Asian Food Journal

Your Professional Guide To Ingredients and Processing

MICA (P) 043/02/2012 PPS1595/07/2012 (022764)

Stevia Wonder

Functional Cocoa

Enforcing Security

Sorting Fruit Gently

CONFECTIONERY

MARKET TREND

TRACEABILITY

PROCESSING

SPECIAL REPORT

Create chocolate products with healthy ingredients such as dietary fi ber and cranberries

Healthy Indulgence

MARCH-APRIL 2012www.asiafoodjournal.com

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NoteEditor's

Sheila WanEditor, Asia Food Journal

ISSN 2010-4200

Staying ConnectedLike top restaurant chefs talking to their patrons nearing the tail-end of their meals, and beauticians and hairstylists lending a listening ear to their clients during a session, equipment and ingredient suppliers are working hard at providing the personal touch to their customers, despite being thousands of miles away from and in different time zones as their clients.

Besides email and fax, many companies would communicate with their customers via other channels such as online chat and call centers. While this may work for those who need fast answers, others needing more attention and explanation may look for third-party solutions provider to solve their problems quickly.

Next, suppliers, especially from the US and Europe, would appoint local agencies or distributors to establish a regional presence in Asia. Others may ultimately set up offi ces staffed by locals and personnel from the company headquarters. This enables the suppliers to maintain their business values, share more knowledgeably of their products to clients, and understand what is on the ground – depending on the relationship between the supplier and its local distributor/agency, the former may not fully understand the trends in Asia due to differences in business dealings, culture and language.

Customer service is liken to marketing and branding a company’s heart and mind – its willingness to talk to customers face to face and have meaningful knowledge transfer for future business development. Satisfi ed customers will help boost business by word-of-mouth recommendations, as branding and marketing help suppliers remain visible in the market.

2 Asia Food Journal March-April 2012

IN THIS ISSUE

ContentsMARCH-APRIL 2012

SPECIAL REPORT10 Stevia Wonder The recent approval of zero-calorie sweetener stevia by the European Union is accelerating the entry of healthy products into the market.

13 Healthy Indulgence Create chocolate products with healthy ingredients such as dietary fi ber and cranberries.

15 Cocoa Trends Cocoa is poised to become important in functional and healthier food products.

17 Making Sweets Quality and low cost of ownership are making depositing an attractive method to producing confectionery products.

PROCESSING20 Enforcing Security Use technology to track products against food scandals and threats of bio-terrorism.

24 Gentle Sorting Processors need to consider the fragility of the produce, the ease of use of the equipment and the reliability of the technology when sorting fruit.

MARKETWATCH 27

IN EVERY ISSUE01 EDITOR’S NOTE & SALES OFFICES30 CALENDAR OF EVENTS32 DO YOU KNOW?

COVER: COURTESY OF PURAC ASIA PACIFIC

STEVIA WONDERCreating healthy confectionery.PG 10

MAKING SWEETSUsing depositors.

PG 17

MARKETWATCHLatest products in the

market.PG 27

HEALTHY INDULGENCE

Cranberries in chocolate.PG 13

GENTLE SORTINGHandling fruit well.

PG 24


BUSINESS

DSM highlights 100 years of vitamins The year 2012 marks the 100th anniversary of the discovery of vitamins. In 1912, a Polish scientist named Casimir Funk coined the term “vitamins” to describe bioactive substances essential for human and animal health. In the years that followed, a series of scientifi c breakthroughs identifi ed 13 vitamins and explored many of their functions in the human body. The last century has witnessed discoveries and research that

have advanced understanding of vitamins and their vital role in health and wellness.In 1912, Funk isolated the fi rst vitamin (B1) from rice bran. At that time, European rice hulling machines were brought to Asia to process rice. However, the hulling process stripped the rice of its vital nutritional elements. As a consequence, health problems began emerging among people and animals that consumed rice as a staple food. Symptoms included weakness, fatigue, and as the condition progressed, apathia, polyneuropathy, paralysis, cardiomyopathy and heart failure. This dietary defi ciency disease is now known as beriberi. Funk realized that a compound found in the rice bran that had been removed in the hulling process could cure patients. He gave the substance he discovered the name “vitamine” — a combination of “vita” (Latin for “life”) and “amine” (a nitrogen compound).For 100 years the word “vitamin” has been an umbrella term for a group of essential, organic micronutrients that play a range of vital roles in our bodies. The majority of vitamins cannot be directly produced by the body and must therefore be obtained through dietary means, except niacin and vitamin D. If vitamin intakes are insuffi cient, it can result in health problems. While there is extensive knowledge on the role vitamins play in the body, billions of people do not have suffi cient intakes of essential micronutrients compared to recommendations. In many developing countries, people do not have access to vitamin-rich foods, which leads to high mortality rates and serious health problems. However, inadequate vitamin intakes are also surprisingly common in people having modern lifestyles. DSM works in partnership with other organizations, such as the World Food Programme and the International Osteoporosis Foundation, to help close up the gaps in essential micronutrient intakes among people and promote the essential role of micronutrients for health.

BUSINESS

Kalsec names distributor for the Middle East, North African marketsKalsec has appointed Orkila as the exclusive distributor to the Middle East and North African markets for its line of quality, natural ingredients. Orkila was founded in July 2005, as the result of a management buyout, concluded by the former management team of the companies of the Middle East and Africa zone of Rhodia’s (formerly Rhône-Poulenc) International Affairs Division, inheriting more than 100 hundred years of experience in the food ingredients industry.

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Industry UpdatesCHINA BANS PRODUCTION AND SALE OF FEED ADDITIVE RACTOPAMINEAuthorities in China has announced a ban on the production and sale of ractopamine, a controversial nerve stimulant used to increase the yield of lean meat in pigs, says SGS Food Safety Services. As a synthetic beta-adrenoceptor agonist (nerve stimulant), ractopamine is a feed additive used to promote the leanness of pig meat. It promotes the growth of muscle tissue, while simultaneously reduces the accumulation of fat in pigs.

TATE & LYLE “REMAINS ON TRACK” TO PERFORM WELL FINANCIALLYTate & Lyle has reported a “solid performance” in its third quarter between October 1 and December 31, 2011 with operating profi t in line with its expectations. It says it remains on track to perform well for the fi nancial year ending 31 March 2012. Within the bulk Ingredients division, its North American liquid sweetener volumes continued to benefi t from robust levels of domestic and Mexican demand. In Europe, higher sugar prices, which provide a reference price for isoglucose, have enabled the company to increase liquid sweetener margins despite higher corn prices.

GIVAUDAN’S PROGRAM FOR LOW-CALORIE SWEET, DAIRY PRODUCTSGivaudan is addressing the mouthfeel challenges that manufacturers of sweet and dairy products face in low-calorie versions with its TasteSolutions Mouthfeel program. The program includes sensory language Sense It Mouthfeel, and technologies to optimize the taste profi le of reduced-calorie sweet and dairy products for premium fl avor perceptions. The company says these initiatives are in response to food manufacturers’ challenge of the growing consumer concern with caloric intake, guiding demand for healthy products with the indulgent fl avor consumers crave.

REGULATORY

EU regulations defi ne maximum nitrate levels for foodstuffsThe European Union (EU) has laid out a regulation that increases the maximum level of nitrates from 4,500 to 5,000 mg/kg in fresh lettuce and from 3,000 to 3,500 mg/kg in fresh spinach, according to SGS Food Safety Services.Nitrates occur naturally in plants and they can turn into nitrites that react with amines and amides to produce N-nitroso compounds. These compounds have been linked to possible causes of gastric, esophageal, nasopharyngeal and bladder cancers in humans. Vegetables that are green and leafy, such as lettuce, spinach, and arugula contain higher levels of nitrates than are typical. The nitrogen fertilizers and light intensity used in their cultivation are the main factors responsible for the high nitrate content in these vegetables.Due to differences in the climate across the EU, it was not always found possible to achieve consistent nitrate levels in fresh lettuce and spinach under the previous maximum levels, which were set in 2006. To resolve this problem, Regulation 1258/2011 was introduced to marginally ease the maximum nitrate levels. On December 2, 2011, it was amended and substituted by Commission Regulation (EU) No. 1258/2011.A study to assess the risks was carried out by the European Food Safety Authority (EFSA) in2008. It concluded that it was unlikely the new maximum levels would result in any appreciable health risks and that the benefi ts from eating vegetables should remain unaffected. The EFSA conducted another study in 2010 to investigate potentially acute effects on infants and young children of nitrate exposure at the new maximum level. It concluded that cooked spinach is more likely to be consumed by infants than lettuce and that neither the current nor new maximum levels of nitrates are likely to pose a health concern, whereas at higher levels the risk could not be entirely discounted. The EFSA also reported there is no scientifi c data to indicate a health risk for young children consuming spinach and lettuce at the new maximum levels of nitrates.

