Top Editors ... Technology on show

Title: Technology on show
Date: 09/11/2006
Autor: By Claire Rowan, Managing Editor & Maureen Byrne,

A wealth of new development and innovations were unveiled at the ANUGA FoodTec exhibition, which was held in Cologne in April
As with past shows, Tetra Pak had a huge presence at Anuga FoodTec, Land had plenty of innovations on offer. "This is the greatest number of products ever launched at Anuga FoodTec," said Jórgen Haglind, senior VR corporate Communications.
Causing quite a stir of interest was the 'world's first aseptic carton bottle', the Tetra Aptiva Aseptic. This combines a carton-based sleeve with a plastic top and screw cap. The Tetra Aptiva Aseptic is manufactured on the Tetra Pak A5, a newly designed filling machine, which will be available in two versions, one for portion packs and the other for family packs.
The Tetra Gemina Aseptic package family also made its debut at Anuga FoodTec. This is a slender, square shaped package with an angled top for better pouring. There are plans for nine in the package 'family' in three different sizes, and three shapes, all produced on the same filling machine: a modified Tetra Pak A3/Flex.
Among the other innovations was an updated version of the Tetra Pak A3/Speed filler, demonstrating a 'record breaking' capacity of 15,000 Tetra Brik Aseptic 1 litre Square packages with StreamCap per hour. Previous models reached 12,000 per hour of the same package. The enhanced packaging line will offer operational cost reductions of 15% compared with the current A3/Speed packaging line, and 30% when compared to the older TBA/8 machines.
There were many other innovations from Tetra Pak, both for chilled and ambient products, as well as processing solutions such as the Tetra Spiraflo tubular heat exchanger, an enhancement of the floating tube design; the Tetra Therm Lacta pasteuriser, offering reduced energy consumption; the SpotOn software solution for optimising the standardisation of milk composition; the Tetra Albatch, which improves batch processing for high viscous and particular products; and the Tetra Plex C15 heat exchanger, one of the biggest hygienic plate heat exchangers ever built. Invensys APV was presenting many new developments, notably technology lo improve the taste and mouthfeel of low fat products; and an interesting concept for cheesemaking, aimed al developing countries, which elimates the formation of whey as a by-product.
The LeanCreme process was developed to address the problems associated with low fat cheese. Although these products are in great demand, the quality of such cheese on the market at present leaves much to be desired. The process comprises an ultrafillration system for the production of whey protein concentrate (WPC); and a microparticulation system that agglomerates the WPC to make LeanCreme with the desired particle size distribution.
The microparticulation process is used lo denature the whey protein concentrate, and to form ideal protein particle sizes similar to fat globules in milk. This results in sensory properties similar to full fat products. LeanCreme can also be used for other low fat products, such as fermented milk products and milk desserts; protein enriched milk drinks and yoghurt; dressings, sauces and mayonnaise; ice cream, chocolate and confectionery; and bakery products.
No liquid milk required
Another innovation, 'fresh cheese without whey separation', has been developed in co-operation with Ingredia, a French ingredient company. This is a technology for producing high quality fresh cheese using very functional milk protein, which is produced using a specialised membrane process.
This will be particularly interesting for developing or hot countries which have a limited fresh milk supply or milk of a variable quality;. The producer simply has to blend milk protein and the fat (it can be erther milk fat or vegetable fat) with fresh milk, then pasteurise and innoculate with starter and rennet, and fill into moulds. In this instance, a lower number of incubation vats are required for a given volume and there is no whey by-product. All of the whey protein is retained in the cheese.
Steritech presented a 'worldwide exclusive' at the exhibition: the C.L.P (Continuous Low Pressure) pasteuriser, which is a patented process.
The main innovation of the C.L.P. is that it is a continuous process with counter-pressure. There is no interruption of the production line, since the system is fully automated. The loading of the products, transported by conveyor, is synchronized with the chains system inside the C.L.P. carrying the 'gondola' designed according to the application.
The products are then transported vertically across the pasteuriser. They can enter and leave from the same side, or enter one way and exit the other side. One innovative aspect is the design of the 'gondola', which allows optimal heat penetration in the products. The stainless steel support is adjustable to all types of packaging, and contains up to 10kg of products. Applications of the C.L.P are surface and 'core' pasteurisation. It is particularly suited to flexible packaging such as pouches and plastic containers.
Energy savings
Increased efficiency, along with energy and space saving during retorting of cans and other containers, was offered in the form of FMC's SuperAgi. A drastic reduction of the retort vessel diameter (with the same product capacity) results in a significant saving in compressed air consumption. Direct steam injection and indirect cooling over the plate heat exchanger further reduces steam and cooling water consumption. The agitating motion of the drum, along with the location of the spray pipes inside the drum, allows improved temperature distribution, and reduced process cycle times.
