< Previous30 Food & Drink Internationalwww.fdiforum.netHEALTH, SAFETY & HYGIENE SPOTLIGHTEngineers from Bunting Magnetics, one of the world’s leading suppliers of magnetic separators and metal detectors, recently conducted a thorough review of all the magnetic separators installed at the Jordans Dorset Ryvita plant in Poole, Dorset. The audit was completed over three days, including attending site on Saturday to prevent any loss in production. A Magnetic Separation Audit involves the inspection and test of magnetic separators to confirm their magnetic and physical integrity. Commonly, such tests are conducted annually, with the final report forming part of the company’s quality audit process. The tests in a Magnetic Separator Audit are conducted in two stages. Stage one involved the inspection of the physical integrity of the magnetic separator. This includes checking welds and assessing any wear and damage to the surface. Stage two involves testing the magnetic strength of the magnetic separator. These tests are conducted by placed a magnetic ball or plate into the magnetic field and then measuring the force (in kgs) needed to remove that object from the surface of the magnetic separator. The actual ‘gauss’ reading of a magnetic separator is not checked as measurement is difficult and often inaccurate. Gauss is the is the cgs unit of measurement of magnetic flux density (or “magnetic induction”) but can be difficult to measure accurately. The metal test piece is attached to the end of the spring balance and then placed into the magnetic field, being attracted to the magnetic pole. The metal test piece is then pulled off the surface of the magnetic separator whilst holding the other end of the spring balance. The amount of force needed to remove the metal test piece from the surface is recorded (in kgs). The test is repeated three times and an average reading taken. Similar techniques are used to test other designs of magnetic separators such as plate magnets. There were a wide range of designs, strengths and ages of magnetic separators in the production process at Jordans Dorset Ryvita. The company had not experienced any problems due to metal contamination and requested the audit as part of their continued improvement plan. Day one was spent assessing the location and recording the customer identity numbers of all the magnetic separators. Checking the location also highlighted any health and safety issues that needed to be considered for the audit, such as working at heights. The review identified 52 magnetic separators. The physical checks of the magnetic separators were conducted on day two and three, on the weekend to minimise any production downtime. Each magnetic separator was removed from its location and visually inspected. Then the magnetic strength was checked using the pull test technique. The data was recorded and presented in a detailed report with recommendations following the audit. This report can then be used as part of the quality management system. It also provides base data for comparison on future audits. Following the audit, the engineering team at Jordans Dorset Ryvita have made several changes to improve the removal of metal during the production process. Magnetic Separator Audit for Jordans Dorset Ryvita For more information, visit www.buntingeurope.com, email sales@buntingeurope.com, or call +44(0) 1442 875081. 24-31.qxp_Layout 1 18/12/2018 14:25 Page 7Food & Drink International 31www.fdiforum.netHEALTH, SAFETY & HYGIENE SPOTLIGHT3M and Clean-Trace are trademarks of the 3M company. © 3M 2016. All rights reserved. J352347.3M anof tGet more than numbers — get answers.Introducing the 3M™ Clean-Trace™ Hygiene Monitoring and Management System.• Verify cleaning effectiveness in seconds• Make confident decisions with accurate results• Be audit ready with powerful reports3M.com/foodsafety/Clean-TraceEMEAFoodSafety@mmm.com3M Driving consistency and control in cleaning The use of ATP (adenosine tri-phosphate) bioluminescence for cleaning verification is well-established in the food industry providing real-time hygiene results that allow corrective action to be taken prior to production. Whilst this is a real benefit, it is analysing the results over time that provides true control of the cleaning regime and underpins continual improvement in cleaning standards. Recording and reviewing results can help to identify problem areas, measure the effect of remedial action and monitor standards of cleaning. It can enable evaluation of changes made to cleaning programmes and provide the opportunity to optimise cleaning without sacrificing effectiveness. Furthermore, it allows maintenance of audit-ready data, saving time when preparing for a scheduled audit, or demonstrating