REGULATORY

ISO standard makes food irradiation safer A new ISO standard has been introduced to provide requirements for food irradiation, which is commonly used to improve quality and safety in food processing that benefi ts manufacturers, irradiation operators, regulators, customers and, ultimately, consumers. ISO 14470:2011, Food irradiation – Requirements for the development, validation and routine control of the process of irradiation using ionizing radiation for the treatment of food, not only provides requirements, but also guidance for meeting them.Food irradiation is the process where food is exposed to ionizing radiation in order to improve its safety and quality. It is intended to be used only on

food that has been produced under good manufacturing practice principles. The irradiation of food can be used for purposes such as controlling pathogenic microorganisms and parasites, reducing the number of spoilage microorganisms, inhibiting the sprouting of bulbs, tubers and root crops, and extending product shelf life or phytosanitary treatment.The ISO 14470:2011 aims to provide requirements for the irradiation of food consistent with current standards and practices; provide directions for a technical agreement between the customer and the irradiator operator; and establish a documentation system to support the controls on the food irradiation process.“ISO 14470 will contribute to confi dence and transparency among the different stakeholders operating in the food sector and will help provide regulators and consumer representatives with improved information on products, thereby enabling better choices,” say Mariana Funes and Noelia Antonuccio, the two project leaders of the committee that developed the standard.

Grab&Go


BUSINESS

Fonterra seeks practical raw milk regulatory changes in New ZealandFonterra welcomes the New Zealand government’s moves that would see independent processors with their supply lose eligibility to regulated milk, but says proposed amendments to the Raw Milk Regulations need refi nement to achieve this outcome. In its submission on the draft Dairy Industry Restructuring (Raw Milk) Amendment Regulations 2012, the cooperative said that to continue to win in the world for the good of New Zealand, the country needs a robust and sustainable dairy sector. Its submission highlights three issues:

• Any amendment to the Raw Milk Regulations should require those obtaining milk to invest in manufacturing plant(s) on the ground to process it. Currently volume limits can be by-passed by “virtual” processors that are like shell companies without visible presence or investment in physical assets.

• The Amendment Regulations propose maximum monthly amounts of regulated milk that independent processors can take, but without a minimum. This allows them to obtain milk in spring and autumn or avoid the peak months. Fonterra submits that independent processors must take at least some milk during peak production months, as it is the case now under what’s commonly called the “October Rule”.

• Instead of the proposed “cold turkey” exit from 1 June 2015, which established independent processors would lose access to regulated milk on that date, Fonterra believes a carefully programed exit would benefi t all parties. By phasing down volumes over two years from 1 June 2013, independent processors would be better able to gradually build their additional supply base, while the cooperative would have greater clarity for its investment planning.

In addition to these issues, the cooperative’s submission also addressed concerns relating to the increase in the total regulated milk supply cap, and the removal of the $0.10 per kg/MS premium. On the supply cap issue, Fonterra said that a proposed increase in the pool of regulated milk would not promote farmgate competition. Instead, it would further discourage independent processors from competing for farmgate supply. In addition, if established processors with their supply become ineligible to obtain regulated milk by 2015, any current pressure on the maximum supply limit milk would be relieved.In order to justify the removal of the $0.10 premium, Fonterra proposes the Raw Milk Regulations to introduce either different price points for each month (that refl ect the differing seasonal cost/value of that milk) or an obligation to order quantities that match the seasonal curve.

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Industry UpdatesCAROTECH’S TOCOMIN SUPRABIO SELECTED AS AWARD FINALISTCarotech’s Tocomin SupraBio natural full spectrum palm tocotrienol complex has been selected as a fi nalist in the “Best New Ingredient” category of the Nutracon’s 2012 NutrAwards. The award category requires the ingredient to have sound science and research; with evidence showing effi cacy and safety; as well as novel and innovative features that increase the ingredient’s market potential and market credibility. The ingredient was selected as a fi nalist by an independent review and selection committee. A second online voting and selection by industry peers will decide the winner of the category, which will be announced during NutraCon in March 2012.

SARTORIUS REPORTS OPERATING EARNINGS OF MORE THAN 30%Sartorius’ group divisions have reported high sales revenue and earnings, as fi nancial targets that the company had raised twice before year-end were achieved. The company expects positive business development for the current fi nancial year. According to preliminary fi gures, Sartorius generated consolidated sales revenue of £733.1 million ($988 million) in fi scal 2011, up from £659.3 million year ago. This equates to an increase of 11.2% (in constant currencies: 12.2%). The gain in order intake jumped 10.0% (in constant currencies: 11.0%) to £749.5 million.

ASHLAND’S SOLUTIONS TO BOOST GUAR SUPPLY Ashland Specialty Ingredients has launched new cellulose gum products Aquacel GSA and Aquacel GSH in response to the current guar shortage in the market and to help supplement or replace guar. These cellulose gums, which can be used either to supplement or replace guar, offer cost-effective alternatives for beverage, bakery and dairy applications.

BUSINESS

Corn Products International to be called IngredionCorn Products International says it intends to change its name to Ingredion, pending shareholder approval at its annual meeting in May, to signify its role as a global ingredients solutions company.Building on the company’s legacy of performance and innovation, the new name was conceived to better refl ect its position as a global supplier of ingredient solutions to a range of industries, including packaged food, beverage and brewing. The name change is part of the company’s global strategy that included the acquisition of National Starch in late 2010.“The fi rst part of the name represents ‘ingredients,’ while the second part has

its roots in the Greek word that means ‘something that goes’. It says that we’re an ingredient solutions company,” says Ilene Gordon, chairman, president and CEO (in picture). “Ingredion encompasses the diversity and growth of our product offerings. It also honors the long-standing values that have contributed to our success while being more representative of the stronger, global company we have become.”Although entities outside of Corn Products International are not expected to change their legal names, the company anticipates a global transition to its new global brand and logo over the next two years, with all geographies using the Ingredion brand by the end of 2013 upon shareholders' approval.

EXPANSION

Probat opens new base in the PhilippinesProbat-Asia, a joint venture between roasting machine and plant specialist Probat and instant coffee producer NMN Global, started its operations in January 2012 in Cebu City, the Philippines. The new company will enable Probat to carry out service job, commission and manage projects in Southeast Asia. The company is staffed by a senior engineer and a German service expert from Probat, who commissions and manages projects, as well as a group of NMN Global technicians. Apart from the services offered and stockpiling with parts subject to wear and spares, the new offi ce is tasked to reduce delivery time to the customer.“Although we can rely on the service provided by our network of agencies and our

organization, we came to the conclusion that there is yet a need of being present locally,” executive VP Rainer van der Beek (in picture) tells Asia Food Journal. “We took about three years to consider this from the fi rst idea and fi nally to deciding our Asian base. We had thought of setting up offi ce in other parts of Asia and even the Northern territory of Australia. We chose the Philippines fi nally after extensive survey.” “The country is centrally located in the Asia-Pacifi c region. The locals can communicate in foreign languages and the costs of labor and real estates are reasonable. But the most important fact is that we made contact with our partner NMN Global in the country, which its employees are experienced in the coffee processing industry for years.”To expand its business footprint in Asia this year, Probat continues to rely on its fi ve training centers in China, India, Indonesia, South Korea and Taiwan, which are established in cooperation with its local agencies. “With the opening of Probat Asia, we will also focus on a higher frequency in customer contact and service roundtrips for preventive maintenance,” he adds.

SUSTAINABILITY

Kraft Foods reduces waste in plantsEmployees at Kraft Foods are reportedly making steady progress in reducing the amount of manufacturing waste they produce, fi nding better uses for waste and turning manufacturing by-products into new energy sources. They continue to improve effi ciency by changing behavior, new business practices and culture, as well as creating new partnerships to turn waste into something of value. Manufacturing accounts for the vast majority of Kraft Foods’ solid waste output. “Today, we have 36 facilities in 13 countries that send zero waste to landfi lls, and we’ve reduced our manufacturing waste by 50% since 2005. Our strategy is to generate less waste and fi nd new uses for the waste we do produce. And

our employees are doing just that,” says Christine McGrath, VP of global sustainability.In 2007, the company launched a program with the global recycling company Sonoco Recycling, using its Sonoco Sustainability Solutions service offering to substantially reduce waste in plants.

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asia food journal 0212.indd 1 17/02/2012 10:05:10


GRAB & GO

Industry UpdatesECOLAB RESTRUCTURES FOR CORPORATE SYNERGYEcolab plans to undertake restructuring and cost-saving actions to help enable and enhance realization of its merger-related cost synergies, as well as streamline and strengthen its global business. These actions, along with merger-related costs, will result in restructuring and other charges from Q4 2011 to 2013. The total merger-related restructuring costs over the period are expected to be approximately $180 million, with other special charges at about $300 million.

WILMAR INTERNATIONAL INVESTS IN BLUE PACIFIC FLAVORSSingapore-based agribusiness group, Wilmar International has made a capital investment in Blue Pacifi c Flavors, a developer and manufacturer of natural and organic-compliant fruit fl avors. Blue Pacifi c Flavors will join Wilmar International’s group of associated companies. The investment allows Blue Pacifi c Flavors to focus on creating true-fruit and whole food fl avors, strengthening its capabilities in natural fl avors and extracts, providing capital resources and having an existing licensing partnership with The New Zealand Institute of Plant and Food Research.

