Dairy Foods April 2011

UNDERSTANDING FOOD SAFETY | GUIDA’S MILK | CHOOSING PUMPS & VALVES April 2011 Innovative Ideas for Dairy Processors w...

Author: Jim Carper

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UNDERSTANDING FOOD SAFETY | GUIDA’S MILK | CHOOSING PUMPS & VALVES

April 2011

Innovative Ideas for Dairy Processors

www.dairyfoods.com

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April 2011 Vol. 112, No. 4

S P E C I A L F E AT U R E S

Trends in Cultured Products Dairy’s healthful halo coupled with an incessant drive by processors to innovate has made today’s refrigerated dairy case the most dynamic it has ever been. More than a dozen cultured dairy innovations have been introduced since the beginning of the year, and more are primed for a summertime roll out. p. 44 On our cover: Americans love yogurt. We ate $4.2 billion worth of the product in 2010, according to the Chicago-based research firm SymphonyIRI. Yogurt is versatile. It’s a food for breakfast or lunch and a healthy snack or a sweet-tart dessert. Yogurt is spoonable, pourable, drinkable and frozen. Read more about yogurt and other cultured dairy foods in our special report, beginning on page 44.

Features News & Trends 10 Newsline Fage, Chobani and Athenos launch national ads for their Greek yogurts; Perry’s Ice Cream’s sour novelties are winners; IDFA promotes the Energy Star Challenge.

Departments 8 16 19 86 91 92 97 98

Special Report: Food Safety For the most part, dairy processing plants are pretty clean, but the new Food Safety Modernization Act has everyone on alert. In this series of articles, product development editor Donna Berry looks at new and improved analytical systems that save time and ensure quality (page 52), while Dairy Foods’ Marina Mayer surveys the probable impact of the FSMA (page 56). Columnist Allen Sayler considers HACCP plans (page 80), and in his Packaging Points column, Mike Richmond writes that safer packaging is needed now (page 82).

Products & Marketing 20 Dairy Market Trends

Ingredient Technology 28

Cheese sales grow at retail.

22

New Product Review Dreyer’s has shakes and smoothies, Turkey Hill goes Old School.

Editorial People Supplier News Equipment Showcase: Fillers Buyers Mart Classified Ads Index of Advertisers Inside Perspective Milk processor Joe Oberweis writes how technology can save the industry.

Texturants How texturants influence product properties

36

Tharp & Young All about sherbets, sorbets and ices

38

Wellness Watch Sweeteners and the healthful halo

REPORTS

61

Guida’s Milk Guida’s Milk, New Britain, Conn., succeeds by co-packing, finding customers to buy its excess cream, developing new products and manufacturing non-dairy beverages, such as water, orange juice and iced tea. While the plant has been modernized, what hasn’t changed is Guida’s commitment to quality products and processing. Its new larger plant (see page 68) helps Guida’s service and acquire large-volume customers.

74 Choosing Pumps and Valves 80 Sayler on Safety 82 Packaging Points 84 Spotlight on Sustainability

DAIRY FOODS Volume 112, Issue 4 (ISSN 0888-0050) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: DAIRY FOODS, P.O. Box 2144, Skokie, IL 60076. Change of address: Send old address label along with new address to DAIRY FOODS, P.O. Box 2144, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

www.dairyfoods.com

5

April 2011 Vol. 112, No. 4 www.dairyfoods.com A Publication of BNP Media II, L.L.C. Editorial and sales offices 155 N. Pfingsten Road, Suite 205 Deerfield, IL 60015 Phone: 847-405-4000 • Fax: 847-405-4100 Publisher Thomas S. Imbordino 773-755-8990; 248-502-2093 (fax) [email protected] Editorial Chief Editor Jim Carper 847-405-4009; [email protected] Executive Editor Marina Mayer 847-405-4008; [email protected] Product Development Editor Donna Berry Field Editor Cathy Sivak Art & Production Art Director Lindsay Leusby Production Manager Lisa Webb [email protected] Sales Amy Vodraska 973-970-9000 [email protected] Wayne Wiggins Jr. 415-387-7784 [email protected] Catherine Wynn 847-405-4010 [email protected] Gabriele Fahlbusch 49-(0)202-271690-15 [email protected] Classifieds Suzanne Sarkesian 248-786-1692 [email protected] Marketing Marketing Manager Elizabeth Wright [email protected] Editorial Reprints Jill DeVries 248-244-1726; [email protected] List Rental Postal: Senior Account Executive Kevin Collopy 800-223-2194 x.684; [email protected] Email: Senior Account Executive Shawn Kingston 800-409-4443 x. 828; [email protected] Audience Development Audience Development Manager Kourtney Bell Multimedia Specialist Katie Jabour Audience Audit Coordinator Carolyn M. Alexander For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected]

Corporate Directors Publishing: Timothy A. Fausch Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Conferences & Events: Emily Patten Clear Seas Research: Beth A. Surowiec BNP Media Helps People Succeed in Business with Superior Information

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From the Editor’s Desk

The Best In Tensions think most people go to work with the best intentions. They show up on time and do their work correctly and productively. But there are the inevitable tensions. You face a deadline to complete a task, but you are also required to attend a meeting. Owning a business is a daily lesson in how to manage opposing forces. Do you invest in new equipment or conserve cash? Do you add staff or outsource functions? Do you fire a difficult client or try to work things out? Since joining Dairy Foods eight months ago, I’ve met many smart dairy processors and talked with them in their offices, on the plant floor and at conferences. Here is a brief summary of six tensions I’ve observed in the dairy industry.