Wild-lndag Process Technology
presented its new patented technology for the heating of foodstuffs, which combines ohmic heating technology with microwave/radio-frequency heating to create a High Power Heating System (IPS) capable of heating 3 tonnes of product per hour, with peak temperatures of up to 140°C within 90 seconds. "We looked at how we could eliminate the disadvantages of current technologies," said Klaus Lochbühler, managing director of Wild-lndag, who has been pioneering the IPS project since 2002. He explained that microwave technology involves conducting heat through a pipe made of either ceramic or glass, neither of which is desirable in a food production plant. "The electrical power for microwave heating is conducted through the pipe resulting in a small penetration depth and a loss of energy of about 50%, for example," he said.
Ohmic heating of product, meanwhile, requires extended exposure of the food chunks to temperatures that can cause degradation of the finished product. This, coupled with the potential for potentially unwanted products from electrolytic decomposition getting into the finished product, has been a drawback for ohmic heating in the past, according to Mr Lochbühler. "Now, the IPS heating method uses a tube made from heat and food safe materials, and the electrodes are insulated from one another but nave direct contact with the food, which ensures a safe and efficient operation."
According to Wild-lndag, the IPS system heats liquid parts of the product almost immediately via current, while the chunks in the food are heated rapidly, and simultaneously, using a radiofrequency field.
"Our IPS technology, consumes about 20% less energy than a comparable conventional double walled heating vessel," said Mr Lochbühler, who explained that Wild-lndag has drawn on its expertise in fruit preparations to adapt the full production process involved, including the mixing and cooling systems, to optimise the finished product. "A further significant benefit is that with the IPS, manufacturers will retain 90% of their calibrated fruit content at the end of the process."
Show stopper
Breaking with the tradition of showing just machines on an exhibition stand, Elopak invited visitors into a wonderland of image and dramatic visual arts to launch its new iCone, a 'revolution' in packaging.
The package has a round base, which graduales upwards into a squared top part, resulting in an innovative new shape that offers a large flat surface on the front of the panel, which maximises consumer brand impact and recognition for premium products.
In consumer tests conducted in the UK and France, iCone recorded very high consumer interest and purchase intent, with 89% and 78% of consumere stating that iCone is 'unique and different'. Superior ratings for ease of pouring, handling, opening, reclosing, stability, and storage were also recorded. "The iCone takes premium to places where premium has never been before," said Borge Kvamme, executive vice president of Elopak for the Europe, Middle East and Africa región. "It is a world revolution in packaging, combining the best of strong functional benefits and emotional values in a uniquely designed coned shape."
Another newcomer at the show was 'Slim', a tall lean version of the recently launched Curve carton. "We are developing solutions with consumers in mind," said Mr Kvamme. "Slim is naturally seen as more 'feminine': the slender slim body and long Slim curve makes it a very harmonious pack, with fitness and lifestyle connotations."
SIG Combibloc also unveiled several innovations in cartons for both beverage and food applications.
For convenient-sized servings for beverages, SIG introduced the combifitSmall, a slim pack that is curved outwards at the front and inwards at the back in 200, 250, 300, 330 and 350ml sizes; and the combifitMini in 150,200 and 250ml sizes. The two formats have joined the combifit range of cartons, which feature a distinctive combifit slanted top. While the combifitMini is fitted with an on-pack straw, the combifitSmall features SIG alICap's new three-part combiSmart screw cap spout for easy drinking from small cartons. Both cartons can be filled on existing combiblocSmall and combiblocMini equipment respectively, and are designed to tap into demand for on-the-go drinking.
SIG alICap's new combiSwift spout utilises the same three-part technology used on the new combiSmart screw cap spout. The three-part spout is applied above an 'over-coated' hole in pre-punched cartonboard. With just one twist, the integrated cutting ring in the combiSwift accurately perforates a hole beneath leaving the pack ready for pouring. The spout has an inside diameter of 18mm, which can be opened easily without a lot of strength, and allows fruit juices, milk products or non-carbonated soft drinks to be poured easily. Consumers can reclose the carton easily to ensure leak-proof storage, according to SIG.
In a move designed to open up further markets for environmentally-friendly carton packaging, SIG Combibloc revealed its new packaging alternative to glass or tin cans. The Combisafe is a flexible volume, heat-resistant carton packaging range that can be filled with almost any chunky food product and then sterilised in an autoclave to give a product with a shelf life of up to two years. The technology builds on the company's existing aseptic filling system with cartons made of cardboard, polypropylene and aluminium. It is this combination that allows Combisafe to withsland the thermal treatment of an autoclave without any degradation of the pack or its contents.
Jütro Konservenfabrik, part of I Schroeder KG of Hamburg, is the first to take advantage of the new retortable carton for a range of vegetable convenience meal products in a CombiblocCompact, 400ml format.
"Combisafe gives us a great chance to set our products apart from the competition and get the consumer's attention. What really convinced us was the flexibility offered by the filling machine system from SIG Combibloc," said Pefer Humbert, managing director of I Schroeder KG. "It allows us to fill different products on one machine, and the size and quantity of chunky ingredients can be varied."
