< Previous30 Food & Drink International www.fdiforum.net FUNCTIONAL INGREDIENTS © Shutterstock /Y ulia Davidovich sweet fibre from the pomace of monk fruit that makes up over seventy per cent of daily total recommended dietary fibre and Galam introduce a novel prebiotic fibre aiming to reduce sugar content while bolstering gut health. Added and alternative proteins make up another key segment within the functional ingredients space, with consumption of protein-rich foods soaring. Food and drinks labelled high in protein from muffins to peanut butter cups and water can be seen across shelves, with manufacturers constantly innovating to create improved products that boost consumer experience and overcome the common problems of off- notes and gritty textures when dealing with added proteins. Area Food Ingredients for instance recently hit the headlines with its new whey protein isolate ingredient for clear beverages, conquering mouthfeel and taste issues faced by protein water manufacturers. Once only recognised in the realm of elite athletes, protein has expanded out into the mainstream as a supporter of weight loss and muscle health, pushing the functional ingredient to be incorporated into various products. Protein claims have rocketed in supermarkets with Nielsen highlighting in 2018 that ‘high-protein’ statements on US packaging have increased 157 per cent year-on-year. The rise in plant-based diets is further driving protein development as consumers aim to incorporate more high protein foods into their diets from non-animal sources. Food and drink manufacturers are looking to uncover new protein sources and better isolates of existing ones, refine sensory attributes, the extraction process and nutritional profile of goods with plant derived protein sources that do not create off flavours that must be masked, or texture challenges. Pea protein, made from yellow/split peas, is one thriving market, increasingly accepted as a replacement for other proteins - not just animal-based but soy, which is reducing in popularity as concerns rise over its environmental impact and association with deforestation. While many companies now have established pea protein ranges, development continues with Ingredion last year launching its first protein isolate, a pea protein which will help manufacturers respond to demand for protein rich products. The isolate holds a minimum of eighty per cent protein and will thus substantiate food firms making ‘high in protein’ claims on labelling. Its use extends across nutrition bars, snacks, ready to drink beverages, meat and dairy alternatives, healthier baked goods and baking mixes. A main criticism of pea proteins however is that they can have a strong flavour that must be masked. Chickpea protein, then, is breaking into the plant-based meat and dairy markets as a potentially better option, chosen for its neutral flavour profile as well as light colour, allowing it to be used as a foundational ingredient across many applications from chickpea milk to energy bars. It also hosts essential amino acids, unsaturated fatty acids, doesn’t represent a common allergen and has a smaller environmental impact than animal protein. Fava beans meanwhile are a key new protein source gaining attention as ingredient makers look to expand their offering and the sensory and nutritional profile of their proteins. Though already utilised by some, new methods have been uncovered for the processing of fava beans, a rich source of proteins and fibres that is gluten-free. Researchers at the University of Copenhagen 28-31.qxp_Layout 1 04/05/2020 11:52 Page 3Food & Drink International 31 www.fdiforum.net FUNCTIONAL INGREDIENTS The use of microbial derived enzymes in response to the consumer demand for clean label products An increased awareness of the potential health benefits that can be achieved from making lifestyle and dietary changes has fuelled the drive from niche market to a mainstream opportunity for functional foods. Large retailers and food manufacturers have been slowly introducing these concepts to their ranges, like prebiotics in yoghurts and the addition of omega 3 in eggs. But they are now looking for new novel offering to excite the consumer and meet their ever-growing demand for new healthy alternatives. The ingredient suppliers are looking for ways to enhance their offering whilst ensuring that they adhere to the strict labelling regulations whilst meeting these demand. The use of microbial derived enzyme to alter the flavour or enhance the functional characteristics of these ingredients without introducing a list of chemicals that can taint the healthy credentials and spoil the clean label claim have become a tool in the arsenal of ingredient manufacturers. Biocatalysts has been building its portfolio of microbially produced enzyme alternatives