I

1. Product development. Being an innovator costs money, but it gives you a head start on the competition. Being a follower means you can step into an existing market, but you’ll probably be a step behind the innovators. What do you want to be? You encounter tensions in making the product. You need to buy quality ingredients but not overpay for them. Then you have to price the product so you can offer the optimum value for the money. 2. Finding (and sticking to) your business niche. Few businesses can be all things to all people. You need to find your strengths and play to them. Perhaps you are really good at producing or co-packing low-cost foods and not so efficient at making premium-priced products. You have to cede that premium niche to others. It can

Jim Carper

be difficult to watch others succeed outside of your niche. 3. Employee relations. You want good people, but you have to watch your payroll. You need experienced individuals, but you don’t want them to bolt after you spent money to train them. So you create a pleasant place to work, acknowledge their contributions to your business and offer incentives to keep them on board. 4. Competition. This tension is a column in itself. There are the beverages that compete with fluid milk: water, juices and soft drinks. There are other dairy processors you compete against; the local and regional processors (though their ranks are shrinking) and the large, national firms entering your market. Importers seek a share of your customer’s wallet (and stomach). There are the competitors who are yet to be. Some bright young food scientist is concocting a new product and will be looking for a co-packer. These arrangements reduce start-up costs and can help new brands get established. 5. Distribution. You aren’t manufacturing just to warehouse your output. You want it at retail, at food processors, on the dock of an exporter or wherever your customers are. Rising fuel prices increase trucking costs. Do you pay a distribution partner or do you do it yourself? You give up control, but you also reduce risks. What kind of deals do you need to cut with retailers to get your product on their shelves? 6. Regulations. Actually, this is more like compression than tension. Regulators squeeze processors, admittedly sometimes for good reasons. Sure, you can lobby and go back and forth with lawmakers to influence them to see things your way, but once the regulation is enacted, you have to live with it. I’m sure you can elaborate on any of these and build your own list of tensions. If you feel like sharing, write or call. Jim Carper is chief editor of Dairy Foods. Phone: 847-405-4009. Email: carperj@ dairyfoods.com.

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Dairy Foods | April 2011

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News & Trends

NEWSLINE... Advertising for Greek Yogurt Brands Goes Prime Time ere’s a recipe for creating buzz about a rather hum-drum dairy product: To milk, add a couple of live cultures. Blend with a creative ad agency. Then stand back for praise (or scorn) from fans (or detractors) on blogs and Twitter. Beginning in February, three Greek yogurt brands (Fage, Chobani and Athenos) launched first-ever national television advertising campaigns supported with social media efforts. One of the most stunning is a 45-second commercial titled “Plain” for Fage Total Greek nonfat flavored yogurts, including Mango Guanabana and Blueberry Acai. The spot, by Mullen, a Boston-based advertising agency, started running in March. It uses live action and computer animation to show a long-haired woman, a calf and colorful fruit set against plain white milk. Actor Willem Dafoe reads words, which have been likened (favorable and unfavorably) to a Dr. Seuss rhyme. This commercial and a series of 15-second spots are the company’s first TV ads in North America. Writing on the website Mediabistro, Stephanie Murg called the ads “anything but plain.” One reader left the comment, “how on earth did they manage to make yogurt look this sexy?” while another wrote on the Mullen website, “It’s just bad all around.” Mullen’s Mark Wenneker said in a statement, “If our advertising is half as good as the yogurt, I will be pleased.” Agro Farma started the “yogurt wars” in mid-February when it debuted a series of ads for its Chobani Greek yogurt brand. Titled “Real Love Stories,” the campaign includes two national television commercials along with digital and out-of-home ads. (Read more on page 44.) The television commercials tell the true stories of fans Stephen Wright and Stephanie Lane. Wright is a college student who biked 80 miles to New Berlin, N.Y., to see Chobani’s processing facility. Lane is a certified public accountant who was frus-