REPORT: ONE IN EVERY TWO FOOD INSPECTIONS FAILED IN CHINA LAST YEARIn 2011, 51% of food inspections conducted in China failed, according to a report in AsiaInspection 2011 Q4 Barometer. While the majority of these inspections failed because of minor defects, 10% were for critical defects with an extreme case involving contamination by a large quantity of rodent fecal matter. The report found that an average failure rate for non-food products in the country stands at 30%. The defi cit in food safety is supported by government fi gures, as China’s State Administration for Industry and Commerce said 62,000 illegal food cases were reported last year.

BUSINESS

Kimberly-Clark sees tough days ahead, sticks to growth initiativesKimberly-Clark says its Q4 2011 net sales increased 2% to $5.2 billion, while organic sales rose 3%, driven by higher net selling prices and sales volumes. The organic growth was highlighted by 7% increase in K-C International.Diluted net income per share for the quarter was $1.01 compared with $1.20 in the same period last year. Q4 adjusted earnings per share (EPS) were $1.28 in 2011, up 7% compared to diluted net income per share in the prior year. The company’s Q4 adjusted EPS benefi ted from sales growth, cost savings and a lower share count, partially offset by input cost infl ation, a higher effective tax rate and lower net income from equity companies. The company expects to increase its dividend at a mid-single digit rate from April 2012. This will represent the company's 40th consecutive annual increase in the dividend."Looking ahead to 2012, we expect economic conditions to remain diffi cult in the near term, particularly in developed markets. Nonetheless, we plan to bring a healthy pipeline of innovation to market, invest behind our brands and growth initiatives and continue to achieve strong levels of cost savings,” says chairman and CEO Thomas J. Falk.

BUSINESS

AB Sciex, Phenomenex partner to improve food safety testingLife science analytical technology company AB Sciex and separation science techniques provider Phenomenex have announced a collaboration agreement to improve food testing. Both companies will create a joint rapid response team to develop the industry's quality and cost-effective methods. This partnership is expected to support efforts that prevent the spread of tainted food and help increase the safety of the global food supply.This joint network will enable food testing laboratories around the world to test for emerging contaminants and identify the cause of tainted food more quickly than previously possible. Food testing scientists and analysts will be able to access the rapid response resource online to help them solve liquid chromatography–mass spectrometry issues that they face in their laboratories.The two companies will be working closely with food industry experts in applications such as pesticides, antibiotics, allergens and natural toxins to provide laboratories verifi ed analytical methodologies for emerging threats to food safety.As part of the collaboration agreement, Phenomenex will work with AB Sciex to expand and sell the portfolio of the latter’s iMethod applications, which provide instructions and parameters on how to most effectively conduct a test to identify food contamination with the highest confi dence. Phenomenex's high performance liquid chromatography (HPLC)/ ultra HPLC columns and sample preparation will be used together with AB Sciex's mass spectrometers. The resources simplify the process for food testing scientists to rapidly address food contamination crises.

BUSINESS

Symrise invests in growth platformsSymrise has agreed to partner with Swedish biotech fi rm Indevex to expand the consumer health division of the ingredients company. Indevex produces and markets a patented nutrient complex called NGC primarily through a licensing model. The product concept for medical nutrition, health and functional foods, as well as products for losing weight, optimally complement Symrise’s existing portfolio.Both companies have also agreed to develop new product concepts through joint research and development. It is assuming a minority stake and will be represented on Indevex’s Board of Directors by its CEO.


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A Perfect Solution: CAVAMAX® W6A new approach to stabilize oil-in-water emulsions is to use alpha-cyclodextrin (CAVAMAX® W6). Enzymatically produced from starch, cyclodextrins are made up of a ring of glucose units shaped like a donut and with a hollow cavity. The outer surface of a cyclodextrin molecule is hydrophilic, whereas the inner surface surrounding the hollow interior is hydrophobic. This allows fatty acid groups to “slip” into the cavity of the alpha-cyclodextrin – and form a surfactant-like structure, which has emulsifying properties.

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SPECIAL REPORT

CONFECTIONERY

The recent approval of zero-calorie sweetener stevia by the European Union is accelerating the entry of healthy products into the market, says Wouter Moormann.

SteviaWonder

A report by Mintel in 2011 found that food and beverage manufacturers are starting to reformulate their products to meet the growing market demand for nutrition. Consumers also seemed concerned about sugars and

sweeteners in what they eat and drink, suggesting that functionality might be waning in favor of products without additives and are “unprocessed and unadulterated”.With the recent approval of the zero-calorie sweetener stevia by the European Union (EU), consumers can expect to see new products sweetened with the herb on the retail shelves in Europe such as yogurts, cereals, beverages, soft drinks, confectionery, chocolate and table top sweeteners. Commonly used as a sweetener in food and beverages throughout the Americas and Asia, steviol glycosides are sweetening compounds extracted from the leaves of Stevia rebaudiana, which are considered as natural and free of calories.Regulatory bodies such as the FAO/WHO Expert Committee on Food Additives and the European Food Safety Authority agree that the sweetening compound is safe for consumption and a suitable sweetening option for diabetics.Stevia-based sweeteners have already been approved for use in the US, Japan, China and Australia. In France, stevia sweeteners with a high purity of steviol glycoside Reb A have been allowed for sale since September 2009. Analysts say the European market for sweeteners is valued at $500 million and its market for stevia-based sweeteners is expected to reach an additional $100 million this year.

Health factorRising health concerns, consumers’ preference for all-natural ingredients and the growing regulatory approval of stevia are driving the rapid growth of the herb in the industry. Market research group Zenith International forecasts worldwide sales of the ingredient to more than triple in volume by 2014, which translates to 11,000 metric tons and $825 million.Asia Pacifi c, where the ingredient has been used as a sweetener in some regions for decades, has the largest market share at 35.7%, followed by North America (30%) and South America (24.3%). The market share in Europe was 8.6%, which is expected to grow quickly as more companies enter the global arena to supply stevia to the industry. While consumers demand foods that are natural, palatable and healthy, manufacturers face technical and formulation challenges, particularly in overcoming off-notes and aftertaste associated with stevia-derived sweeteners. While the taste of stevia may work with certain fruity

Manufacturers face technical and formulation challenges in overcoming off-notes and aftertaste associated with stevia-derived sweeteners.


Asia Pacifi c, where stevia has been used as a sweetener in several regions for decades, has the largest market share at 35.7%, followed by North America (30%) and South America (24.3%).

fl avors in beverages, those in other products may require changes in order to be acceptable to consumers.Flavor and ingredient companies are therefore helping manufacturers to optimize fl avor and taste profi le with natural solutions in a broad range of applications, as well as creating naturally-made products that are free of chemical processing.

Natural sourceThe increasing market popularity of stevia can be attributed to the changing demographics and consumption patterns, as well as the sophisticated consumer market that is favoring naturally-derived foods that boost health – consumers today are willing to pay more for wellness-advocating products. The industry has therefore offered a range of natural and synthetic sweeteners, which, when combined with enhancers and formulated into foods and beverages, can mimic the properties of sugar. The current challenge for food technologists is to reduce the calories in sweeteners while maintaining the taste and fl avor profi le of sugar (sucrose).Stevia is about 300 times sweeter than sugar in its natural state. It gets sweeter when processed. The source of its sweetness is largely due to its complex stevioside molecule. Another compound, called rebaudioside, which is present in stevia, also contributes to its sweetness profi le. Stevia is a natural, non-caloric; sweet-tasting plant commonly used for its pleasant taste. The herb offers health promoting qualities such as regulating blood sugar, preventing hypertension, treating skin disorders and preventing tooth decay. Other studies show that it is also a natural antibacterial and antiviral agent.

Several regulatory bodies consider stevia to be safe for consumption and a suitable sweetening option for diabetics.


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Stevia is about 300 times sweeter than sugar in its natural state, which gets sweeter when processed.

Natural low- and no-calorie alternative sweeteners have been introduced to the market over the past couple of years. They have been well received by consumers due to the ever-growing concerns over obesity, cancer and diabetes. Being calorie and carbohydrate free, stevia is being positioned as a viable replacement for artifi cial sweeteners and refi ned sugar.

Tapping the confectionery marketLow-calorie beverages form the fastest-growing segment in the food and beverage market, as they offer a more convenient diet and meal replacement option than food. On the other hand, stevia is used in products such as gummies, fruits, functional beverages, juices, yogurts and sauces, as well as toiletries and pharmaceutical goods. However, the use of stevia in the confectionery sector remains small, especially products for children, who are the major consumers of this segment. A growing awareness and concern among parents about the impact of eating too many sweets on their children’s health are causing confectionery manufacturers to reconsider the role confectionery plays on preventing dental caries, as sugar-free and tooth-friendly products are mainly limited to chewing gum, mints and herb drops.Research has showed that consumers are looking for healthier alternatives to sugar-coated chocolate sweets and they are willing to pay premium for toothfriendly variants if these alternatives are available in the market.

• Sugar-free, tooth friendly offeringsWhile toothfriendly products do not necessary mean that they are free from sugar, carbohydrate Palatinose (isomaltulose) is however an ingredient to have toothfriendly credentials. Derived from beet sugar, the ingredient is a white crystalline powder that has similar energy and sweetness as sugar. While it cannot be claimed as sugar-free, being fully digestible, Palatinose enables the production of tooth-friendly chocolate, chewable sweet and gums without negative side effects on digestibility.The approval of stevia in the EU could signal a breakthrough for sugar-free and toothfriendly confectionery as manufacturers break the artifi cial association with such sweeteners. Parents could view stevia as a healthier alternative to certain high-intensity sweeteners for their children. While several companies are able to create sugar-free variants of most confectionery products, they recognize that formulations can become more diffi cult to create for soft products. In addition, manufacturers need to determine the suitable sweeteners or bulking agents for use, which meet consumers’ needs and gain their acceptance.