initially in response to the growing consumer demand for kosher, halal and vegetarian alternatives and to food manufacturers and ingredient suppliers requesting more specific enzyme activities that can be targeted at a selected process. Our extensive range of LipomodTM microbial produce enzyme can enhance the flavour characteristics of your dairy ingredients. The Lipomod enzymes are specifically targeted to hydrolyse triglycerides to liberate fatty acids to produce different flavour profiles, such as LipomodTM801MDP a microbial alterative to pancreatic lipase that produces high lipolytic notes and round flavours, including brothy and sulphur undertones. If you’re interested in a sample, or more information regarding enzymes for hydrolysing fats please contact Biocatalysts to discuss your needs. Visit www.biocatalysts.com/contact, email enquiries@biocats.com, or call +44(0) 1443 843712. have produced a concentrated protein powder using wet fractionation to concentrate fava bean protein and remove substances that would otherwise inhibit the digestion of the protein, allowing fava bean proteins to be more readily absorbed when consumed. In this method, beans are milled into a flour, water added and then blended into a soup. Substances that aren’t beneficial are then easier to sort out, to form an optimised product, and the method is said to improve protein content. While enhancing nutrition and physical health is an important aspect of the functional ingredients space, the future is expected to see significant growth of products with relaxation and stress relief properties, expanding opportunities for functional ingredient makers. Cannabidiol is gaining attention here, though until governments decide how to regulate cannabidiol goods, food and drink manufacturers are likely to move slowly on developing products in this arena, falling back on established ingredients like chamomile and melatonin that are in the mainstream. While enhancing nutrition and physical health is an important aspect of the functional ingredients space, the future is expected to see significant growth of products with relaxation and stress relief properties, expanding opportunities for functional ingredient makers 28-31.qxp_Layout 1 04/05/2020 11:52 Page 432 Food & Drink International www.fdiforum.net CLEANING AND MAINTENANCE By design By design There’s no overstating the importance for cleanliness and hygienic design throughout the food and drink supply chain, but during the coronavirus outbreak, both have become even more critical. 32-35.qxp_Layout 1 04/05/2020 11:56 Page 1Food & Drink International 33 www.fdiforum.net CLEANING AND MAINTENANCE Although food and drink manufacturers are required by law to ensure their machinery and equipment is kept clean and hygienic, sometimes cleaning products can work against them. By their very nature, cleaning products are purposefully designed to provide disinfection and biocide, but some can be so strong they actually damage machinery and equipment. Machinery would ideally be corrosive resistant, but this isn’t industry standard and replacements could be costly for manufacturers. There are, however, cleaning products that promise strong disinfection without damaging surfaces. The cleaning of any machine inevitably results in downtime which can increase exponentially in the event of a corrosive reaction with a cleaning product. Corrosion can accrue over time often without a manufacturer realising until it’s too late and rust or metal flakes find their way into products. There’s also the environment to consider when it comes to cleaning. Of course, industrial cleaning products themselves can often be hazardous to the environment, but water usage is one of the industry’s biggest issues. According to Waste & Resources Action Programme (WRAP), cleaning can account for as much as seventy per cent of a site’s entire water use. This excessive usage brings with it several additional costs such as labour, downtime, lost materials, cleaning chemicals and the extra energy expended for heating and pumping. To say it’s advantageous for manufacturers to optimise their water usage might be stating the obvious, but too many food makers are still literally pouring money down the drain. Optimisation requires a change in cleaning routine that, over time, will not only help to cut water supply bills, but also reduce the volume of concertation in effluent. There’s a pervasive chain of thought that a thorough and effective washdown routine requires a great torrent of water, or that a reduction in water compromises hygiene requirements. But this simply isn’t true, with a number of ways of minimising water usage whilst also maintain hygiene levels and, in some cases, even improving them. An average food and drink plant will spend an average of twenty per cent of