes the two go hand- in-hand.
Osterstrom’s business unit supplies processors of meat, poultry, seafood, fruit, vegetables, French fries, bakery goods and other food products with in-line freezing equipment for products that eventually will be sold in the freezer cases of grocery stores, or to restaurants and institutions.
“For example, a manufacturer of meatballs will have mix-ing equipment, a former, an oven or fryer, an in-line freezer and packaging equipment,” Osterstrom says. “The in-line freezer has now been requested to become a piece of equip-ment or machinery that can be easily cleaned instead of just a freezer building.”
Higher-quality ingredients and the emergence of a more culinary approach to food science and product development
As frozen foods get more sophisticated, so do their manufacturing processes.By David Phillips, Plant Operations Editor
P L A N T O P E R AT I O N S
Manufacturing theBIG CHILL
ABOVE: Strawberries roll off the conveyor of the Freshline DM tunnel
freezer from Air Products. Designed with flexibility in mind, the freezer
can switch from processing individually quick frozen (IQF) products to
non-IQF products using the same equipment.
have helped add excitement to frozen foods in the past 10-15 years. But the use of better processes and more sophisticated equipment also has played a major role in elevating quality.
“If you go back a couple of decades, frozen food was a not so ap-pealing, especially compared to the fresh alternatives. But consumers are now more familiar with the idea that if you freeze immediately, you preserve the freshness,” Osterstrom says. “Salmon is a good ex-ample. The perception of freezing is better these days.”
The two phases in heat removal with cold air are convection and conductive heat transfer.
“In the beginning, we use a very powerful air stream to remove the surface heat,” Osterstrom says. “Once the surface is cold, then it is important to have the coldest temperature outside of the product to the drive the heat to the surface.”
Achieving efficient freezing requires appropriate sizing of the freezer. GEA Refrigeration Canada is using advanced engineering tools like computational fluid dynamics in the design of in-line freez-ers. This helps GEA consistently to design freezers more efficiently and cost effectively.
“For years, knowing how to design a freezer has been an art in this business,” says Osterstrom. “Today, food processors are requesting consistent and efficient freezing solutions with documented proof of performance. We have invested in technology to confirm the design of our freezer and test frozen food products in our Food Tech Center. This has proven to be very important when developing speedy and innovative freezing solutions for food processors.”
Freezing costs Like any other kind of manufacturing, refrigerated and frozen food producers look to control costs through automation. Making more
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eggrolls with fewer line workers is one way to help the bottom line, says John Kadinger, market manager at Key Technology (www.key.net) Walla Walla, Wash.
“It is an issue that will be with them into the foreseeable future – doing more with less,” he says.
Key off ers sorting, conveying and optical inspection solutions to a variety of food manufacturers, including those in refrigerated and frozen foods. Along with automation, these companies are looking for better control and use of information.
Kadinger uses the example of a French fry manufacturer moving raw potatoes from the cutter to the fryer. Using high-tech optical sorters, those raw French fries can be sorted into multiple streams including rejects that will go to animal feed and irregulars that could be used as rework to make ground potato products. Modern sorters can feed data to a SCADA sys-tem or some other control system that will allow for on-the-fl y upstream adjustments, based on the qualities of those fries going into the fryer, or, if they are placed downstream, they can provide information on the fi n-ished product. Either way, adjustments can be made more quickly.
“It’s important for the operators, or the equipment itself, to get as much information as possible in a way that it can be used,” he says. “Th e sorter can tell the cutter to peel more or peel less or tell the fryer to fry more or to fry less.”
Key recently introduced a new line of optical sorters that uses four cameras to provide even more data than current equipment. A trend that Kadinger has seen is the positioning of scanner and sorting equipment in multiple locations. While it is crucial to catch defects just prior to packaging, earlier detection helps minimize waste of ma-terials and energy, he says.
“Th ere is no point to using all that energy to process something that you are just going to throw away,” Kadinger adds.
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With the use of higher-quality ingredients and the ongoing ef-forts to reduce carbon footprints, plant operators are willing to do more to catch and segregate waste as early as possible in the manu-facturing process.
“In the past, the most important sorting was done just after the freezer, which indicates that you also freeze your defect,” adds Frank De Brauwer, market manager at Tomra Sorting Solutions (www.tomrasorting.com), West Sacramento, Calif. “Removing these de-fects earlier and before freezing gives energy savings, more storage capacity for good product.”
Cold and clean The emphasis on hygiene has led to changes in equipment, processes and construction.
“Food safety has become a big concern all over the world,” says GEA’s Osterstrom. “Freezing equipment has to be easy to clean and must include CIP capabilities. We have emphasized this over the last 15-20 years, and that has helped us become one of the leaders in in-novative hygienic freezing equipment.”
An easy-to-clean in-line freezer must be built based on stainless steel welded construction rather than bolted, Osterstrom adds. The construction needs to be open to ensure accessibility for easy cleaning
and inspection, and there should be no hidden areas, no horizontal surfaces, etc., that will make the freezer difficult to clean.
Much of the attention now is paid to the design of floors and en-closures. Previously, in-line freezers were built with enclosure panels that had caulked joints. These joints were found to harbor bacteria and were very difficult to clean. In-line freezers available from GEA Refrigeration Canada have stainless steel enclosures with welded seams, which is the most hygienic approach.
“Bacteria can more easily grow in the caulked joints of the en-closures of floors and in crevices created in a bolted design, since it is difficult to clean,” Osterstrom points out. “Previously, welded designs were often an expense that was difficult for the food proces-sor to justify. Now, they cannot afford not to have food-safe freezing equipment.”
Observations on the trends toward hygienic equipment and envi-ronments are echoed by Kurt Warzynski, process engineering man-ager at Stellar (www.stellar.net), Jacksonville, Fla. Stellar is a design-build firm that works extensively with food manufacturers, and its capabilities include freezing rooms and equipment integration.
One technology adaptation Warzynski sees more of lately from food manufacturers is clean-in-place. Entire spiral freezer enclosures are now fitted with CIP, he says.
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Flow rates up to 600 gpm Pressures up to 360 psiGentle handling of food productsHigh and low viscosity capabilities3A, EHEDG and QHD certifiedSanitary and Aseptic designs availablePrecise metering
“Without CIP you would have to shut down the spiral freezer and maintenance crews would have to walk into the freezer with hoses and scrub brushes and foaming units and spray everything down,” Warzynski says. “And when they are done, they get out and let it dry before you could start it back up.”
Automated CIP systems on the other hand are faster and leave less room for human error. A maintenance team can work on other tasks while the equipment runs and then do a quick inspection and touch-up if needed once the rinse cycle completes. Th e movement toward CIP dovetails with trends toward hygienic design in equipment.
Warzynski says clients who are building new plants and expand-ing them are more likely than ever to go with top tier freezing and refrigeration solutions.