• No more sticky candiesWith the global consolidation of the confectionery industry and complex supply chain, products are required to maintain their quality for a longer period of time. However, a long supply chain can result in unwanted stickiness in candies, which is due to sugar inversion, where sucrose turns into glucose and fructose. Confectionery manufacturers can use acid sanding to overcome this issue. This process coats sugar confectionery with a blend of sugar and acid powders, which would react with exterior infl uences once the packaging is opened. The choice of acid powder is critical to the success of an acid sanded product. Purac’s powder for example consists of malic acid, which is coated with sodium hydrogen malate. The powder provides stability, low hygroscopicity and clean, taste profi le.Nominated in the category "Confectionery Innovation of the Year" at the recent Food Ingredients Europe Excellence Awards 2011, this powder coats candies with a more stable acid, yet having a fresh, fast sourness release.

Masking solutionsWhile certain intensive sweeteners have bitter, metallic, or a licorice-like cooling aftertaste, sweeteners with a lingering sweet taste can accentuate off-notes of other ingredients in candies, which is unnoticeable in the product, but consumers would typically detect an “artifi cial aftertaste”.Confectionery manufacturers can use Purac’s ultra purifi ed natural L-Lactic acid solution to mask disagreeable aftertaste imparted by intensive sweeteners. The ingredient enhances desirable characteristics in hard-boiled candies such as fruitiness and sweet fl avors. By regulating the pH levels, the product also strikes a balance between taste, health and function.

Sweet futureThe stevia landscape is fast changing as new product launches are subject to regulatory and consumer scrutiny. As a zero calorie, natural, non-carcinogenic intensity sweetener, stevia can potentially gain market share from alternative sweeteners, as well as replace starch syrups when blended with sugar or other bulking agents. Developing innovative, great-tasting products is the fi rst step to expanding the reach of such natural sweeteners in growth markets. And using stevia as an alternative all-natural sweetener, manufacturers will not only save money but offer health benefi ts to consumers for a sweet future.

Wouter Moormann is market unit manager (food division) of Purac Asia Pacifi c.

Today, there is a range of natural and synthetic sweeteners, which, when combined with enhancers and formulated into food and beverages, can mimic the properties of sugar.


SPECIAL REPORT

CONFECTIONERY

Create healthier chocolate products by reducing the sugar content and adding healthy ingredients such as dietary fi ber, omega-3 and cranberries. Marion Burton shares.

Healthy Indulgence

Despite the growing emphasis on healthy eating worldwide, consumers in Asia are increasingly treating themselves to indulgent products – a Mintel report in 2011 stated that traditional confectionery market in China reached almost

RMB20 billion ($3.18 billion). It has now reached volume sales of 700,000 tons a year. Chocolate is the largest confectionery category in both China and Japan. It is also growing across the region, particularly in Indonesia – the sector is expected to overtake Japan to have the largest volume sales by 2015, says Mintel. Extensive media coverage has made consumers aware of the health concerns presented by certain food groups, which might have caused many to reassert their right to decide what they should and should not eat. While confectionery sales show that Asian consumers are as keen as ever to treat themselves well, collective conscience is infl uencing many to purchase indulgent products that remove the feeling of guilt – they often seek products with a “healthy halo”.A Mintel report in March 2011 concluded that, “Changing attitudes to healthy eating have made holistic ‘eating for health’ more interesting than simply limiting fat intake and cutting down on calories. Chocolate has been redefi ned in this context, as a ‘permissible indulgence’ – a luxury treat which can also be of some benefi t to health, however tentatively.”

TrendsHealth and indulgence will continue to dominate the confectionery market in the coming years, as recent publicity surrounding the health benefi ts of dark chocolate and cocoa is gradually changing perceptions of related confectionery to “less unhealthy”, or even nutritionally benefi cial. However, reports about the dangers posed by saturated fat and recommendations for decreasing its intake may have wide-reaching implications for chocolate manufacturers. In addition, production guidelines pose challenges for manufacturers to reduce the saturated fat content of chocolate, causing the need for alternative ways of increasing the health benefi ts of their products.Manufacturers will have to invest heavily in new product development and innovation in order to compete in the market and meet changing consumer demand. As consumers in Asia look for guilt-free indulgence, manufacturers could add healthy ingredients to chocolate that do not compromise its indulgent qualities such as taste, mouthfeel and appearance.

Sweetened dried cranberries (SDCs) are perceived as sophisticated fruit and are easy to use, tasty and colorful, which enable manufacturers to offer premium products with “luxury” messages.


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One of the ways to offer guilt-free indulgent products is to increase the healthy properties of the chocolate. Companies have created healthier chocolate ranges by reducing the sugar content and adding healthy ingredients such as dietary fi ber and omega-3. Just add fruitTo increase the health benefi ts of chocolate confectionery, manufacturers can add fruit such as sweetened dried cranberries (SDCs) into their products. SDCs are perceived as sophisticated and are easy to use, tasty and colorful, which enable manufacturers to offer premium products with “luxury” messages.Several manufacturers have begun developing premium chocolate products containing SDCs. In Asia, notably China, Japan and Malaysia, products ranging from premium bars of chocolate with SDCs and similar luxury gift items are proving to be popular among consumers. Dried cranberries are particularly well liked in Japan, especially during in winter. Their vivid red color and association with Western cuisine and culture enhance the celebration of Christmas and Valentine’s Day, making sales of confectionery featuring cranberry inclusions soar in the country. Taste is a crucial success factor when developing any product. This is even more so when formulators reduce sugar and fat content in chocolate, or add ingredients such as omega-3 to the product. The natural, strong and tart fl avor of cranberries blends well with all varieties of chocolate. SDCs can also combat the bitterness of some dark chocolates and their fl avors can mask any off notes. The fruit can be blended into melted chocolate without requiring additional ingredients or special settings. While diced or double-diced SDCs do not protrude from the chocolate once set, soft and moist SDCs can be used when they are needed to be visible in products. Whole SDCs are however typically used to add indulgence to products. These options allow manufacturers to increase the healthy benefi ts of chocolate products without having to reinvent the wheel.

Marion Burton is marketing manager of Ocean Spray Ingredient Technology Group.

News about the dangers of consuming saturated fat and regulatory recommendations for decreasing its intake may have wide-reaching implications for chocolate manufacturers.

The natural, strong and tart fl avor of cranberries blends well with all varieties of chocolate.

Manufacturers need to invest heavily in new product development and innovation, such as those incorporating cranberries, in order to compete in the market and meet changing consumer demand.

To increase the health benefi ts of chocolate confectionery, manufacturers can add fruit such as SDCs into their products.

The vivid color of cranberries and the fruit’s association with Western cuisine and culture enhance the celebration of Christmas and Valentine’s Day in Japan, making sales of confectionery featuring cranberry inclusions soar in the country.


SPECIAL REPORT

CONFECTIONERY

Cocoa – the antioxidant-rich raw ingredient for making chocolate – is poised to become important in the market for functional and healthier food products, Sheila Wan fi nds out more.

Cocoa Trends

Pointing to an Article 13.5 health claims application recently lodged by chocolate producer Barry Callebaut in Europe, cocoa had the potential to be “a health ingredient as successful as cranberries”, says an analyst.

Switzerland-based Barry Callebaut is for example seeking approval from the European Food Science Authority for a claim linking cocoa fl avanols with a healthy blood fl ow. The company says it is confi dent that the dossier, which contains fi ve clinical studies, will be favored by the authority.Consumer awareness of the benefi ts of cocoa is creating the environment for companies to market successful health products containing the ingredient. Companies wishing to capitalize on cocoa’s growing “health halo” would need to consider the suitable product format, particularly as it might be hard to convince consumers that a simple chocolate bar is good for them, Julian Mellentin, director of consultancy of market research company New Nutrition Business, tells Asia Food Journal.

Asia Food Journal: Are seasonal periods such as Christmas and Valentine’s Day instrumental in educating health-conscious consumers about the goodness of cocoa, instead of seeing the ingredient as “fat food”?Mellentin: Cocoa has a head start to winning the consumer, as the health benefi ts of antioxidants found in the ingredient and chocolate have been gaining media attention for almost a decade. This has raised consumer interest to the point where the confl uence of perceived antioxidant benefi ts (with good taste) has produced double-digit growth in sales of dark chocolate products in many countries.Media reports on “naturally healthy” food and beverages containing ingredients such as blueberries and cocoa have resulted to a surge in sales in the last decade. Consumers typically like to hear that the foods they enjoy are also good for them. While I do not think festive seasons such as Christmas and Valentine’s Day had any effect on educating consumers on the goodness of chocolate, the messages about cocoa's natural healthiness and high

Like ice cream, chocolate is marketed as a pleasurable and not a healthy product.

Any format that can deliver positive nutritional profi le and does not have the "fat food" indulgent image of confectionery can be used to penetrate into new sectors.