on-going diligence and preparedness if facing unannounced audits. Trending of data provides the hygienic status of the facility over time and allows the manufacturer to build an understanding of cleaning performance and effectiveness. In turn, this gives the manufacturer the opportunity to achieve consistency in results and take control over the cleaning. As a consequence, overall cleaning improves, pass and fail levels can be reduced accordingly as a new, achievable level of cleaning is reached, thereby driving a cycle of continual improvement until best possible targets are met and levels can be maintained. The 3MTM Clean-TraceTM Hygiene Monitoring and Management System provides a straightforward, intuitive means to data trending of ATP results, and is just one of many innovative solutions from 3M that gives food producers peace of mind when making critical product manufacturing and release decisions. Tel: +44(0) 08705 360036 Web: www.3m.co.uk/foodsafety Email: emeafoodsafety@mmm.com 24-31.qxp_Layout 1 18/12/2018 14:25 Page 832 Food & Drink Internationalwww.fdiforum.netSIEVES AND SEPARATORS© Shutterstock/Marco OssinoSift and separate 32-34.qxp_Layout 1 18/12/2018 10:01 Page 1Food & Drink International 33www.fdiforum.netSIEVES AND SEPARATORSEfficiency speaks to the swiftness with which industrial processes can be undertaken, with many machines found on a modern production line fulfilling more than one function. Sieves are one of the best examples, offering as they do a pivotal part of a manufacturer’s quality control, filtering out contaminates and other impurities from liquid and powdered food. Sieves, however, are also used in achieving certain sensory textures for products, be that silky or foamy. While this is no doubt advantageous from the point of view of manufacturers, sieves and separating equipment can present a challenge – and threaten efficiency – during the washdown routine. When it comes to washing and hygiene, the food industry can agree that speed and simplicity is best. It’s counterproductive to invest in a machine designed to streamline one’s production line only for it to end up slowing things down due to a convoluted washdown routine. The ideal, then, is for machinery and equipment to be washed thoroughly in the shortest possible time but with the maximum result. This can be difficult when it comes to sieves, which by the very nature of their wire mesh and grating design, can trap food product and particulates. Of course, this accrued matter can be blasted free from the mesh or grating during the cleaning process, but this comes with its own disadvantages – with the mesh instead retaining cleaning fluids and other harsh chemicals which can affect the texture and flavour of the end product and pose a risk to consumer health. Downtime = cost. It’s a simple equation that can see manufacturers put out of pocket. So, in order to keep both to a minimum, the industry is embracing more intuitive designs. This can help to alleviate many of the issues associated with sieving machinery, such as keeping the number of touching parts to a minimum, which allows for a quick and thorough cleaning. Though this is an industry standard for many machine makers, bespoke options allow a food manufacturer to customise equipment to fit their exact specifications and the unique needs of their products. Design is also paying off when it comes to assembly, with tool-less disassembly more commonplace. It means that manufacturers can take the processing line into their own hands rather than having to call out a specialist for costly consultations and repairs – not to mention the potential downtime that can accrue. Sometimes, however, there’s no getting around the fact that experts are required to fix a broken machine and deciding to do things yourself can, in fact, make matters worse. 34 Á© Shutterstock/Vereshchagin DmitrySieves and separators are indispensable to the modern food production line, but that doesn’t mean they’re without challenges as Food and Drink International explores. 32-34.qxp_Layout 1 18/12/2018 10:01 Page 234 Food & Drink Internationalwww.fdiforum.netSIEVES AND SEPARATORSAs the regulations governing the food industry become ever more stringent, processing equipment is required to shoulder some of the responsibility. Some of the newer sieving machines will employ finer screens and meshes in order to meet industry quality standards without sacrificing production flow rates. A finer screen that doesn’t impact flow is especially prudent for processing fine powders, such as whey protein and infant formula. But where the processing of powders takes place, there’s always a risk of clumping. Though fine, powders can – and often do – clump together, which can block machines and