Frozen fl avorsNot so long ago, the most exotic item in the frozen food aisle at the supermarket might have been something vaguely Chinese. Today’s consumer can choose from items that are co-branded with celebrity chefs (Wolfgang Puck) or serious ethnic food (Saff ron Road Crispy Samosas) or complete meals that cater to common dietary concerns, or organic off erings (Amy’s Mushroom Risotto Bowls).
Here is how American Halal Co. (www.saff ronroadfood.com) Stamford, Conn., describes those samosas on the company website:
“We fi ll each pastry with a savory mélange of farm fresh vegetables, lentils and mashed red potatoes. Add a touch of garlic and a dash of aro-matic fennel and this is a vegan appetizer that will titillate every palate, and bring joyful delight to your guests.”
Th at’s a tall order for a plant freezer. Today’s frozen foods are a far cry from the functional TV dinner that once off ered little be-yond convenience. Th e sea-change in product diversity has defi nite implications on the plant fl oor. As noted previously, the need to minimize waste became elevated when rare spices or organic veg-etables are included.
GEA’s Osterstrom says the complexity of frozen foods makes for interesting challenges. “I really do like working in this fi eld because each product has its own attributes and characteristics,” he notes.
“We have the means to match the right equipment to a specifi c food application, and that is key,” he sums. “It is easy to simplify the characteristics of a food product. For example a blueberry is not just a blueberry – it can be a cultured blueberry or wild grown one and can have diff erences in size and sugar content. All of these details are important when designing freezers. As a freezer manu-facturer, we know the requirements in freezing diff erent foods and take this into consideration during the selection, design and manu-facturing processes.”
FOODPROCESSING.COM
P L A N T O P E R AT I O N S
Whatever your area of interest, we have more on our piece of the web. Type “freezing” into the search bar at www.Food-Processing.com and you’ll see 516 stories; “refrigeration” will net you 400 more. Or visit our Topics (second gray tab near the top of our home page) and pull down the menu to fi nd resource centers for plant maintenance or production line.
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hree companies showing extraordinary commitment to Integrated Pest Management (IPM) partnerships were named 2012 Gold Medal™ IPM Partner Award winners by Orkin, The IPM Institute of North America and NSF International.
The Gold Medal™ IPM Partner Awards honor companies showing the greatest dedication to making IPM work at their sites through vigilant sanitation, prompt adherence to structural pest management recommendations, diligent record keeping and staff participation in IPM training sessions.
An awards jury of IPM experts selected the following winning facilities from an elite group of approximately 50 nominees from across the country. All of the nominees employ Orkin’s Gold Medal™ Protection,a comprehensive IPM service that emphasizes quality assurance and documentation.
Dominion Packaging, Inc. (Richmond, VA) – Packaging solutions company offering printing, finishing and slitting services.
Petco Distribution Center #300 (Stockton, CA) – One of ten regionally based distribution centers for the leading specialty retailer of premium pet food and supplies.
Powertray, LLC (Mocksville, NC) – An environmentally-friendly manufacturer and distributor of paperboard trays, bowls and lidding systems for the food industry.
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Weighing Profitably, SafelyWeigher advances show how food safety measures can be profitable, too.By Bob Sperber, Contributing Editor
Profitability and food safety. It seems those two terms work their way into every story we write about plant-floor equipment. For ovens and freezers, the associa-
tion is obvious. But for weighing systems, the connection is less apparent but there all the same.
Food companies are demanding more of both – food safety and profitable operation – on their packaging lines, and that includes weighing systems. Some of the latest weighers feature sloped, self-draining parts, streamlined designs with fewer bolted fasteners, greater use of FDA-approved plastics and sealing materials and additional tweaks to prevent microbial harborage. Such improvements reduce sanitation and change-over times, which contribute to a more profitable operation.
Introduced at October’s Pack Expo, the new Ishida CCW-RV series of combination weighers from Heat and Control (www.heatandcontrol.com), Hayward, Calif., features all of the above safety features. It’s also watertight, with IP66, IP67 and IP69K
ratings for resistance to high-pressure, high-temperature washdowns.
Other features include new onboard electron-
ics that transmit data 300 percent faster than existing models for more immediate response to control in-puts; an improved in-feed camera for sharp, wide-angle viewing of incoming product flow; and sustainabil-ity features such as
three electric power-
saving modes and RoHS (Restriction of Hazardous Substances) compliance. Additionally, Ishida’s all-new operator interface features automated setup with a “simple five-step setup” of any product as well as quick changeovers.
Food safety has been a key concern of Mettler Toledo (www.mt.com/pi). Robert Rogers spent 15 years in Mettler Toledo field service, training and product testing before taking on the title of Senior Advisor for Food Safety and Regulation. “As a result, he understands every aspect of the role of inspec-tion equipment in ensuring the safety of food products and in meeting the requirements of both local and global food safety regulations,” says a spokesperson for the company.
In addition to sitting on several committees (at Grocery Manufacturers Assn., Packaging Machinery Manufacturers Institute and others), Rogers will consult with any company that has a food safety concern that involves product inspection.
Software and communications are becoming more user-friendly and easier to integrate industry-wide as control and automation components move toward industrial Ethernet, OPC, digital field buses or device networks and many more industry standards.
Another industry standard growing in use is PackML (Packaging Machinery Language), a set of models and pro-cedures to improve packaging system performance and pro-gramming efficiencies by way of standard communications. Customers “both large and small” are very advanced in their use of it, says Kyle Thomas, marketing manager with Mettler Toledo Hi-Speed (www.mt.com/hi-speed), Ithaca, N.Y.
Mettler Toledo is among those companies implementing and offering it. While food plants may not do as much con-trol engineering as they did in decades past, such standards help OEMs and integrators move more quickly to help plants realize incremental gains in efficiency, accuracy, quality and overall equipment effectiveness.
“When you’re running thousands of packages an hour, these things add up,” Thomas says of incremental gains. A ma-chine that can run millions of cycles with-out breaking down or exceeding tolerances
M R O
Heat and Control introduced the Ishida CCW-RV
combination weighers at Pack Expo in October.
The inset shows sloped, self-draining parts for
better sanitation.
can save minutes per shift. Likewise, the abil-ity to reduce product giveaway a fraction of an ounce per package can add up to millions of dollars in savings.
Thomas says paybacks can now be mea-sured in days or weeks as opposed to years ago when ROI could take months or years. Beyond a defensive “policing” role, he says, “most peo-ple buy checkweighers to make money.”
Both Hi-Speed and Ishida checkweigh-ers feature mechanical food safety enhance-ments – Ishida promotes its DACS-G unit’s IP69K rating and quick-release belts and conveyors – but they also play an active, au-tomated role in food safety management as well as process optimization.
“The more you can do to make the parts and component systems simpler and easier to inte-grate, the more robust they tend to be in terms of long-term operation,” Thomas says. He cites savings made possible by integrating weigher controls with the rest of a packaging line: When the weigher is sitting idle, even intermittently, this can indicate a problem with upstream ma-chines that can be measured and corrected for a more desirable, constant throughput.