SPECIAL REPORT

antioxidant content are made all year round. These seasons are typically about pleasure and indulgence, not health.I consider chocolate, not cocoa, as the "fat food", which most people consume. Chocolate is the indulgent, not-so-healthy food. Like ice cream, chocolate is marketed as a pleasurable and not healthy product. In this sense, we will not see high-sugar chocolate bars promoting the health benefi ts of cocoa. It will require new formats with healthier nutritional profi les to do so.

Asia Food Journal: What are some of these new formats?Mellentin: Any format that can deliver positive nutritional profi le and does not have the "fat food" indulgent image of confectionery can be used to penetrate into new sectors. The biggest success using cocoa in the food and beverage industry have come from creating categories and associations that did not exist before, such as Red Bull and energy drinks, Yakult and probiotic dairy, as well as Anlene milk powder and bone health. Similarly, cocoa can go forward using this approach.Mars and Hershey have had successful market tests of products containing cocoa, healthy grains and fruit. Beverages that combine cocoa with green tea or with milk and protein have also been developed and tested by major companies in the market. These are the future product types for cocoa.

Asia Food Journal: What should confectionery manufacturers be mindful of then?Mellentin: The signifi cant advances in processing cocoa made by companies such as Mars, Hershey, Barry Callebaut and Meiji have resulted to fi nished powder that retains more of the intrinsic health properties of cocoa, which is easier to formulate in a wider range of products such as snacks and beverages, but not confectionery. Manufacturers should make developmental improvements in confectionery plants to prevent them from being left behind by the advancements made to cocoa in other sectors and product formats.

Sheila Wan is editor of Asia Food Journal.

Media reports on “naturally healthy” food and beverages containing ingredients such as blueberries and cocoa have resulted to a surge in product sales in the last decade.

Scientists have now found new evidence that chocolate or cocoa powder containing higher amounts of cocoa fl avanols can positively infl uence brain performance in healthy middle-aged individuals in a natural way.

Julian Mellentin, director of consultancy of market research company New Nutrition Business.

High fl avanol chocolate as brain food

Research indicates new potential areas of benefi t from chocolate, says Barry Callebaut.

The right kind of chocolate can be good for the brain. Chocolate – in particular the dark variety – is already well known for its positive effects on health when consumed in small quantities. Scientists have now found new evidence that chocolate or cocoa powder containing higher amounts of cocoa fl avanols can positively infl uence brain performance in healthy middle-aged individuals in a natural way. This means that people who regularly consume cocoa fl avanols can think just as well as others, but with less effort. This was revealed in an independent study by Professor Andrew Scholey and Con Stough from the Center for Human Psychopharmacology at Swinburne University in Australia.

TestA total of 63 individuals between the ages of 40 and 65 were observed over 30 days in a randomized, controlled, double-blind study. They were divided into three test groups and consumed a prescribed drink daily containing different proportions of cocoa fl avanols. The fi rst group received 10g of dark high fl avanol chocolate (corresponds to 500mg cocoa fl avanols) in their beverage, the second group had 10g of conventional dark chocolate (corresponds to 250 mg of cocoa fl avanols) and the control group got a drink with 10g of dark chocolate that contained hardly any cocoa fl avanols. During the sample period, the test subjects were not allowed to consume products containing caffeine, fl avonoid-rich fruit or an excess of alcohol so as not to infl uence the results of the study.

Results The steady state visually-evoked potential method (SSVEP) was used to measure human brain activity in the research. In order to compare brain activities, computer-tomography or CT brain scans of the test subjects were made on the fi rst and the 30th day of the experiment, while participants solved tasks dealing with spatial working memory. Spatial working memory describes one's ability to remember, for instance, the location where an object appeared and also to recall a series of earlier locations of other objects. The results of the study show that the brains of individuals who consumed the cocoa drink with a medium or a high proportion of cocoa fl avanols were less strained than those in the control group. The differences in the accuracy or the reaction times of the test subjects in solving the task were not ascertained between the various groups.

Media reports oonn ““nnaatttuurraallllyy hhealthy” f


SPECIAL REPORT

CONFECTIONERY

Quality and low cost of ownership are making depositing an attractive method to manufacturing confectionery products. Keith Graham tells us more.

Making Sweets

As consumers look for new and innovative candies for variety, confectionery manufacturers are competing beyond a like-for-like basis with importers and seeking to develop their identities with creative product ranges.

This means they require the most fl exible process and equipment that can produce the widest selection of end products. For most hard and soft confectionery, including lollipops, this invariably points to depositing as the process of choice. Depositing can produce quality products in one to four colors with stripes, swirls, layers and hard or soft center fi llings. It can handle sugar, low-sugar and sugar-free recipes using virtually any fl avor. Besides hard candy and lollipops, depositing can also be used to produce soft confectionery such as toffees and caramels, fudge, fondant creams, jellies and fruit snacks.

Depositing equipmentThe development of the depositing process continues to produce innovative confectionery products such as hard candy with a soft center-fi ll, totally spherical ball lollipops and profi led fl at versions. The advancement of multi-headed depositors has also extended the range of layered candies with varying textures and/or fi llings. A triple-headed depositor can be used to create “long term” three-layered products with a “sandwich” appearance. Such “long term” layering requires the fi rst layer of the deposited candy to partially set before the next one is added. This ensures a clear separation between deposits for a “layered” effect. This physical separation means that each layer can feature various colors, textures and fl avors that are contrasting or complementary such as lemon and lime, as well as sweet and sour or spicy. They can be in sugar, low sugar or sugar-free variety, as the combination of sugar-free polyol and Xylitol layers are most commonly used.A multi-headed depositing system can be used in the soft confectionery sector to produce toffee cups with fi llings, toppings and/or inclusions. Indulgence products can be made more

The provider of the depositing line should offer upgrades for installed equipment, as on-going technological development extends the useful life of new equipment, reduces operating costs, and adds product styles.

The most effective depositors can handle up to four components independently, which the servo control maximizes the effectiveness of this capability.


SPECIAL REPORT

economically than conventional processes using the two and three-headed depositors and fl exible rubber mold technologies.

• Product appealTo penetrate the health food market, manufacturers can use the depositing process to create fruit snacks in bite size pieces or bars using up to 100% of fruit sources such as paste, puree, pulp, juice/juice concentrate, peel and dried fruit. They can be produced as center-fi llings and layers with nuts. The result of deposited pieces are perfectly shaped products, with smooth and glossy surface, minimal air bubbles and no sharp edges. Besides looking attractive, the products also taste better through enhanced fl avor release and smoother mouthfeel.The resultant shape is regular and consistent, as hard candy syrups take the shape of die-cast aluminum molds and product ejection by a pin mechanism that ensures the desired shape at depositing is achieved and retained. The rigid molds used for soft toffees, creams, jellies and truffl es ejection the confectionery by compressed air. On the other hand, fl exible molds are used for hard toffees, creams and chews, with ejection by air or mold deformation. These methods ensure the consistent shape of the confectionery.

• ControlOperationally, depositing provides manufacturers a greater control over product dimension and weight, reduces labor, space and running costs, as well as improves hygiene and safety.In addition, when the depositing system has been primed by a couple of strokes in the piston arrangement and production has started, there is a short start-up for the small and barrier-free chamber to begin fi lling.The time taken to clean machinery and clearing waste is minimized at the end of each run as there is a small amount of syrup left in the hopper. There is no need for material to ensure adequate fl ow and operation is ensured without the presence of cavities and dead spots.Additionally, product weight is made accurate due to the repetitive nature of the depositing process, the precise servo-control of the machine motions and the mold.

A triple-headed depositor can create “long term”, three-layered products with a “sandwich” appearance.

Manufacturers can use the depositing process to create fruit snacks in bite size pieces or bars using up to 100% of fruit sources.

The time taken to clean a depositor and clear waste is minimized at the end of each run as there is a small amount of syrup left in the machine.

Choosing suppliersOnce the confectionery manufacturer has decided to use a depositing system, it is essential for the company to have an integrated solution for cooking, depositing and cooling the products – the machinery supplier would need to demonstrate an understanding of the relationship between the recipe and the production process. It should ideally be both the designer and provider of the complete line.The cooking, depositing and cooling operations of confectionery should be considered as an integrated process – if the cooked candy syrup is not delivered to the depositor at the pre-determined temperature and moisture content, production and quality problems will arise. The cooking parameters that work for other processes may also not be applicable to a depositing plant.A supplier offering a complete process solution should provide evidence of installing complete lines in various locations and for a broad range of products. It should ideally have in-house facilities to develop new products, run trials, train operators and test products in the market.

• Servo control Depositors generally require full servo control to achieve the largest possible weight range and a variety of constructions. The most effective depositors can handle up to four components independently, which the servo control maximizes the effectiveness of this capability. The tree-axis servo control also fi ne tunes depositor operation “on the run”.The ease of use of equipment enables unskilled operators to maintain product consistency and quality. Full programmable logic controller control and touch sensitive human machine interface offer full process visualization and precise repeatability via push-button, automatic setup of parameters for various deposit patterns such as colored, striped, swirled, fi lled and layered, as well as records of weight stored in the system.