the day cleaning during which time a lot of water and energy can be expended. Much of this is extraneous and can be significantly minimised without sacrificing quality or safety assurances. WRAP advise using dry cleaning-up wherever possible which helps to stop the use of water, keeps waste material out of drains and maintains quality assurance and food safety. It’s also often the most practical and effective means of reducing water consumption and chemical oxygen demand (COD) in effluent. Clean in place (CIP) systems are commonplace throughout the food and drink industry and while effective, these systems are intensive and require large amounts of water, chemicals and energy to function. Essentially the system works by using non-foaming detergents and disinfectants which are circulated through pipework and process equipment. But tanks, large diameter pipes and large containers can be more thoroughly cleaned using spray balls or rotating jet devices. This helps to avoid the unnecessary and uneconomical filling of vessels with solutions as well as slashing overall water usage. Because CIP systems are automated it means that it requires no human contact, so stronger detergents can be used for circulation as well as boosting overall onsite safety. Disinfectants used in the food and 34 Á 32-35.qxp_Layout 1 04/05/2020 11:56 Page 234 Food & Drink International www.fdiforum.net CLEANING AND MAINTENANCE Holchem introduces free COVID-19 online course Holchem, the Society of Food Hygiene and Technology’s (SOFHT) ‘Training Company of the Year 2019’, has launched a free course providing an overview and guidance on COVID-19. It sits alongside Holchem’s comprehensive choice of eLearning courses designed primarily for hygiene and technical teams involved in the management of hygiene, the courses include: - Introduction to Cleaning and Chemical Safety - Working safely with chemicals - Cleaning in Place (Level 3) - Level 2 Food Safety - Allergen Awareness The courses have been developed in conjunction with Holchem’s partner, Totrain, and are a very popular web resource amongst food processing, brewing, dairy processing and food service industries. They provide an ‘always on service’ which is ideally suited to sectors that operate within a shift culture. It means employees can find the time that suits them and their lifestyle to complete the courses and stay ahead of relevant legislation and best working practice. To find out more, visit www.holchem.co.uk. drink industry are purposefully designed and used so that any potential residues left on surfaces do not taint the food or harm the consumer. However, many still affect the skin, eyes or respiratory system and, if ingested in sufficient quantity, can be harmful to human health. But they’re also usually much stronger than those used domestically, requiring careful handling. Indeed, according to The Health and Safety Executive (HSE), exposure to disinfectants is one of the biggest causes of occupational ill health in the food and drink industry. Although CIP and spraying systems help to automate the process, cleaning is still predominantly undertaken by human workers, so it’s critical for companies to ensure the welfare of operatives. The handling of such harsh chemicals means operatives will need to outfitted with appropriate personal protective equipment (or PPE) including industrial cleaning gloves – which are usually made from either latex, PVC or rubber depending on the requirement – goggles and overalls. Depending on the cleaning process itself, operatives may also need breathing apparatus. Cleaning is only one part of the wider maintenance of machinery and equipment that manufacturers must be cognizant of. Because of the influx of new machines coming to market faster and with greater frequency, manufacturers are left facing unique challenges around equipment © Shutterstock /Marcin Balcerzak © Shutterstock /Lopolo 32-35.qxp_Layout 1 04/05/2020 11:56 Page 3Food & Drink International 35 www.fdiforum.net CLEANING AND MAINTENANCE • Saves costs • Meets the highest requirements on hygiene • Increases safety and quality • Used in breweries and food & beverage industries www.sera-web.com Contact: 01733 396040 sales.uk@sera-web.com YOUR EXPERTS IN CLEANING IN PLACE Contact: +44 1283 753400 sales.uk@sera-web.com www.sera-web.com Sparc pipeline x-ray system hits new food safety heights To address the unique food safety requirements posed by the protein and dairy sectors, Sparc Systems designed a pipeline x- ray solution to detect contaminants in vacuum filled and pumped products. Combining accuracy and reliability, the hygienic Iris inspection system remains a top choice for food manufacturers. Utilising x-ray technology, the Iris Pipeline inspection system can identify a variety of different physical hazards. The high resolution