A weigher, when integrated into the same network as other equipment, can play a direct role in a plant’s food safety manage-ment plan, where of course HACCP is the centerpiece. In fact, checkweighers are of-ten designated critical control points when
mated to a metal detector. In such cases, the Hi-Speed CombiChecker, can be ordered with extra software to monitor accuracy and verify rejects.
From food safety enhancements that
span stainless steel to software; and automa-tion upgrades from automated setup to elec-tronic “openness”; from machinery to plant and business systems, weighers are solid con-tributors to your plant’s profitability.
M R O
Food industry process temperature control can
be tricky. That's why Paratherm has focused
key individuals on this market. With over 3,000
food processing customer locations served
world-wide our high, mid and low temp fluids
answer your needs for temperature sensitivity.
Paratherm NF® heat transfer fluid is a
leader in poultry further processing where
high-volume fryers, spiral ovens and belt grills
produce convenience and frozen prepared
foods for home kitchens and fast-food restau-
rants. Paratherm engineering support focuses
on preventive maintenance of the whole heating
system. Paratherm customer service can ship at
any time from six North
American warehouses to
get lines back up and
running in the event of
the emergency.
Two more fluids
(Paratherm MR®, Paratherm
LR™), serve specific
operating conditions for
safe processing of food
additives, flavorings,
ingredients and other
applications where
non-toxic, NSF food-
grade performance
is specified.
Contact Ray Klim
directly for specifics or
go online.
HEAT TRANSFER FLUIDS
®
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Temperature range chart for Paratherm NF, MR and LR heat transfer fluids
Industry Specialists dedicated to your Food GradeHeat Transfer Fluid needs.
Industry Specialists dedicated to your Food GradeHeat Transfer Fluid needs.
George Schrieber,General Manager"There's a broad variety of applica-tions to understand."
Ray Klim,Food IndustrySpecialist"Safety, handling,and environmentalissues are critical forfood processors."
Make your systemmore profitable,more sustainable.
Fluid Analysis
Fluid Maintenance
Training
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Consulting
Services
Optimal Use Range
Booth 6370 At IPE, Atlanta GA January 29-31 2013
CONFERENCE MIXES WEIGHING, FOODSAFETYMettler Toledo staged its first Food
cago. It was enough of a success the company is already planning
at the Hilton Chicago/Indian Lakes Resort in Bloomingdale, Ill.
together food processors, retailers, auditors, standards owners, trade
in food safety to network and learn
For more information go to www.foodsafetyexchange.com.
ver since Ron Popeil introduced the Veg-O-Matic in 1960, people have had fun with the phrase, “It slices! It dices!”
Cutting and size reduction are mainstay processes from the kitchen to the large-scale plant. But the latter must meet increasingly demanding criteria to deliver safe, accurate reli-able and cost-eff ective operation. Here are just some of the equipment selection considerations:
One machine that can handle diff erent types of prod-ucts and cuts/sizes can fuel innovation and prevent the
need to buy additional machines.
consistent quality.
mize changeover, cleaning and maintenance.
equipment can speed your time to market.
M R O
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Better Malt Makes Better BeerAnd better malt results from a breakdown-free process at Malteurop North America, thanks to triple-sealed bearings.
Malt, a processed form of barley, is one of the key ingredients used to brew beer. Often referred to as the “soul” of beer, malt provides most of the com-
plex carbohydrates and sugars needed to give this beverage its distinctive flavor and color.
The Malteurop Group, one of the world’s leading malt producers, has perfected the control required to produce pre-mium quality malt barley. Although headquartered in Reims, France, Malteurop acquired ADM Malting in 2008, includ-ing a malting facility in Milwaukee, a city historically linked to the beer industry. Soon after, work began to upgrade the facility, including one of the large malt houses at the plant.
Gary McLoughlin, vice president of operations for Malteu-rop North America, says all 12 malting beds needed to be upgraded, replacing aging equipment with more reliable and more efficient technology. Each bed is nearly 127 ft. long and 18 ft. wide and holds 100 tons of cleaned and hydrated barley.
Over a four-day period, 11 screw mixers move back and forth through the bed while the barley germinates. Moisture levels are maintained or raised during this process by moving humidified air through the barley. McLoughlin says there is no room for error in this time-critical process because equip-ment failure can result in substandard barley malt.
“Once we give the barley water and air, there is no stopping the germination process. The barley doesn’t care that we’ve had a breakdown, it just keeps growing,” he explains. “If we are down too long, we’ll have to throw the batch out. If we can’t evacuate the bed in time, we have a real problem with backing up production because there is always a batch waiting. This is why equipment reliability is so important to us.”
The high humidity and the extensive cleaning between batches led to a high failure rate for both mechanical and electrical equipment. Working with Kurz Electric Solutions, a local distributor, Dave Hinners, the facility’s project engi-neer, mentioned bearings were especially troubling, difficult to maintain and even more difficult to remove.
The Kurz team demonstrated the features of the Dodge Imperial bearing. “The unique mounting method of this bearing makes it easy to install but also easy to remove,” says Hinners. “But it’s the triple-lip sealing system that really sold us on the Imperial. The biggest enemy in our facility is water, and if we can keep water out, a major problem is solved.”
Needing to be certain before making the final decision, an Imperial bearing was installed to see how it would per-form. Hinners says after an 18-month test, he got the results he was hoping for.
“Taking a bearing off in the past would have involved hy-draulics, torches and saws,” says Hinners. “But the Imperial was easy to get off. The sealing system worked because this bearing looked very good.”
While the bearing was under test, a motor and gearbox
package was put together. The products had to be engineered to withstand the harsh conditions, and because this was a retrofit, they had to fit the existing envelope. Because motors were failing due to severely corroded housings, Baldor’s SSE Stainless Steel Super-E motor was recommended.
“This stainless motor is designed to perform in harsh con-ditions longer than anything else available today,” says Mike Glynn, a Kurz vice president. “And, to make sure we could get the right reducer to fit, the Dodge sales engineer helped us with a design for the Dodge Quantis E-Z Kleen. And just like the bearing test, we placed a plate from the unit in the en-vironment to prove that the reducers’ 13-step coating system would hold up without rusting – and it did.”
As an added benefit, Baldor preassembled the motors and gearboxes, so the Malteurop team didn’t have to worry about assembly on-site.
With the project nearly complete, McLoughlin says he’s pleased with the results. Between the performance, reliabil-ity and energy savings these products offer, he is convinced they have found the right solution. He credits the success to the skills of the in-house engineering team and the expertise provided by the partners.
“This has been a significant project for us,” says McLough-lin. But with this collaboration and the attention to detail, the project is a success. “We knew what we wanted, and with help, we got what we wanted. And now we believe we have the right solution.”