cause a backlog of product that can be difficult to resolve once it has occurred. Not only can this lead to periods of downtime while the issue is resolved, but it can also severely effect efficiency of the sieving machine. Vibrating sieves can help to overcome this issue, as well as improving overall flow, homogenising mixes and removing impurities. Separators, on the other hand, divide the constituent parts of a raw material or product as well as playing a critical role in quality control checks, dividing stock that doesn’t meet aesthetic or weight criteria. They also oust any harmful contaminates – including metals, plastics and any others that have come into contact with a product during the production process. One such example is a centrifuge, which relies on rotational force to cause separation of liquids within liquids or separating denser solids from liquids. Separators of this kind typically offer a degree of flexibility for producers, with variable speeds and specific ranges allowing for fine-tuned adjustment, which can be adjusted product to product. It’s difficult to imagine a modern food production line without one kind of metal detection system or another in place, but sensors aren’t the only defence against metallic containments at a manufacturers’ disposal. Magnetic separators detect and remove metals during food processing, though the type of magnet needed will depend on the product being removed, the speed at which it moves and the equipment in which it’s housed – criteria manufacturers should bear in mind when looking to upgrade their facilities. While plate magnets are ideally suited for use at the bottom of an inclined chute, or suspended above conveyor belts or vibratory feeders, grate magnets are designed to allow materials to pass through. Manufacturers can use a combination of these magnets at multiple points across a single production line, working in tandem with other quality control and safety measures. Sieves and separators are indispensable to modern food manufacturing facilities, ensuring quality control as well as texturizing and improving the sensual appeal of products. Therefore, companies shouldn’t compromise on quality. © Shutterstock/Marco Ossino32-34.qxp_Layout 1 18/12/2018 10:01 Page 3Food & Drink International 35www.fdiforum.netFLAVOURING & COLOURINGThe role of flavours and colours in food and drink has perhaps undergone more changes in the past few decades than anything else in the industry – and it’s mostly been driven by consumer demand. The consumer has become a much more intelligent creature as of late, less prone to impulse purchases based upon brightly coloured packaging, and more concerned with health benefits, E-numbers and the welfare of any animals involved. This has had a profound effect on the ingredients market as a whole. And those who have adapted to this trend have flourished from it. Yet despite the value consumers place on natural, high quality ingredients, they still won’t purchase products that don’t offer the flavours and tastes they’re used to. Those of a certain age still shudder at the thought of Coca-Cola’s disastrous attempt to change their recipe in the eighties, which remains the gold standard for ill-advised revamps and relaunches. Fortunately, it’s now possible to make changes to recipes without removing everything people like about the products in the first place. The colouring industry is no less robust in this regard. Following on-going efforts to reduce the amount of food waste within supermarkets, there was a campaign run to inform consumers that products that are not the accepted shape, or are slightly past the sell-by date, are still consumable and fully healthy. The campaign saw some success, with a number of well-known chains actually stocking dedicated “out-of-shape” produce, © Shutterstock/Nataliya Hora36 ÁWith demands from consumers becoming ever healthier, ever less artificial, how is the flavouring and colouring markets coping? Aesthetic without compromise35-37.qxp_Layout 1 18/12/2018 10:02 Page 136 Food & Drink Internationalwww.fdiforum.netFLAVOURING & COLOURINGincluding wonky bananas and uneven cucumbers. Fantastic news for the farming industry, as they are now less likely to have a large proportion of their supplies thrown away. What did not see success however, was the tangential campaign to promote food products that were not as colourful. No matter the shape, or the assurances behind it, retailers found great difficulty in convincing consumers to purchase finished products that were less brightly coloured, or in some cases – were not the accepted colour. A particular example was fresh salmon, which continued to sell more effectively where food colouring was used to create an even tone amongst