of the 0.4mm X-ray sensor allows it to detect foreign materials with sensitivity levels that outperform any current technology. Any product shown to contain contaminant on the display screen is immediately rejected from the system before it is transferred downstream. A fully integrated, servo actuated rotary reject valve provides accurate and repeatable reject performance. Pipelines can be inherently difficult to sanitise. The Iris X-ray is completely different to anything else on the market as it has a magnetic centre piece which operatives can literally pull out, clean and reinsert. To find out more, visit www.sparc-systems.com. maintenance. So while companies are adding new machinery or modifying existing equipment for new product lines, they are also trying to maintain a seamless production capacity simultaneously. Of course keeping up with production advancements requires significant expenditure and its no surprise that food and drink manufacturers invest more in equipment than almost any other industry. Historically, food manufacturers operated schedule-based preventative maintenance practices, but this can often be highly inefficient, resulting in wasted time as maintenance is carried out regardless of whether it is needed. This also results in financial inefficiencies, with many manufacturers too focussed on only one area of maintenance. This can lead to hoarding spares of parts they may never actually need to use, wasting hundreds if not hundreds of thousands of pounds. Instead, manufacturers are advised to take a more holistic approach and instead include a variety of different approaches such as total productive maintenance and computerised maintenance management systems. Switching to condition-based monitoring, for example, can reduce predictive maintenance tasks by as much as thirty per cent – quite the saving. Key to the food and drink products enjoyed by consumers is a supply chain that adheres to stringent hygiene levels. Despite being governed by regulations and legislation, cleaning practices can result in extended downtime and financial inefficiencies. Exploring a maintenance programme and identifying these inefficiencies can yield savings in time and money. And during the coronavirus pandemic, cleaning and hygiene has never been more important. 32-35.qxp_Layout 1 04/05/2020 11:56 Page 4CAPS AND CLOSURES 36 Food & Drink International www.fdiforum.net In recent years, food and drinks manufacturers have developed a variety of innovative cap and closure solutions. The sports-drink industry has been leading the way with a range of sophisticated bottle-tops and zip-seals that ensure added freshness and allow consumers to drink on the move. As consumers continue to demand fresher and more convenient products, companies across the sector can benefit by incorporating these solutions into their existing product range. The advantages of using plastics to manufacture caps and closures are twofold. Plastic closures are much more convenient because, unlike metal ones, they do not usually require the use of a secondary implement (e.g. a bottle- or tin-opener) to operate. This means, of course, that they are easier to use on the move. Moreover, many can be repeatedly re-sealed. But the big advantage for manufacturers is that widely-used plastics and polymers such as polypropylene and high-density polyethylene (HDPE) are more malleable than metals and can Sealing the deal Convenience is king when it comes to caps and closures, and this ethos has led to strong shifts in the market. 36-38.qxp_Layout 1 04/05/2020 12:03 Page 1CAPS AND CLOSURES Food & Drink International 37 www.fdiforum.net © Shutterstock /risti180884 therefore be put a greater variety of purposes. They are also more lightweight and easier to recycle, so manufacturers can pitch to the green market as well. Caps and closures also help to prevent counterfeit or knock-off products, usually via use of some kind of seal or code that cannot be recreated once the vessel is opened. Counterfeiting in the drinks industry is a multi-million pound industry. But, thanks to new security measures, including anti-refill and tamper evidence caps, many of which are designed using complex injection moulding techniques in the UK, drink companies are fighting back against the illicit bootleggers. In the UK, the alcoholic beverage market is one of the worst affected by counterfeiting with the Intellectual Property Office reporting that alcohol accounts for seventy-three per cent of all UK Trading Standard investigations. Due to their brand value, premium spirit and wine brands are generally the most vulnerable. The counterfeits commonly contain low-grade liquors, such as adulterated wine or whiskey thinned down with water. Seized bottles of alcohol have also been found to contain lethal ingredients, such as