M R O
The Malteurop team selected Dodge Imperial roller bearings because
of their triple-lip contact sealing system, which prevents water and
other contaminants from entering the bearing. The team is also
pleased with the adapter mounting system that makes these bearings
easy to install and remove.
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The “9 Dot Logo” and “Sealed Air” are registered trademarks of Sealed Air Corporation (US).
RUN WITH A SMARTER PACK Learn more at cryovac.com
EXPERTISE SERVICE TOTAL PACKAGING COSTS
Box-free cereal packaging yields green payoffs for
MOM Brands.By Kate Bertrand Connolly,
Packaging Editor
U sing less packaging can be good for the environ-ment, but it can also deliver business benefits by reducing packaging costs. No processor under-
stands these dual advantages better than family-owned MOM Brands (www.mombrands.com), Minneapolis.
MOM Brands, formerly Malt-O-Meal Co., has long focused on keeping packaging and other operating costs down to ensure competitive pricing for its products, A key tactic is to use bags instead of bag-in-box packaging for its ready-to-eat cereals.
Currently about 90 percent of MOM Brands’ cereals are packaged in resealable bags. These products include Honey Nut Scooters, Crispy Rice, Golden Puffs and Frosted Mini Spooners. Three Sisters- and Bear River
Valley-branded cereals also are packed in bags. The com-pany only uses paperboard cartons if retailers won’t ac-cept cereal in bags, or if consumers are so biased against bags that they’d snub the product if it were sold without a box.
“We started packaging our cereals in bags when we started producing ready-to-eat cereal back in the mid-1960s,” says Linda Fisher, director of marketing commu-nications for MOM Brands. “We did it primarily because it was a cost-saving packaging solution. We don’t need a paperboard box covering the bag. And over time we have maintained that.”
The cost component is essential, as MOM Brands’ business strategy combines “high-quality cereal, bag
PAC K AG I N G
More BANGfor theBAG
packaging and affordable pricing,” Fisher explains. A product like MOM Brands’ Coco Roos, for example, provides a lower-cost alternative to General Mills Cocoa Puffs.
Bag the box With consumers’ interest in ecological issues growing in the past sev-eral years, MOM Brands recognized that its bag packaging could be a strong selling point – if consumers fully understood the bags’ green benefits.
To get the word out, the company launched its Bag the Box cam-paign (www.bagthebox.com) in 2010. Bag the Box works with tradi-tional media and social media such as Facebook and Twitter to edu-cate consumers about the environmental virtues of bags versus boxes.
Although MOM Brands’ bags are not recyclable, they provide noteworthy waste reduction benefits, versus bag-in-box cereal, by eliminating a layer of packaging. According to the company, its packaging system creates 75 percent less consumer packaging waste.
According to the Bag the Box website, more than 2.3 billion ce-real boxes are produced in the U.S. annually. Manufacturing them requires 345 million pounds of paperboard and, to power the box plants, 2.4 trillion BTUs of energy. With regard to shipping, the site explains, “If the boxes travel 100 miles to get to the cereal plant (conservative guess), this consumes 1,400 tons or the equivalent of 46 tanker trucks full of fuel.”
To save money, MOM Brands doesn’t advertise on television. But its cost-effective Bag the Box campaign, which has generated plenty of buzz, shows that TV ads aren’t necessary to engage consumers.
Fisher says the campaign generated 55 million media impressions and 4.2 million video views in its first 18 months.
Upcycling into the futureTo provide an end of life for its bags that doesn’t include landfill, MOM Brands has partnered with TerraCycle Inc. (www.terracycle.com), Trenton, N.J., to create the Cereal Bag Brigade. Brigade par-ticipants, representing schools and other organizations, collect used MOM Brands bags and ship them to TerraCycle for upcycling into products like backpacks.
TerraCycle accepts bags from Malt-O-Meal, Three Sisters, Bear River Valley, Isabel’s Way and Sally’s cereals. The Cereal Bag Brigade collects about 25,000 bags per month.
MOM Brands also ships to TerraCycle all film that it cannot use for packaging, such as ends of film rolls and waste generated when changing over equipment. The company’s bag material is made from a food-grade, polyethylene-based film; details of the multilayer film’s structure are proprietary.
TerraCycle currently is conducting a pilot program that lets in-dividual households pack up mixtures of used packaging and ship them to TerraCycle for upcycling. MOM Brands is one of the brand owners participating in the pilot.
“This would give every consumer who buys a package of our ce-real the ability to send it someplace where it would be repurposed and made into something else,” Fisher says. “That’s a great end-of-life solution.”
Beyond the packageMOM Brands’ environmental and financial sustainability efforts
extend well beyond packaging, shaping its plant operations and shipping practices. The company buys renewable (wind) en-ergy credits to offset all the electricity used to make its broad assortment of natural cereals. These products are sold under the Mom’s Best Naturals, Isabel’s Way, Bear River Valley, Three Sisters and Sally’s brand names.
In addition, the company has created strict waste-reduction goals for its plants. “The goal is to recycle 95 percent of our waste, and we have hit that in our largest plant [Northfield, Minn.] year after year,” Fisher says, noting that even food waste is re-cycled – by pig farmers. The plants also make it a priority to reduce energy and water use.
To improve shipping efficiency, the company participates in the U.S. EPA’s SmartWay Transport Partnership. The pro-gram helps companies improve their carbon
.
footprint by reducing greenhouse gas emissions related to shipping freight.
MOM Brands is active in the Carbon Disclosure Project (CDP), as well. CDP is an international not-for-profi t organization that collects and reports data on companies’ greenhouse gas emissions, climate change strategies and water use.
Bottom lineTh e success of MOM Brands’ strategies vis-à-vis packaging and operations is
evident in its fi nancials. According to Fisher, sales fi gures show that “our ready-to-eat cereal busi-ness is up 7.1 percent, in
dollars for 2012 year-to-date.” In contrast, the national brand owners with which the company competes have experienced fl at or declining sales during the same period.
“We are so sure of our business model and our strategy of high-quality products at aff ordable prices that we’re investing in growth,” Fisher says, adding that MOM Brands has invested $500 million in expansion and capacity enhancements since 2008.
She adds, “We’re the only cereal company investing in new plants in this country.” Th e company just opened a greenfi eld one in Asheboro, N.C. “Th e beauty of being privately held is that our shareholders say, ‘We don’t care about the next quarter. We care about the next generation.’ We have very patient capital.”
Considering that Malt-O-Meal was founded in 1919 with $900 in poker winnings, “patient” pretty well sums it up.
PAC K AG I N G
Bag packaging originally was a money-
saver for MOM Brands, but now it carries
a good ecological message.
Use the search bar at www.FoodProcessing.com to search for just about any packaging topic you need information on – we have thousands of relevant stories. Or visit our Packaging Topic Center by pulling down the second gray tab (Topics) in the navigation bar at the top of every web page.
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When you need a motor that has a reputation for quality and reliability, U.S. MOTORS brand washdown duty motors won’t let you down. These stainless steel motors withstand high-pressure cleaning with water or chemicals and provide durability in moist, humid environments.