• SafetyThe line should have an alarm management for operators to locate and identify faults for immediate investigation and correction. Integrated upstream and downstream equipment would provide


Depositors today feature automatic cleaning to replace the diffi cult, messy, time consuming and costly manual cleaning process.

Indulgence products can be made more economically than conventional processes using the two and three-headed depositors and fl exible rubber mold technologies.

operators control of the complete cooking and depositing process, with links to other systems such as supervisory control and data acquisition or SCADA.

• Saving resources Depositors today feature automatic cleaning to replace the diffi cult, messy, time consuming and costly manual cleaning process. A washout system is activated and withdrawn automatically, as the washing and fl ushing cycle is pre-programmed and carried out without operator intervention.

The provider of the depositing line should offer upgrades for installed equipment, as on-going technological development extends the useful life of new equipment, reduces operating costs, and adds product styles. The equipment supplier should also offer equipment that enables the ambient cooling of hard candies before they are ejected from the mold, thereby eliminating the need for refrigerated cooling.

Keith Graham is marketing manager of Baker Perkins Group.

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TRACEABILITY

Regulatory authorities are working to ensuring that their supply chains are safe and reliable. There is also a need for a greater accountability and traceability from fi eld to fork as food scandals continue to surface in Asia. In

November 2011, The Economic Times reported that Unilever’s Lipton Tie Guan Yin tea was one of the 19 brands that fell short of China’s quality standards. The tea was reportedly found to contain rare earth metals, and was subsequently taken off the shelves and destroyed.In the same month, local doctors told China Daily that the substances can accumulate in the body to cause liver and bone damage. Unilever claimed that the source of contamination was the soil in which the tea was grown, and ruled out the possibility of its introduction during production and processing.In a separate incident, Chinese authorities in the Guangdong province found that 62% of cooked foods in major supermarkets in Foshan and Zhongshan cities met quality standards in November last year. In its statement to China Daily, Wal-Mart said cooked food that did not meet health standards have been taken off the shelves of its China stores.Taiwan also experienced its share of food scandals in last year. Based on a news report by The Economist in June 16, 2011, government inspectors detected unhealthy levels of industrial plasticizers in sports and soft drinks sold in the country. This resulted in the removal of 900 products from 40,000 shops. As a demonstration of the government’s commitment to enforce regulation, Taiwan president described the government raids on shops and suppliers as the country’s greatest effort in combating food contamination.

Bio-threats, foreign demandUnintentional food contamination can damage the reputation of companies, affect the lives of consumers and undermine the credibility of regulatory authorities. Yet, a potentially greater threat could stem from bio-terrorism, where a deliberate attack on a country’s food supply could cause death and/or economic disruption. An introduction of biological substances into production processes could potentially cause widespread epidemics and affect the health of the local population.While random regulatory checks and tests on product samples at manufacturing facilities and customs entry points can help ensure consumer safety, these methods may fall short in a bio-terror scenario.

Cases of contaminated food can damage the reputation of companies, affect the lives of consumers and undermine the credibility of regulatory authorities.

Didier Lacroix advises manufacturers to use technology to trackproducts against food scandals and threats of bio-terrorism.

EnforcingSecurity


In order to ensure the security and safety of its food supply, the US has for example implemented the Public Health Security and Bioterrorism Preparedness and Response Act 2002. The act allows the USFDA to detain food products if an offi cer fi nds credible information that a shipment poses a health threat to humans or animals. The USFDA is also stepping up its efforts in ensuring food safety right at the source. According to a statement released online in September 2011, staff have been conducting routine inspections of facilities in various countries via the organization’s foreign inspection program. It reported an incident where its fi rst-ever import alert was issued, as a result of a China-based food producer refusing an USFDA offi cial to conduct an inspection in the factory.

Looking for answersToday, manual methods are still being employed as part of quality control measures in food factories, which typically involve operators checking each product on the production line. This gives rise to subjective checks, as operators exercise personal judgment to differentiate a defective product from a good one. However, these operators are subject to fatigue, the state of their health and emotions. Often, manual checks produce inconsistent results in detecting errors such as missing batch/lot information on products. Operators are also unable to read barcode data on certain items.To overcome this problem and adhere well to local and foreign regulations on product quality, food and beverage manufacturers should ensure traceability throughout the production process using technology. A robust, vision-based barcode system is for example instrumental in helping factories keep track of the expiry dates of food ingredients. It can also generate reports for operators to remove older ingredients in the factory before they spoil or expire. These reports also serve as evidence that the factory is adhering to fi rst in, fi rst out procedures.Similarly, information on manufactured products such as batch/lot numbers and manufacture/expiry dates should be captured and stored in the system, which can help the manufacturer track where the product was delivered to, and when it changed hands in event of a product recall – thereby reducing the time and resources required for the operation – assuming that product tracking continues after the shipment has left the manufacturing facility. When sound traceability procedures had been adhered to throughout the supply chain, the system would also be able to perform tracking upstream. This helps to determine the source of the problem or contamination, and when it occurred – during pre-manufacture, production or distribution.Besides requiring a barcode system to read and store information, manufacturers should determine if it should be modular in order to support higher production line speeds by

Product information such as batch/lot numbers and manufacture/expiry dates should be captured and stored in barcode systems to enhance traceability.

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PROCESSING

adding more vision cameras, instead of launching a major overhaul to accommodate growth.

Rooting out mistakesJust as a chain is only as strong as its weakest link, a system is only as effective as the hardware and software that support it. Besides being able to read and validate barcodes correctly, the system should pick out products with missing barcodes and/or other information effectively. The system can be linked to a rejection unit to identify defective products, which are promptly removed from the production line.When manufacturing products such as canned food, inspection cameras need to be able to read barcodes in various orientations and angles – all while keeping up with the production speed. This is possible via the use of Patmax, a software tool that allows the cameras to read “un-oriented” codes. The images of the codes are also stored by In-Sight vision barcode systems to generate reports and troubleshoot problems.A vision-based barcode system ensures that the correct information is present on packaging that is stored for tracking purposes. It also reads both one and two dimensional (1D; 2D) barcodes, as the latter could store more information than the former using vertical dimension.By ensuring that the necessary controls for traceability are in place from end-to-end in the supply chain, stakeholders in the food industry can effectively prevent deliberate attempts to disrupt the supply chain. Such safety mechanisms can help to avoid “accidental” contamination that is reported in the media. Should one such incident were to occur, the supply chain players would be better equipped to assist governing authorities track down the source and culprits.

Didier Lacroix is senior VP of international sales & services at Cognex.

Beyond the BarcodeBesides enhancing product traceability, a vision-based system is also an effective quality control (QC) tool to check products for physical defects. In a soft drink bottling plant for example, every bottle is checked for the presence of a correctly sealed cap. This is especially important if the factory produces more than one type or brand of soft drink, which has the potential for a mix-up. A vision system can be used to detect when an incorrect label has been attached to a jar or bottle, and if the affi xed label is out of position. Advanced systems can even determine whether two of the same labels are pasted onto a product. This capability helps the manufacturer prevent the situation where the nutritional and ingredient information shown on the packaging varies from contents of a product, thereby avoiding customer complaints and expensive recalls. It also prevents the manufacturer from having to conduct lengthy investigations and explain why and how the problem occurred to the authorities.Such QC tools are useful for contract manufacturers that make products for competing brands. A factory in Vietnam could be producing beer for brands A and B and if an incorrect cap or label is being placed on a bottle, there can be a major cause of embarrassment to the manufacturer and a loss of reputation to the beer brands. Vision technology can also verify the presence or absence of contents in a product packaging, such as ensuring that a plastic scoop in the right color and size is present in a powdered milk tin.

Factory Effi ciency Amidst InstallationTo implement a vision system, besides installing the right equipment and software, the technology vendor needs to make adjustments to the system after having studied the production environment.For example, a production area with bright lights can produce an external glare that may affect the quality of images taken by the inspection camera. As replacing the lighting can be a costly and time-consuming affair, the vendor may work out the right amount of light needed by the camera and install tinted plastic/glass panels on it.When installing the vision system, manufacturers would typically prefer the vendor to work around the production schedules of their factories to minimize downtime and disruption to operations.

When sound traceability procedures had been adhered to throughout the supply chain, a barcode system can perform product tracking upstream.

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THAIFEX - World of Food ASIA covers• Food & Beverage featuring HALAL & ORGANIC Food

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PROCESSING

VEGETABLES/FRUIT

Among the most fragile of foods, blueberries need to be handled carefully to preserve their visual appeal and prevent damage to the membrane. This seasonal produce requires trusty processing tools that are optimally designed

to ensure long postharvest shelf life, quality and optimal yield. When processing fresh berries, it is important to keep their “white bloom” by minimizing drops and rolling of the fruit during inspection, as well as picking those that are bruised after harvesting. The ideal berry sorter needs to handle the fruit gently. It should have small belts that are thin and round, which ensure gentle product handling of the delicate fruit. The blueberries should be transported between two belts with minimal operator intervention, as the defective ones are being accurately rejected from the quality batch using an air gun.Berries are traditionally sorted on two machines. One machine would sort out the discolored products and foreign material, and the other would detect soft berries – there is however a high risk of bruising as the fruit would be dropped onto the sorters twice. To minimize the risk of damaging the berries, a machine can be used to perform the two tasks of product inspection, which could pose the problem of a higher false reject load. The machine may also be unable to handle all defects, especially when the incoming load typically as many defective products, as berries are commonly picked by machines. The ideal berry sorter can help farmers sort the fruit based on color, reject those that do not meet their specifi cations, and remove the softer ones. The sorter should also have inspection and rejection functionalities, which allow processors to limit the risk of damaging their products and ensure a more precise and accurate sorting. The processors can also determine the sorter to have two reject streams, where the one containing the fruit and not foreign materials such as stems, leaves and insects can be used to produce marmalades and juices to minimize wastage. For certain varieties of berries, farmers would require sorters to identify those that needed to be kept on the bushes, since these low quality fruit have many defects. This also minimizes labor cost and a better sale later.