chemicals, which can be harmful when consumed. Efficient use of caps and closures can help create a barrier against this behaviour, however. One way to counteract counterfeiting and product tampering is through the innovative design of packaging that cannot be easily copied. Until recently, this may have involved putting shrink or foil sleeve around a bottle of wine. However, for premium brands, cap 38 Á 36-38.qxp_Layout 1 04/05/2020 12:03 Page 238 Food & Drink International www.fdiforum.net CAPS AND CLOSURES © Shutterstock /Chones moulders are stepping up the anti and investing in dedicated cells to produce high quality closures made up of a number of complex parts. Other methods of deterring counterfeits include concealing unique identifiers, such as a QR code or holograms, on the inside of cap labels. While these can assist with track and tracing, Kevin claims that they only really help to validate the origin of a bottle. “To outsmart quick-witted counterfeiters, drink manufacturers may need to deploy several tactics simultaneously to prevent brand value being diluted, including tamper evident caps, barcoded labels and batch codes, and even chemical markers.” While valuable in an effort to protect sales, such measures have traditionally not been viable to smaller manufacturers or traders, but improvements in technology have led to such applications being far more affordable. Because major multinational companies are ordering the latest caps and closures in huge bulk (nearly 300 billion units per year, in fact) prices are dropping, making it viable for smaller businesses to get on board. Furthermore, plastic caps and closures are compatible with plastic bottles, cartons and metal and glass containers, so companies who usually package their products using the latter don’t have to shell out on new packaging materials or designs. Finally, there are fresh marketing opportunities that companies can exploit should they choose to invest in the latest products. Zip-seal closures may appeal to elderly consumers and parents with young children, for example, as they can be opened and re-sealed at one’s leisure – ideal for people who are unable (or simply don’t want) to consume a product in one go. Caps and closures are becoming safer, easier to use, and most importantly for manufacturers, cheaper and more flexible than ever before. Additionally, while it may be premature, and perhaps even arrogant, to claim that the counterfeit drink industry’s days are numbered, this is certainly a step in the right direction. To cap it all Looking for a recyclable caps and closures manufacturer with ranges to inspire you and to make your product stand out and give shelf appeal? Then look no further, Measom Freer manufacture and stock 16 different recyclable closure ranges in all varieties and sizes to suit your chosen bottle, in neck sizes from 15mm through to 31mm. Choose from general screw, disc and flip caps to more precise application from nozzle, dropper, plugseal and luer caps or more directional application from spray, trigger, gel and lotion pumps, all available in a range of colours to order. Minimum order of just a single box, next day delivery from stock. To find out more and to buy online, visit www.measomfreer.co.uk. 36-38.qxp_Layout 1 04/05/2020 12:03 Page 3© Shutterstock /Andrew Angelov With the fast-changing nature of COVID-19 responses, this article considers the state of the industry from the start of the outbreak, through April 2020. As countries across the world impose their own lockdowns, of varying levels of stringency, the foodservice sector has been effectively flattened. While supermarkets clamber to maintain stock for consumers upping their grocery lists in the wake of COVID-19, the foodservice industry is almost completely shut down. At the outset of the novel coronavirus, much of the impact was identified as foodservice operators in places like London were losing out on tourists, particularly from China. But when many areas across the world were only starting to discuss COVID-19, in China, over Chinese New Year in January, coronavirus caused a fifty-eighty per cent revenue loss in the foodservice sector. As the virus spread across borders, new hygiene measures were introduced with regular sanitising of front-of-house surfaces and tables moved further apart. The eating out of home sector then began losing out on regular customers from their own cities, and travel slowed until full mandated lockdowns saw restaurants, pubs, clubs Food & Drink International 39 www.fdiforum.net FOODSERVICE The crushing impact of COVID-19 The foodservice sector has been practically shut down by the novel coronavirus. With this also comes trouble for suppliers, as food becomes waste while firms scramble for diversion options. 40 Á 39-41.qxp_Layout 1 04/05/2020 12:05 Page 1Next >