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If you feel a void in your life right about now it could be because, for the first time in many years, there is no Pro-cess Expo this month. We hope you already know the Food
Processing Suppliers Assn. (FPSA) and the International Dairy Foods Assn. (IDFA) have joined forces to co-locate Process Expo and the International Dairy Show in Chicago, beginning in 2013. That means Process Expo is taking 2012 off.
Next year, the two shows will take place Nov. 3-6, bring-ing together more than 800 exhibitors and 15,000 industry professionals in the north and south halls of McCormick Place. Attendees will have unlimited access to both show floors and educational programs.
“We are very excited to co-locate Process Expo with IDFA’s International Dairy Show, as it truly is the nation’s premier trade event for the dairy industry,” says David Seck-man, president & CEO of FPSA. “Considering the explosive growth we experienced at our last show, we are confident that this co-location will help us to continue building Process Expo into an event that simply can’t be missed.”
IDFA concurs. Neil Moran, IDFA senior vice president, said: “Process Expo is a great way to enhance and expand our show without sacrificing the dairy focus that is so important to all of our stakeholders. It will allow us to bring to exhibi-tors even higher numbers of qualified buyers while helping exhibitors make the most of their marketing expenditures. By returning to Chicago, selecting a later fall date and teaming with FPSA, we have achieved the best blend for 2013.”
In fact, the International Assn. of Exhibitions and Events in September named Process Expo 2011 a winner of an Out-standing Achievement in Sales and Marketing award. The award recognizes show management’s efforts in marketing and sales activities, such as total event revenue and profit, attendance, exhibit space sales, advertising revenue and spon-sorship revenue. Merit is based on achievement of defined objectives, including measurable comparable metrics.
“Being recognized by the trade show industry’s premiere association is such an honor,” adds Seckman. “We believed our numbers were good, so it’s flattering when seasoned trade show specialists think so, too.”
Attendance for the 2011 event nearly doubled to 12,732 and the growth rate for sponsor revenue was 576 percent. Ad-ditionally, exhibitor revenue growth rate surged 153 percent. Process Expo earlier was named the nation’s fastest growing trade show in 2011 by Expo Magazine.
And just as we went to press, the North American Meat Assn. (NAMA) and the Meat Import Council of America
(MICA) said they will co-locate their fall 2013 conferences dur-ing Process Expo 2013. NAMA and FPSA signed an agreement to support each other’s events, and FPSA will have a presence at the NAMA MeatXpo’13 in Las Vegas, Feb. 10-13, 2013.
NAMA will assist in developing the meat education pro-gramming at Process Expo in a dedicated theater on the show floor at McCormick Place. NAMA’s Outlook Conference general sessions and forums will take place in the theater.
Other NAMA events will take place at the Drake Hotel, which FPSA has designated the meat industry headquarters hotel. MICA will hold its annual conference concurrently at the hotel.
NAMA is one of the larger associations in the global meat trade, with about 700 member companies in the U.S., Canada, Mexico and other countries. NAMA provides its members regu-latory guidance, workplace issues support, legislative analysis, media assistance, and great educational opportunities. MICA is a trade association representing the U.S. industry that imports fresh, chilled and frozen beef and sheep meat into the U.S.
“We are extremely excited about working with NAMA and bringing the Outlook Conference to Process Expo,” said Seckman. “The hundreds of equipment manufacturers and service providers for the meat industry on our show floor are an excellent complement to the world class educational program of NAMA’s Outlook Conference. By bringing these two important events together, we are confident that attend-ees to both will benefit greatly.”
While Process Expo 2013 is still a year off, processing technology continues to advance. On the following pages, a few equipment vendors have provided midpoint updates of their technology. Check them out and mark your calendars now to see even more advances when Process Expo 2013 re-turns to Chicago Nov. 3-6, 2013.
Midway to the New Process ExpoNow a biennial event co-located with the International Dairy Show, the FPSA event will be Nov. 3-6 of next year.
S H OW P R E V I E W
T
A multitude of high technological solutions
Joining forces
TOMRA Sorting SolutionsWest Sacramento, Calif.
ALLIANCE PROVIDES SENSOR-BASED SORTING AND PEELING SOLUTIONS
URSCHEL INTRODUCES USDA-ACCEPTED LARGE CHEESE DICER
Cheese processors requested Urschel engineers design a
heavy-duty, sanitary large cheese dicer. They needed a durable dicer possessing a number of key elements: a clean, sanitary design combined with rugged construction, but they also demanded a machine that would deliver precision cuts. Along with these characteristics, the dicer needed to be simple to operate and maintain, so Urschel answered this request, through research and development, with this new large cheese dicer: the Affinity Dicer.
Sanitation is a major concern among cheese proces-sors. With this in mind, Urschel designed the Affinity with the following:
stainless steel construction including Ra 32 stainless surface finish on all components within the product contact/cutting zone.
from the mechanical zone eliminating cross-contam-ination concerns.
down procedures.-
chine from the sanitary large impeller down to the types of fasteners, threads, washers and nuts used throughout the product contact/cutting zone to discourage bacterial growth and assist in cleaning practices.
Urschel Laboratories Inc.Valparaiso, Ind.www.urschel.com; Email: [email protected]
SPECIALISTS IN VACUUM PROCESSORS, MILLS AND HOMOGENIZERS
Romaco FrymaKoruma, based in Neuenburg (Germany) and Rheinfelden (Switzerland), has handled the processing business area of
the Romaco Group since 2000. With 181 employees
company is one of the world’s leading suppliers of machines for process engineering and processing plants. Over 23,000 machines are currently in use in over 180 countries, and each year another 350 or so plants are added to the list.
Sales, marketing and the ProTec Process Technol-ogy and Training Centre are located at the Neuen-burg site. Product management, production, general administration and customer services are located in Rheinfelden.
FrymaKoruma technology is used in the manufac-ture of the widest range of product types. Active pharmaceutical substances, lipstick masses, creams and even ketchup and chocolate are produced in these plants. Whether in wet milling, homogeniza-tion, dispersion, mixing, de-aerating or disagglom-eration, FrymaKoruma provides the right process to manufacture high-quality products with short pro-duction times.
In the ProTec Process Technology and Training Centre in Neuenburg, customers can test machines and carry out trials. Recipes for liquid and semi-solid products are developed and optimized in the analyti-cal laboratory, together with specialists from Fryma-Koruma. In addition, ProTec is an international forum for training and conferences.
Romaco FrymaKoruma Lincoln Park, N.J.
S H OW P R E V I E W
New melt systemTwo advances have been added to the Liqua-melt adhesive system: a bulk feed option that eliminates the need for on-fl oor staff to refi ll the adhesive reservoir and a gateway I/O op-tion that will allow the system’s operation to be monitored by the packaging machine con-trol system. Th e bulk feed capability is done by the delivery of adhesive in a large container that is replaced when emptied. Typically hot melt adhesive is dispensed from the hot tank of a conventional system or from a reservoir close to the hot melt system.