the products on offer. It could be hypocritical that consumers desire healthier produce and more transparency when it comes to ingredients. But that at the same time, are completely unwilling to compromise on taste, colour or even texture. Simply put however, that is the nature of the consumer, and it is unlikely to change. What can change however are companies catering to these markets, who are rapidly adapting and researching new and innovative ways to meet the demands put forth by customers, no matter how complex. After all, as the Chinese proverb says – crisis and opportunity are the same word. Natural sweeteners, research into plant-based extracts, even looking at high-protein ingredients such as insects (with limited success currently in the west). Ingredients companies are doing what they can to tap into the growing market, while moving away from areas that are trending negatively at the moment. Artificial flavours and colours, ingredients with too much sugar content – research is consistently showing us that these can have health implications, from obesity to high blood pressure, through to – in some rare cases – carcinogenics. It’s not all about the risks to health however, and many manufacturers have started to expand and diversify their ingredients to cater for increases in © Shutterstock/Romantik8935-37.qxp_Layout 1 18/12/2018 10:02 Page 2Food & Drink International 37www.fdiforum.netFLAVOURING & COLOURINGBringing you the Tastes of the World... Naturally• Flavours and Bases• Natural Colours• Fruit Pieces & Powders• Veg Pieces & Powders• Nuts and Nut Products• Fruit Juices, Purées & Concentrates• Veg Juices, Purées & Concentrates• Dairy, Meat & Fish Powders• Inclusions for Bakery, Ice Cream• Organic IngredientsFor more information contact: www.kanegrade.com Tel: +44 (0) 1438 742242 Fax: +44 (0) 1438 742311 Email: info@kanegrade.com Global Ingredients Suppliercustomer taste. Simply put, the consumer industry has never been as diverse as it is now, with many people actively looking for new and exciting taste experiences – particularly those which come from different cultures. This has led to a boom in the import and export industry, as ingredients suppliers seek to extend their stock to cater for such foreign power foods as Freekah, amaranth, buckwheat, kamut and teff. Many of these have been staple parts of the human diet in their own regions, but failed to take off internationally. Not the case now however, as they have each seen success in the UK market, as well as further afield – a success story that mirrors those of more well-known products such as quinoa. Flavours, colouring and ingredients remains one of the most free-flowing parts of the food and drink supply chain, despite that they will likely always remain integral to manufacturing. Consumers have not yet adapted to accept food that looks different to our perceived perfect food, now are they willing to accept any compromises when it comes to taste. As always, it will be up to suppliers and manufacturers to find the correct balance.© Shutterstock/stockcreations35-37.qxp_Layout 1 18/12/2018 10:02 Page 338 Food & Drink Internationalwww.fdiforum.netSNACK FOODSSnack foods have long been an important part of the consumer experience, both in the home and, of increasing importance and profitability, on-the-go. Traditionally, this market was made up crisps, biscuits and other beige coloured fare. But this market is hardly static, evolving as it does to meet the changing wants and needs of today’s shoppers. Of late consumers have turned away from traditional snack foods in favour of something healthier, more exotic and something that’ll make a good snap for Instagram. Rather than admitting defeat, brands and manufacturers have embraced the change and sought to put a health halo around snacks foods, both with reformulated, redesigned favourites and bold and exciting new flavours. With the global snack foods market predicted to be worth as much as $620 billion by 2021, it’s clear the industry’s collective efforts are paying off. It’s patently obvious visiting any supermarket or store of the seismic shift that’s taken place in the snack food market. Traditional potato crisps, for example, are now regularly stocked alongside varieties made form peas, lentils and even quinoa. But these traditional crisps have also updated their image, with baked varieties and lower calorie options and canny marketing positioning them as part of a balanced diet and lifestyle. This is only the tip of the iceberg, however, with favour for something more wholesome. Yet this isn’t the only danger potentially lurking in those metallised plastic films. The last few years has seen a rise in consumer awareness over acrylamide, a natural chemical formed