Dairy solutions
GEA Group company Westfalia Separator
was promoting several solutions for dairy processing. According to Westfalia, many dairies throughout the world are switching to cold milk separation. For this reason, the company has developed Ihe PROCOOL system. This new separator model features performance parameters that it claims no other machine on the market can achieve in cold milk separation. The PROCOOL separator also offers the user additional value with the belt drive or the Protein-Plus-System that boosts protein yield.
Equipped with hermetically closed feed and discharge systems for skim milk and cream, Westfalia's new MSE 500 high performance cold milk separator is a useful addition to the range of separators already offered by the company. It is equipped with the advanced features of the E generation, such as flat bell drive with frequency converter and precise piston valve-based solid discharge system.
For drying of products such as whey protein concentrate and isolate, whole and skim milk powder, high and low fat whey blends, baby food and non-dairy creamer, Anhydro was promoting its new Triple-A Dryer at Anuga FoodTec. This allows complete customisation of a drying solution for production of free-flowing agglomerated dustless powders, to suit stringent customer specifications, according to Anhydro.
By offering a large number of combinations of air distribution options, integrated second-stage fluid bed dryers, an optional external third-stage fluid bed, and choice of exhaust and fines return systems, the Triple-A Dryer can be customised to Virtually any combination of quality and capacity requirements'. This enables dairies and other manufacturers to meet increasing demands for very specific qualities and particle size distributions.
ALPMA and its development partner, the Polish cheese manufacturer Hochland Polska, jointly celebrated the winning of a Gold European FoodTec Award for the Formatic continuous filler for blocks of semi-hard cheese. Developed for cheeses such as Gouda or Edam, the new Formatic system now eliminates the need for an intermediate pre-pressing table as it handles both the filling of the mould and the pressing process in one step.
"We nave had continuous filling lines available for soft cheese for some time, but we are now moving to lower moisture curds to provide the technology for yellow cheeses, to allow for the advantages of continuous production," said Charles Aikenhead, managing director of ALPMA GB Ltd. "Each cycle of the Formatic makes a complete sealed cheese."
The Formatic features filling nozzles and a pressing plate, which allow whey and curd cubes to flow gently into the mould from the bottom upwards under a layer of whey. The plate moves gently up to the top of the mould, thus controlling the speed of the flow. Once the correct amount of curd and whey has entered the mould, the plate then functions as the pressing plate compressing the cheese with a specified pressure. By containing the flow and filling from the base, the Formatic also prevents air from entering the curd and ensures the consistent production of individual cheeses, each with the same weight and same total solids.
"In the past, manufacturers nave had to over fill their moulds in order to ensure the right quantity of finished product," Karim Chalabi, area sales manager explained. "In the Formatic system, we fill from the bottom upwards, which avoids the generation of foam, which would confuse the level detectors and subsequently cause false readings for the fill of the mould. In this way, manufacturers produce consistently sized cheeses on a continuous basis."
Other Gold winners were Valio for its technology for producing lactose-free dairy products; Krones for its cold aseptic 'rainbow filler', developed with Molkerei Heinrich Gropper, for filling multiple dairy products in one process line; and Buhler for an innovative extrusion system that reduces the loss of vitamins during the processing of raw rice.
Handtmann was highlighting its patented Conpro System for the continuous processing of sausages, which co-extrudes the filling and the alginate casing simultaneously ready for cutting into portions.
"We worked with Ruitenberg of The Netherlands to perfect the vegetarian casing (called Rudin VegaCasing)," said Thomas Neher, commercial director of Handtmann, which has taken three years to develop the technology. "Existing systems supply casings on a stick. The Conpro System is continuous because the casing is actually made inside the same system and extruded with the paste filling."
Already used in the meat industry, the technology is now being extended to fish sticks, cheese, vegetable sausages. "The technology is suitable for vegetarian products because the casing is made of alginate, and, as it imparte no taste of its own, the casing can be used with any filling," said Mr Neher. The filling can be coloured, orflavoured, and produced in 13 to 34 mm widths.
A new group emerges Anuga FoodTec provided a great opportunity for visitors to meet the newly formed Sidel Group, which links five well-known brands: Sidel, Simonazzi, Alfa, Gebo and Cermex. At the end of 2005, Sidel and Simonazzi joined forces to form an integrated group dedicated to delivering complete solutions for packaging liquid foods in glass and PET bottles and cans.
A number of technologies were showcased, including Sidel's GWm, a low fo high speed gravity weight filler, which can now handle pasteurised milk products; along wifh developments in ESL and aseptic filling. New developments in labelling technology under the Alfa brand, and Sidel's latest linear blow molding machines were amongst the other developments presented.
This year's Anuga FoodTec was full of bright innovations, and the level of new introductions by large and small players alike was arguably higher than any seen before. lt will cerfainly be a challenge for companies to spend the next three years building on these achievements, ready for the next show in 2009.
This article was reproduced with permission from Food & Beverage
International (copyright Haydon Jackson Publishing Ltd)
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