X-ray inspectionsTh e Safeline PowerChek Plus X-ray inspec-tion system is designed for volume producers of bulk and packaged food products to pro-vide a defense against contaminated prod-ucts. Using low energy X-ray technology, the units detect many contaminants, including metal, stone, glass and bone. A 15-in., full-
color touchscreen user interface and intuitive software make operation simple, eliminating manual changeover operations and requir-ing no specialized knowledge about X-ray inspection technology.
High speed agitationShaka 1600 high-speed agitation retorts broaden shelf-stable product horizons beyond current batch retorts. Shaka retorts shake the product, leading to more consistent steriliza-tion throughout the product package and to shorter process times inside the retort (which leads to energy savings). Th e new 1600 is so-named because of its larger, 1600mm (63-in.) diameter. For most products, that’s double the capacity of the 1300 size Shaka retort. Brands should expect particulate products to mix better, dairy products to be scorch-free and starches to have improved hydration. Th e
For additional information, please contact Foster Printing Service,
the official reprint provider for Food Processing.
Call 866.879.9144 or [email protected]
REPRINTS ARE IDEAL FOR: New Product Announcements Sales Aid For Your Field Force
PR Materials & Media Kits Direct Mail Enclosures Conferences &
Speaking Engagements Recruitment & Training Packages Customer &
Prospect Communications/Presentations Trade Shows/Promotional Events
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vendor also offers lab-sized Shaka retorts to assist in the development process. Allpax Products, Covington, La.
Fans for foodPowerfoil X2.0 Wash Down is a large-diam-eter, low-speed fan designed with food man-ufacturers in mind. The 8- to 24-ft. diameter fan features a stainless steel, washdown mo-tor, food-duty epoxy and a completely sealed gearbox with food-grade oil to withstand frequent intense cleanings. The overall non-pooling design of the fan utilizes nonporous, nonabsorbent and corrosion-resistant mate-rials throughout. It eliminates condensation problems in food facilities by bringing the
necessary air movement to provide uniform temperatures from floor to ceiling.
Mixing for smaller batchesThe multifunctional Ystral PiloTec process-ing system brings induction, mixing and dis-persing processes to a laboratory or smaller scale production. It offers dust- and loss-free powder induction, wetting under vacuum and dispersion – all in one passage. A simple exchange of mixing tools allows innovative Multi-Z- or Z-Inline-dispersing with multi-stage shear ring systems. It also does emul-sifying, homogenizing, wet grinding and mixing, including mixing without applying shear energy. Its modular capabilities allow problem-free upgrades to a PiloTec plant processing system.
Eliminate fluctuating weightsThe Hopper Topper is a product transfer system designed as a solution to the many challenges faced by bakery and food produc-ers, especially fluctuating deposit weights. Equipped with an optic product sensor, the system maintains precise hopper levels. It has a unique tilt mechanism that allows for easy changing of mixing bowls while the Powerlift quickly lowers or raises as needed with the flick of a switch.
Smooth operatorThe Formax Maxum700 forming system incorporates servo-powered mold plate and knockout drives to ensure smooth operation at rates of up to 120 strokes per minute or 10,000 lbs. (4,536 kg) per hour raw weight. The servo-drives provide complete control
over the motions of the mold plate to maxi-mize quality of a wide range of products. It yields exacting portion control, a high level of food safety, greater productivity and reduced maintenance costs. Among other features is a
product hopper that tilts 90 degrees without disassembling major parts, and at the touch of a button offers clear access to the conveyor, feed screws and plungers. The conveyor as-sembly pivots with the product hopper, facili-tating belt removal and thorough washdowns.
Secure connectionsSecure connections are provided by the new MegaPress and MegaPressG systems for in-stalling schedule 5 to schedule 40 black iron pipe in sizes ½ in. to 2 in. The systems make secure water-tight and air-tight connections in fewer than seven seconds. They use cold-press connections for pipe installation. The system is for hydronic heat, chilled water, compressed air, fire sprinkler systems, low pressure steam and vacuum lines. More than 200 fittings are available for both systems and include el-bows, couplings, reducers, tees, reducing tees, threaded adapters and unions.
Upgrade to synthetic lube oilAn upgraded formulation of its Synthetic PAO (polyalphaolefin) lubricant oil means better performance than conventional mineral-based oils, the vendor says. Improved features include enhanced oxidation stability (increasing the service interval rating to 10,000 hours), im-proved lubricity for increased component life, extended seal life due to the elimination of seal shrinkage and improved varnish cleanability for optimal machine efficiency. The addition of purple coloring will assist in leak detection to help prevent fluid loss. Although suitable for a variety of applications, Synthetic PAO Lubricant is most commonly suggested for use in rotary screw compressors, heavy-duty service reciprocating compressors, anti-friction
For Food Safety, Equipment Reliability &
Extended Lubricant Service Life
Summit Industrial Products offers a full line of Food Grade lubricants that
conforms to the requirements of ISO 21469 and ISO 9001:2008 governing
quality and food safety. These lubricants provide superior extreme pressure,
heat transfer and anti-wear properties for equipment reliability. They are
resistant to oxidation, deterioration from steam/water and harsh chemicals to
provide extended lubricant service life. In addition, most Summit food grade
lubricants and greases are Kosher, Halal and CFIA approved.