The ideal berry sorter help farmers sort the fruit based on color, reject those that do not meet specifi cations, and remove the softer ones.

When sorting fruit, processors need to consider the fragility of the produce, the ease of use of the equipment and the reliability of technology. Bjorn Thumas tells us more.

GentleSorting

Although a sorter is a product of technology, it is easy to operate through a simple graphical user interface.


PROCESSING

Using sortersAlthough a sorter is a product of technology, is easy to operate through a simple graphical user interface, where operators of various skills set can intuitively set machine parameters to improve the sorting process. All optical sorting techniques work by illuminating products with electromagnetic waves such as light. When these waves hit a target, there may be changes to certain characteristics of the light, depending on the product type. These differences are detected and the image is created to aid the sorting process. The characteristic that provides the biggest difference between good and defective products is generally used as a sorting parameter.

• ParametersIt is necessary to sort based on product color, structure, shape, size and even fl uorescence, which camera and laser sorting can be used for this purpose. Cameras such as black and white, color and even near infra-red (NIR) or (short wave infra-red) SWIR varieties can be instrumental in the process. The NIR and SWIR cameras make use of the invisible infra-red light spectrum, which is invisible to the human eye, to detect foreign materials.

Color sorters may be unsuitable to detect objects such as glass, metal and plastic, as well as those that have a color that is indistinguishable from good products like shells with nuts.

Short wave infra-red (IR) technology can sort all kinds of vegetables and fruits, which uses invisible IR waves that are absorbed by water.

All optical sorting techniques work by illuminating products with electromagnetic waves such as light.

Figure 1: A sorting process in a factory.

Color sorters may be unsuitable to detect objects such as glass, metal and plastic, as well as those that have a color that is indistinguishable from good products like shells with nuts. Laser technology can thus be used to distinguish structural differences, without targeting any of the good products. When a sorter is equipped with laser technology, soft berries can be detected effectively to prevent them from affecting boxes of fresh berries.

• Fluorescence technologyFluorescence technology can be used to sort green products such as vegetables. It detects contaminants based on natural fl uorescence, which is dependent on the amount of chlorophyll present in the products – healthy vegetables contain high amounts of chlorophyll while unwanted materials such as twigs and plastic do not contain the green pigment. This makes the sorting criteria simple: when the lasers pick up the fl uorescence caused by the chlorophyll, the machine detects that a good product is passing by the belt. Those without the green pigment are considered as defects and are rejected milliseconds later.

• SWIR technologySWIR technology can sort all kinds of vegetables and fruits, which uses invisible infra-red waves that are absorbed by water – while fruit and vegetables contain 70-90% water; most foreign objects contain very small amounts of water or none at all. When the SWIR sorter detects a product that contains water, it will be allowed to pass through the belt. If water is not detected in an item, it will be considered as a foreign object and is promptly removed from the belt by high speed ejectors.

Is perfection possible?To meet the growing needs in the sorting market, suppliers of sorters should strive to use the latest technological developments in optics, electronics and mechanics for better performance of the equipment. Optical sorters today should feature performance, effi ciency, user-friendliness and reliability characteristics. While demanding 100% perfection in sorters is a near impossible task, processors can enjoy machines that can detect as many defective products as possible and limit occurrences of false rejections for better returns of investment.

Bjorn Thumas is sales manager at Best Sorting.


MARKETWATCH

Vitiva’s stevia lineVitiva launches its stevia line, under Sweet’nVit brand, to provide manufacturers maximum sweetness with minimum bitterness, following the recent approval by the European Commission (EC) for use of stevia in food and beverage applications in Europe. The company says it will market its stevia intense sweetener throughout Europe, North America, South America and Asia Pacifi c.“The Sweet’nVit line can be used as a solo sweetener, in combination with bulk natural sweeteners such as erythritol and maltitol or with sucrose to offer optimal taste and mouth feel,” says CEO Ohad Cohen.The Sweet’nVit products are extracted from leaves Stevia rebaudiana bertoni, which are also standardized with a minimum of 95% steviol glycosides, in compliance with EC legislation on food additives and has generally recognized as safe or GRAS status in the US. The all-natural products do not contain calories and carbohydrates. They also do no induce a glycemic response upon consumption.

www.vitiva.eu

MultiSweet Stevia for beverages, dairy productsDoehler has developed a natural sweetening system for products with a well-balanced taste profi le under the MultiSweet Stevia brand, which makes it possible to reduce 5-6 Brix of sugar, depending on the product. The fl avor technology of sweetness improving technology or SIT is also used to improve stevia's sensory properties. Through cooperation with natural stevia sweeteners company PureCircle, Doehler has access to premium stevia ingredients of the highest purity grade and consistent quality. Doehler has since developed products sweetened with MultiSweet Stevia in beverages and dairy products such as carbonated soft drinks, still, tea and sports drinks, nectars, beer mixes and syrups, milk and fruit mixes, dairy and drinking yogurt.

www.doehler.com

Natural waxes for confectioneryKahlWax presents its natural waxes for confectionery and snacks at ProSweets in Cologne, Germany, which includes polishing, gloss and non-stick waxes that are developed for fi nishing applications and/or as effective coatings for sweets and snacks.While KahlGloss lends a shine to soft, hard and chocolate candies, KahlGlue provides adhesion, shine and protection to snack products. Meanwhile, KahlOil offers non-stick properties and shine, especially to soft and hard mogul products such as wine gums, as KahlSeal serves as a protective shell for gumming, coating and protecting dragées. In addition, KahlTex is a gelatin-free texturizer that gives chew candies their special consistency, and KahlWax is designed to add shine to soft and hard dragées.“An appealing appearance and product consistency are especially important for sweets like chocolate dragées or gummi bears as well as hard candies,” says product manager Gabriela Wohlenberg. “Our polishing waxes give these products a high-gloss fi nish. At the same time, our sealant coatings protect sweet snacks from drying out, losing their fl avor or being damaged by external factors.”

www.kahlwax.de

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MARKETWATCH

Treatt's key notes for natural fruit fl avorTreatt has introduced two Tropical Keys to its portfolio of natural fl avor ingredients. Tropical Key M and Tropical Key MG are created to offer natural fl avor reminiscent of mango formulated with natural fractions considered as GRAS by the Flavor and Extract Manufacturers Association.Tropical Key M and Tropical Key MG offer fl avorists a choice of starting points. Depending on the variety they wish to imitate, Tropical Key MG features enhanced green top notes, while Tropical Key M delivers stronger sulphur base notes. Also suited for use in other exotic fruit fl avors, these ingredients can be creatively blended to produce a variety of fruit fl avors. Being colorless to pale yellow/green, natural and solvent free, Tropical Keys are produced by physical processes and are compatible with ethanol, vegetable oils and terpenes. The recommended dosage in fl avored products is 20ppm v/v and Usage levels are suggested at 80-90%.

www.treatt.com

Functional bakery ingredientsKampffmeyer Food Innovation introduces two clean label baking ingredients from its Slow Milling range for manufacturing wheat-based baked goods. While the baking-active Slow Milling Ferment’tic is an alternative to common baking agents including emulsifi ers, the Slow Milling Apple Fibre enhances baked goods with dietary fi ber. Also high in dietary fi ber are the wholemeal fl ours of the company’s Optigrain range, which contain whole kernels with a mild taste.

www.kampffmeyer.de

Energy-providing compounds for baked goodsFrutarom has developed a range of energy-providing, bake-stable compounds for products such as buns, croissants and rolls that can incorporate fruit or vegetables to offer well-balanced energy-giving carbohydrates and vitalizing natural functional ingredients to consumers. The bakery compounds contain scientifi cally proven herbal extracts to enhance one's physical and mental performance. The extracts from the new “natural energy” range can be chosen and later combined to meet tailored energy requirements. Amongst them are the green yerba maté extract Finomate, which supports the body with essential vitality and energy due to its caffeine content, and the Neuravena that is extracted from wild green oats – it has been shown in human studies to promote mental performance, alertness, as well as coping with stress and learning abilities. The purslane herb extract Portusana maintains healthy blood sugar metabolism and aids weight management. As a powerful adaptogen, schisandra can increase energy levels and at the same time calm the nervous system.