when starchy foods – such as bread and potatoes – are cooked at high temperatures for long periods, be that fried, baked, roasted or grilled. It typically manifests visually as a brown or umber colour – think the brownness of toast, or, returning to our example of potato crisps, those brown edges and black bits. Studies in rat and mice models have found acrylamide to be cariogenic and while evidence in human models is inconclusive at best, it’s best for regulators, consumers and, indeed, manufacturers to err on the side of caution. Makers of baked, crispy goods now have a whole host of innovative options at their disposal to reduce the presence of acrylamide in their products. These include all-natural, high-antioxidant solutions and yeast enzymes which can be used in the processing, preparation and cooking of products. Not only can this offer an edge over competitors but can help to set consumer’s minds at ease. Sugar and fat Although the evidence linking the consumption of acrylamide to cancer in humans is inconclusive, there’s no denying the impact saturated fat can wreak on the body. With an obesity The future of snacking The snack foods industry has seen one of the most dramatic evolutions across the food and beverage sector in recent years. Driven by a hunger for healthier food and in response to increased pressure over excessive salt, sugar and saturated fat, manufacturers have had their work cut out for them. © Shutterstock/M. Unal Ozmenregulators and manufacturers alike looking for ways to make snack foods both attractive and healthier. Minimising acrylamide At this point in time, few could plead ignorance over the dangers posed by high levels of salt and saturated fat – despite Brits falling back in love with butter. Nevertheless, salty snack foods and those with saturated fat in the red zone are more likely to be bypassed in 38-41.qxp_Layout 1 18/12/2018 10:04 Page 1Food & Drink International 39www.fdiforum.netSNACK FOODSNew Phantom metal detector quashes upgradeable illusion for snack SMEs Metal detector specialist Fortress Technology has just re-launched its flagship entry-level Phantom model. Now, when future production requirements and retailer codes of practice demands it, a Phantom unit can be upgraded to include the data capture specifications in the company’s Stealth model. Aimed squarely at new food manufacturers, SMEs and companies in emerging markets, the Phantom range offers robust metal detection functionality and quality assurance in a fit-for-purpose, reliable way that Fortress is renowned globally for. By rationalising some of the technology options previously available, Phantom users pay for the features they need to satisfy local and international food safety standards at a price point that suits their budget. Yet, by sticking to a universal modular design and introducing a common membrane panel, all customers benefit from being able to upgrade to a Stealth level of performance to meet the most stringent UK retailer codes of practice when it’s demanded. For more information, visit www.fortresstechnology.co.uk.crisis affecting much of the western world, and even developing nations, it’s clear that the snack foods we know and love need an overhaul. Yet that’s not to say they need to be changed beyond recognition, but rather imbued with better-for-you ingredients, whist using innovative solutions to limit their high fat levels. Fat replacers are by no means a new solution on the food scene, but manufacturers and food producers have more readily embraced them in recent times as campaigners and action groups crack down on high fat foods and governments consult over levies and taxes. Targeted fat replacers allow manufacturers to maintain a desirable texture and crumb to their pastry and cake goods with less of the calories. Reformulating products and amending the recipes to create a healthier variety can risk alienating loyal consumers – as A.G. Barr learnt after slashing the sugar from its beloved Irn Bru beverage. Yet utilising solutions such as fat replacers mean that a product can retain its tried and tested taste and texture whilst also helping to minimise a consumer’s intake of saturated fat. But of all the food industry’s bug bears, it’s sugar that remains public enemy number one. Here in the UK, the tides have turned on sugar, with the government introducing its much-mooted sugar tax on soft drinks in April 2018. Although some studies doubt the effect the move will have on public health, as far as economics go, it’s a winner with the tax raising £153.8 million from its introduction to the end of October. It isn’t simply an example of the ‘nanny state’ either, with a survey © Shutterstock/Evan Lome40 Á38-41.qxp_Layout 1 18/12/2018 10:04 Page 2Next >