Depend on Summit Synthe�c NSF H1 Food Grade Lubricants
ISO 9001:2008
Scan to see Summit’s
food grade products
Summit Industrial ProductsP.O. Box 131359 • Tyler, TX 75713
Ph. 800.749.5823 • www.klsummit.com
EQUIPMENT SUPPLIER GUIDE
FOODPROCESSING.COM
COMPANY PHONE WEB
DrivesAltra Industrial Motion 815-369-6227 www.altramotion.comApplied Industrial Technologies 216-426-4000 www.applied.comBaldor Electric Co. 479-646-4711 www.baldor.comBosch Rexroth 800-739-7684 www.boschrexroth-us.comBoston Gear 888-999-9860 www.bostongear.comCleveland Motion Controls Inc. 800-321-8072 www.cmccontrols.comDanfoss Drives North America 815-639-8600 www.danfossdrives.comElectra-Gear 800-877-4327 www.electragear.comEmerson Industrial Automation 800-626-2120 www.emerson-ept.comGrove Gear, Div. Regal-Beloit Corp. 262-878-1221 www.grovegear.comIBT Inc. 888-809-3464 www.ibtinc.comKB Electronics Inc. 954-346-4900 www.kbelectronics.comKEB America Inc. 952-224-1400 www.kebamerica.comLee Industries Inc. 814-342-0470 www.leeind.comLeeson Electric Corp. 262-377-8810 www.leeson.comMotion Industries 800-526-9328 www.motionindustries.comNidec Motors/U.S. Motors 888-637-7333 www.nidec-motor.comOmega Engineering Inc. 888-826-6342 www.omega.comOmron Electronics LLC 847-843-7900 www.omron247.comRockwell Automation 800-227-6143 www.ab.com/drivesSchneider Electric North America 847-397-2600 www.us.schneider-electric.comSEW-Eurodrive Inc. 864-439-8792 www.seweurodrive.comStober Drives Inc. 800-711-3588 www.stober.comSumitomo Machinery Corp. of America 800-762-9256 www.smcyclo.comToshiba International Corp. 800-231-1412 www.tic.toshiba.com
DoorsAleco 800-633-3120 www.aleco.comAmerican Insulated Panel Co. 508-823-7003 www.americaninsulatedpanel.comBerner Intl. Corp. 724-658-3551 www.berner.comChase Doors 800-543-4455 www.chasedoors.comDynaco 800-459-1930 www.dynacodoor.usEliason Corp. 616-327-7003 www.eliasoncorp.comEnviro Door Systems 800-558-7068 www.envirodoors.comHormann Flexon LLC 800-365-3667 www.hormann-fl exon.comJamison Door Co. 800-532-3667 www.jamisondoor.comKingspan Insulated Products 877-638-3266 www.alumashield.comMars Air Systems 800-421-1266 www.marsair.comMaster-Bilt Products 800-647-1284 www.master-bilt.comNor-Lake Inc. 800-955-5253 www.norlake.comRite-Hite Corp. 414-355-2600 www.ritehite.comRytec Corp. 888-467-9832 www.rytecdoors.comSimplex Isolation Systems 800-854-7951 www.simplexstripdoors.comTMI International 800-888-9750 www.tmi-pvc.comTrax Industrial Products Corp. 800-520-8729 www.traxindprod.comVerilon Products 800-323-1056 www.verilonvinyl.comZer-o-Loc Insul Panel/Door 604-607-1101 www.zeroloc.com
FreezersAir Products and Chemicals Inc. 610-481-4911 www.airproducts.comAmerican Insulated Panel Co. 508-823-7003 www.americaninsulatedpanel.comBassett Mechanical 800-236-2500 www.bassettmechanical.comCloudy & Britton, CBI Freezing Equipment 866-762-5414 www.cbife.comDunbar Systems Inc. 630-257-2900 www.dunbarsystems.comFoodesign Machinery & Systems Inc. 503-685-5030 www.foodesign.comFood Tech LLC 781-261-9701 www.foodtechstructures.comFrick/York/Johnson Controls www.johnsoncontrols.comGEA Aerofreeze Inc. 604-278-4118 www.aerofreeze.comJBT Foodtech 312-861-5100 www.jbtcorporation.comKelly Refrigeration and Freezer 866-713 6307 www.kellyfreezer.com Linde Group 800-262-4273 www.linde.comMetl-Span 877-585-9969 www.meltspan.comMollenberg-Betz Inc. 716-614-7473 www.mollenbergbetz.comNiagara Blower Co. 800-426-5169 www.niagarablower.comOdenberg Engineering Inc. 916-371-0700 www.odenberg.comRMF Freezers Inc. 816-765-4101 www.rmff .comSpiralsystems 800-998-6111 www.spiralsystems.comTetra Pak Hoyer 847-955-6000 www.tetrapakhoyer.com
bearings, hydraulic systems, chain drive sys-tems and power transmission reservoirs.Bel-Ray Co.; Farmingdale, N.J.732-378-4080; www.bel-ray.com
Filling bulk materialsTh rough its specialty-engineered, form-fi ll-seal (FFS) technology, the new FFS 2500 can fi ll granulated and microgranulated bulk materials at a rate faster than any other fi ll-ing system on the market. Its MEC electronic weighing system can be programmed with up to 99 product specifi cations, including bag size and weight. Th e system off ers precise con-trol from feed-in to fi nished product. Th e unit works quickly and accurately, without sacri-fi cing quality and producing a tightly sealed package every time. Bags can withstand long storage times and are durable during trans-port. Th e compact design makes it suitable for tight spaces. A mobile version also is available for transport between multiple silos.Haver Filling Systems Inc.; Conyers, Ga.770-760-1130; www.haverusa.com
GEA Refrigeration North AmericaAddress: 3475 Board Road, York, PA 17406Phone: 717-767-6411 ext. 338URL: www.gea.comEmail: [email protected] Executives: John Ansbro, Presi-dent, GEA Refrigeration North America; Gary Schrift, Vice President Food & Beverage, North American Sales Orga-nizationProducts: GEA IQF tunnels (Aerofreeze),GEA A-Tec spirals (Aerofreeze), GEA Maxi-Stack (Aerofreeze), GEA I-SRT &, I-VRT Carton Tunnels (Intec), GEA screw and piston Compressors, Chill-ers, Heat Pumps
GEA Refrigeration Technologies de-signs, engineers, installs and maintains innovative key components and techno-logical solutions for customers for whom refrigeration and freezing is an essential part in their primary process. Our team of experts provides innovative industrial freezing and chilling solutions that sat-isfy customer requirements
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Advanced Food Systems 34Allpax Products 58
Food Process Systems 48
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list of the 100 largest
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companies in the
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www.foodprocessing.comPublisher: Larry [email protected]
NORTHEAST U.S./EASTERN CANADA
Jim Maddox, Regional Sales Manager
CENTRAL U.S.
Larry Bagan, [email protected]
SOUTHEAST U.S.