www.frutarom.com

LycoRed's natural red formulation for surimiLycoRed has developed a tomato lycopene formulation for use as a natural colorant in surimi applications. This enables food manufacturers to use a natural and vegetarian colorant to avoid having artifi cial colorants in food products.The texture and color of surimi are often identical to the meat of lobster crab or other shellfi sh. In North America, surimi is often called imitation crab or mock crab. In other countries, it is typically referred to as seafood, crab or fi sh sticks and seafood extender.The common red colorant used in the production of surimi is carmine, which is extracted from cochineal insects. However, consumer aversion and growing concern over possible allergies have made carmine a less desirable colorant to processors. Carmine is often blended with paprika to achieve the correct shade for the local surimi market. LycoRed’s Tomato lycopene formulations can blend freely with other colors such as paprika for fl exibility in processing.

www.lycored.com


MARKETWATCH

Key Technology introduces auto dryer for fresh-cut produceKey Technology introduces the new, redesigned auto dryer for removing surface water from fresh-cut produce while enabling continuous line fl ow. Available in one-, two-, and four-drum models, the new auto dryer is engineered to achieve the smoothest operation with controls, motor, and structure that improve the operating condition of the dryer. The dryer removes moisture from fresh-cut produce gently and consistently to enhance product quality and extend shelf life. Compared to traditional batch dryers that require manual loading and unloading, the auto dryer achieves fully automated, uninterrupted processing. Compared to batch drying, the system doubles throughput in half the fl oor space while reducing labor, improving worker safety, and enhancing sanitation. The unit typically handles 1,100-3,000lb of products per hour per drum. The four-drum aup to 12,000lb per hour when handling heavier products. The auto dryer effectively dries a wide variety of fresh-cut produce including baby leaf and cut leaf lettuce, cabbage, spinach, and cut vegetables such as carrots, onions, and peppers, as well as whole green beans and herbs. Product settings, which control spin speed, cycle time and fi ll level, can be stored in the system’s programmable logic control and easily recalled via the color touchscreen control panel.

www.key.net

3M unveils molecular detection system for food borne pathogensThe 3M Molecular Detection System has been designed as a fast, accurate and easy-to-use method of detecting dangerous pathogens such as Salmonella, E. coli O157and Listeria. The system is based on technologies involving isothermal deoxyribonucleic acid (DNA) amplification and bioluminescence detection. The compact, simple, robust system offers easy implementation and low maintenance without compromising accuracy and reliability.The automated technology delivers highly sensitive results by targeting and amplifying nucleic acid in enriched samples. It has been evaluated with a variety of food types, including produce, meats, processed foods, pet food and food-processing related environmental samples. As part of the 3M Molecular Detection System platform, individual, pathogen-specific assays, or procedural tests are available as a test kits. Each assay test kit uses the same software interface and DNA extraction protocol for testing between one and 96 samples per run. Assays for Salmonella, E. coli O157 (including H7) and Listeria are available immediately; and a test for Listeria monocytogenes is expected to be available in early 2012.

www.mmm.com

Two Fold Software creates module to control consumable stock automaticallyTwo Fold Software is adding a Consumable Stock Control software module to its Version 1.1 release of its Qualoupe LIMS software. The software module ensures that laboratory users do not require any additional effort to keep control of their constantly changing stock of consumables. It enables users to avoid having to lack a suitable consumable when processing a vital sample by creating a record for each associated consumable. The record contains all the consumable’s details such as name, code, supplier, cost and shelf life.“The Consumable Stock Control laboratory information management system (LIMS) software is optimized to make use of Qualoupe’s user interface, which makes it simple for a user to associate consumables that they are using when performing a specifi c test method and automatically record how much is consumed. As a result, when a sample is processed using a specifi c test method, the LIMS can automatically deduct from stock the amount of each consumable used,” says MD Clive Collier.

www.twofold-software.com


SHOW PREVIEW

Frozen Food Asia will make its debut from September 11 to 13, 2012, at the Hong Kong Convention & Exhibition Centre in Hong Kong. The show, which is created to meet the growing demand for frozen food market in

China and Hong Kong, will be co-located with Restaurant & Bar Hong Kong and the Asian Seafood Exposition. The latter shows are expected to bring more than 10,000 buyers and sellers to one location.According to Datamonitor in 2009 China’s growing frozen food market is expected to reach $16.1 billion by 2012, while Hong Kong’s annual growth rate is at 3.9%. With more disposable income and fast-paced lifestyles, consumers in these countries are demanding ready-made, convenient frozen and chilled foods and ingredients.The show will focus on bringing top buyers looking for manufacturers and suppliers of ready meals, meat products, frozen fish and seafood, vegetables, potato products, fruits, pizza, bakery products, ice cream and frozen desserts, as well as chilled products to the event. “We expect ready meals such as pasta, convenience food, frozen potato items and bakery to gain prominence in 2012. Frozen, processed and packaged food have become increasingly popular among consumers due to the rising number of single-person and dual-income households. More are also considering these products to be produced more hygienically,” group VP and publisher of Diversified Business Communications Mary Larkin tells Asia Food Journal. The company is organizing the debut show.“With an average work week of 49.5 hours, more consumers are looking at purchasing quicker food solution, such as ready-to-eat meals and packaged food items. Supermarkets are also offering a larger and varied selection of convenience foods, especially processed and ready-to-eat foods.”“In addition, more convenience stores are expected to increase their frozen food offerings – processed meat products are popular in Hong Kong, especially pork and chicken drumsticks, registering 20% and 16% share of total sales respectively.”

www.frozenfoodasia.com

Frozen Food Asia 2012The show will make its debut from September 11 to 13, 2012 in Hong Kong. Sheila Wan fi nds out more.

Frozen Food Asia will be co-located with Restaurant & Bar HongKong and the Asian Seafood Exposition, which are both expected to bring more than 10,000 buyers and sellers to one location.

Show organizer says the largest number of exhibitors for Restaurant & Bar Hong Kong will come from Hong Kong, Japan and China.

Datamonitor in 2009 stated that China’s growing frozen food marketis expected to reach $16.1 billion by 2012.

Frozen, processed and packaged food products have become increasingly popular among consumers due to the rising number of single-person and dual-income households.


EVENT PREVIEW

The World Halal Forum (WHF) 2012, which will be held in in Kuala Lumpur, Malaysia from April 2 to 3, 2012, will focus on

cultivating a universal appeal on Halal lifestyle. “The growing Halal industry, with enormous and untapped potential, is moving towards a more holistic values-based direction, which consolidates Islamic principles and universal values,”

says Hajjah Jumaatun Azmi, the founder-director of the forum.“The awareness on Halal among people has begun to move beyond the food sector towards other industries, including tourism services, to facilitate and grow Halal-friendly travel and hospitality,” says Darhim Hashim, CEO of International Halal Integrity Alliance. The organization is the host of the annual event. The global Halal food market is reportedly estimated to be worth more than $800 billion, while the market value of Halal products in Malaysia is said to be more than $9.5 billion last year.The event, back in its 7th year and also part of the Malaysia Halal Week 2012, expects to receive 400 delegates. There will be more than 50 speakers from organisations such as Yıldız Holding (Turkey), Darul Jailani International and Al-Wariseen Trust, as well as scholars from Kuwait, Malaysia, Russia and the UK at the event.In line with its theme “Inspire-Innovate-Invest”, WHF will discuss business perspectives, consumer issues and universal challenges in the industry during the two-day event.

www.worldhalalforum.org

World Halal Forum 2012The event, back in its 7th year and also part of the Malaysia Halal Week 2012, expects to receive 400 delegates in April.

Calendar MARCH 2012

17 - 19Food & Technology Exhibition & Conference PakistanLahore, Pakistanwww.foodntechnology.com.pk

18 - 20Fleischer ForumSalzburg, Austriawww.fl eischerforum.at

26 - 29AlimentariaBarcelona, Spainwww.alimentaria-bcn.com

28 - 30Food Ingredients China 2012Shanghai, Chinawww.chinafoodadditives.com

APRIL 2012

2 - 3 World Halal Forum 2012Kuala Lumpur, Malaysiawww.worldhalalforum.org

17 - 20FHA 2012Singaporewww.foodnhotelasia.com

17 - 20Wine & Spirits Asia 2012Singaporewww.winespiritsasia.com

MAY 2012

15 - 18Barcelona Food Technology ExhibitionBarcelona, Spainwww.bta-bcn.com

23 - 27Thaifex-World of Food Asia 2012Thailandwww.worldoffoodasia.com

29 - 316th Annual Congress on Food Safety & QualityShanghai, Chinawww.foodsafetycongress.com

JUNE 2012

13 - 16 Propak AsiaBangkok, Thailandwww.propakasia.com

JULY 2012

18 - 20Propak ChinaShanghai, Chinawww.propakchina.com

19 - 2223rd Malaysia International Food Processing and Packaging Exhibition Kuala Lumpur, Malaysiawww.esevent.com.my

SEPTEMBER 2012

6 - 7FI IndiaMumbai, Indiafi india.ingredientsnetwork.com

17 - 19Fine Food IndiaNew Delhi, Indiawww.fi nefoodindiaexpo.com

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Workout Buddies for PetsAn online, weight loss program by Nestlé aims to help pet owners in the US and their four-legged friends shed excess pounds together. The company’s pet and people weight management experts from Project: Pet Slim Down at Nestlé Purina and Jenny Craig are driving the initiative. “Pets are loyal, non-judgmental, and supportive. They are the ideal weight loss partners,” says a veterinarian for Nestlé Purina. The pets would defi nitely welcome more walks in the park.

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