Jim Maddox, Regional Sales Manager
WESTERN U.S./WESTERN CANADA
Larry Bagan, [email protected]
INTERNATIONALLarry Bagan, [email protected]
Polly Dickson, Digital & Print Sales Specialist
Taiwan - Sydney Lai
China - Craig Shibinsky, International Media, Director
Food Processing
CHEMICAL PROCESSING, CONTROL, CONTROL DESIGN, PHARMA-CEUTICAL MANUFACTURING, PLANT SERVICES, WELLNESS FOODS
THE JOURNAL W. PIERCE ROAD, SUITE 301, ITASCA, IL 60143 (PHONE: 630-467-1300 FAX: 630-467-1179)
FOOD
PROCESSING, P.O. BOX 3436, NORTHBROOK, IL 60065-3436
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1. Publication Title: FOOD PROCESSING2. Publication Number: 0015-65233. Filing Date: 09/30/124. Issue Frequency: Monthly5. Number of Issues Published Annually: 126. Annual Subscription Price: $100.007. 555 West Pierce Road, Itasca IL 60143
Contact Person: Jeremy Clark Telephone: 630-467-13008. 555 West Pierce Road, Itasca IL 601439. Full Name and Complete Mailing Address of Publisher, Editor, and Managing Editor: Publisher: Larry Bagan, 555 West Pierce Road, Itasca IL 60143 Editor: Dave Fusaro, 555 West Pierce Road, Itasca IL 6014310. Owner (Do not leave blank. If the publication is owned by a corporation, give the name and address of the corporation immediately
followed by the names and addresses of all stockholders owning or holding 1 percent or more of the total amount of stock. If not owned
address.) Putman Media, Inc., 555 West Pierce Road, Itasca, IL 60143, John M. Cappelletti, 555 West Pierce Road, Itasca, IL 60143, Julie A. Cappelletti - Lange, 555 West Pierce Road, Itasca, IL 60143, Jenny G. Cappelletti, 555 West Pierce Road, Itasca, IL 60143, Nicholas G. Cappelletti, 555 West Pierce Road, Itasca, IL 60143, Melody L. Cappelletti, 555 West Pierce Road, Itasca, IL 60143
11. Known Bondholders, Mortagees, and Other Security Holders Owning or Holding 1 Percent or More of Total Amount of Bonds, Mortgag-ees, or Other Securities. None
Has Not Changed During Preceding 12 Months Has Changed During Preceding 12 Months13. Publication Title: FOOD PROCESSING14. Issue Date for Circulation Data Below: September 201215. Extent and Nature of Circulation:
Average No. Copies Each Issue No. Copies of Single IssueDuring Preceding 12 Months Published Nearest to Filing Date
a. Total Number of Copies (net press run) ................................................................ 55,075 ..................................................54,870 b. Legitimate Paid and/or Requested Distribution
(By Mail and Outside the Mail)(1) Outside County Paid /Requested Mail Subscriptions Stated on
PS Form 3541. (Include direct written request from recipient, telemarketing and Internet requests from recipient, paid subscriptions including nominal rate subscriptions, employerrequests, advertiser’s proof and exchange copies). ....................................... 45,770 ..................................................46,011
(2) In-County Paid /Requested Mail Subscriptions Stated on PS Form 3541. (Include direct written request from recipient, telemarketing and Internet requests from recipient, paid subscriptions including nominal rate subscriptions, employerrequests, advertiser’s proof and exchange copies).........................................NONE .................................................. NONE
(3) Sales Through Dealers and Carriers, Street Vendors,Counter Sales, and Other Paid or Requested Distribution Outside USPS ......................................................................................................336 ...................................................... 321
(4) Requested Copies Distributed by Other Mail Classes through the USPS ..............................................................................................NONE .................................................. NONE
c. Total Paid and/or Requested Circulation [Sum of 15b. (1), (2), (3), and (4)] ............................................................................. 46,106 ..................................................46,332
d. Non-requested Distribution (By Mail and Outside the Mail)(1) Outside-County Non-requested Copies Stated on Form 3541
(include Sample copies, Requests Over 3 years old, Requestsinduced by a Premium, Bulk Sales and Requests includingAssociation Requests,Names obtained from BusinessDirectories, Lists, and other sources .................................................................7,557 ....................................................7,521
(2) In-County Non-requested Copies Stated on Form 3541(include Sample copies, Requests Over 3 years old, Requestsinduced by a Premium, Bulk Sales and Requests including Association Requests, Names obtained from BusinessDirectories, Lists, and other sources ................................................................NONE .................................................. NONE
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(4) Requested Copies Distributed Outside the Mail (Include Pickup stands, Trade shows, Showrooms and Other Sources) .................................... 217 ...................................................... 200
e. Total Non-requested Distribution (Sum of 15d (1), (2), and (3)) ..............................7,774 ....................................................7,721 f. Total Distribution (Sum of 15c and e) .................................................................... 53,880 .................................................54,053
g. Copies Not Distributed ............................................................................................1,195 ..................................................... 817 h. Total (Sum of 15f and g) ......................................................................................... 55,075 ..................................................54,870 i. Percent Paid and/or Requested Circulation
(15c divided by f times 100) ...................................................................................85.57% ................................................85.72%16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the NOVEMBER 2012 issue of this
publication. 17. Signature and Title of Editor, Publisher, Business Manager, or Owner
JEREMY L. CLARK, VP of Circulation09/23/12
I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information
and/or civil sanctions (including civil penalties).
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444 Carpenter Avenue, Wheeling, IL 60090
wabash
iane Toops, our beloved News & Trends Editor and a 24-year employee
of Food Processing (and our parent firm, Putman Media), died Oct. 31 following a brief illness.
Every month, Diane deliv-ered three key features of Food Processing magazine. Roll-out (p20) was certainly her fa-vorite. Diane loved new food products – everything from the development and launch to the marketing of foods and bever-ages thrilled her. She sampled as many as she could. She truly loved everything about food.
Food Biz Kids was a carry-over from her work on a previ-ous magazine at Putman, Food Business. To my knowledge, no other magazine (or maga-zine writer) gives seventh- and eighth-graders a podium to critique new food products that are aimed at them. How Diane made sense out of some of the kids’ comments, I’ll never know.
Likewise, few magazines allocate their back page to edi-torial content, much less a single columnist. It takes a strong personality to make people read beyond the classified ads. Diane was just that kind of personality. Her Toops Scoops column won a number of writing awards over the years as she took critical issues (and some lighthearted ones) facing the food industry and stamped them with her insightful personal commentary.
With the advent of the Internet, Diane took up blogging on our web site, three times a week delivering what her job title said: news and trends.
She tirelessly worked the floors of so many food industry trade shows over the years, never showing the fatigue that people half her age show after a day full of smiles, handshakes and note-taking. She was just as tireless in her writing, always volunteering to do the toughest cover stories, interviewing more people than most writers have the patience for, writing
more words than we could fit in the magazine. In that regard, the Internet may have been made for her – there was always room for more on the web. And she always wanted to tell her readers more, never less. As her editor in chief, I read every word she wrote for the magazine. I will soon find a replacement for the words; I will never find a replacement for the sweet soul behind them.
“With Diane’s passing, the Food Processing team has lost a great colleague and dear friend,” writes our publisher, Larry Bagan. “The food and beverage industry has lost a true superstar, an avid ‘foodie,’ a proponent and a classy example of all that is good within
our industry. It’s been an honor to work alongside Diane for the past four and a half years, and to have her represent us and our industry. Her sincere warmth, understanding and passion can only be matched by her unique style and love of life – and of the food and beverage industry. Diane was able to connect with everyone, from industry professionals old and young to grade school kids. While Diane kept a watchful eye on us all, now she has an even better view of all we do. Diane’s memory and spirit live on.”
From our company’s CEO John Cappelletti: “I will miss Diane greatly. I can’t remember a meeting we had where she didn’t have a smile on her face. Putman Media has lost one of the nicest, most humble and positive people I’ve had the privilege to work with in my 30 years here. She personified everything that makes a great editor: a natural curiosity, a passion for her industry, a dedication to bringing new ideas and insights to her audience every month.”
There’s a reading I hear at a lot of funerals: “In death our life is changed, not ended.” Diane isn’t gone. She’s just moved on the next big trend – as usual, a few steps ahead of the rest of us.
- Dave Fusaro, Editor in Chief