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trated by co-workers who stole her yogurt from the office refrigerator. VP of marketing Doron Stern tells Dairy Foods that the results have been “staggering.” Retail sales and website traffic have increased as a result of the campaign, he says. “The love we’ve seen since Chobani first hit stores in 2007 has been overwhelming,” says Hamdi Ulukaya, president and founder of Agro Farma, Norwich, N.Y. “We have the best fans in the world and this campaign celebrates them and their passion for the brand.” Those fans are called “Chobaniacs” who share their love of the yogurt on social media platforms such as Twitter, Facebook and YouTube. Wright and Lane shared their passion on Facebook, leading to their roles in the TV advertisements. “Our aim with this campaign was to tap into, amplify and extend the current phenomenon of Chobani ‘love’ that is already spreading across the nation,” says Peter McGuinness, CEO of Gotham Inc., the New York ad agency that developed the spots. “People love good brands that make good products. It’s no more complicated than that.” Kraft Foods tapped a Greek grandmother (yiayia) to promote its Athenos brand of Greek yogurt, as well as hummus, feta cheese and pita chips. This campaign is centered on Athenos products that are made simply, with respect for traditional ingredients, and yiayia’s approval of them. Athenos brand manager Marshall Hyzdu says these grandmothers are “blunt, yet relatable Greek yiayias with old-school mentalities” who share unsolicited opinions of modern situations. In the spot for yogurt, a young woman and man are at a breakfast table. Finding out that the two live together and are not married, yiayia tells them, “You are going to hell.” In the ad for hummus, yiayia tells a young woman in a party dress, “You dress like a prostitute.” Created by the New York-based advertising agency Droga5, the TV spots are designed to appeal to women in their 20s and 30s who are making the transition from college to life away from their par-

Yoplait Plays Alone Among Yogurt Brands Brand

Dollar Sales (millions)

Yoplait Light

$402.1

Yoplait Original

390.1

Dannon Light ‘n Fit

296.7

Dannon Activia

258.1

Chobani

240.5

Fage Total

136.9

Dannon Activia Light

136.3

Yoplait Go Gurt

131.9

Stonyfield Farm

131.8

Dannon

90.2

For the 52-week period ended Dec. 26, 2010. Private-label yogurt sales were $407.5 million. Source: SymphonyIRI, Chicago

ents. Athenos market research shows that this group seeks foods made with simple ingredients “that don’t compromise flavor.” “We’re reinforcing what our consumers like, which is products made the traditional Greek way with simple ingredients,” Hyzdu says. That includes its Greek yogurt, made without preservatives or artificial flavors. In addition to television ads, Athenos will be supporting the campaign and the brand’s portfolio of products through integrated marketing strategies, including social media engagement, digital integration and in-store communications. Kraft’s spokeswoman Angela Wiggins says, “We’ve taken a very different approach to marketing this year through a provocative creative campaign. The campaign is centered on what we as a brand stand for, which is products made simply and with respect for ingredients. Creatively we bring that to life through a funny, witty, yet relatable traditional grandmother persona, yiayia, to establish a stronger connection between us and consumers.” The ads have consumers talking. If the talk is converted to purchasing, then the campaigns will be deemed successful. — Jim Carper, chief editor Continued on page 12

10

Dairy Foods | April 2011

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EVERY THING AND EVERYONE YOU NEED IN JUST ONE SHOW. Advanced technology, innovative packaging, green transportation, food safety solutions, expanding markets, sustainability, enhancements in plant operations, new ingredients — all make up the universe of hot trends, education topics and exhibitors that will highlight the 2011 International Dairy Show. Everyone who has a stake in the dairy industry will be on hand to share ideas to streamline processes and improve plant performance.

Don’t miss the premier event of the year for dairy professionals.

PACKAGING, PROCESSING AND TECHNOLOGY SOLUTIONS FOR THE GLOBAL DAIRY INDUSTRY

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News & Trends

IDFA Names Winners at Ice Cream Tech Conference New frozen desserts that feature salty or sour tastes were among the most innovative trends during the “What’s Your Favorite New Ice Cream Flavor?” contest at the International Dairy Foods Association’s (IDFA), Washington, D.C., annual Ice Cream Technology Conference, March 2-3 in St. Petersburg, Fla. Salted Caramel Chocolate Pretzel ice cream, developed by SensoryEffects Flavor Systems, Bridgeton, Mo., was the most innovative prototype flavor. Meanwhile, Perry’s Ice Cream, Akron, N.Y., won for Most Innovative Novelty for its Sour Buddie Bars, which will be available this spring at retail locations in sour green apple or sour blue raspberry sherbet with a vanilla ice cream center, and Most Innovative Ice Cream Flavor for its red velvet-flavored ice cream, which is a red velvet cake base with cream cheese-flavored swirls. It is now available at ice cream stands in New York and Western Pennsylvania. “It is an honor to be selected for the IDFA awards by our respected peers in the dairy industry. Red Velvet is one of the hottest trends in food right now and our Sour Buddie bars were developed with a fun, young-

12

Dairy Foods | April 2011

er consumer in mind,” says Robin Waite, research and quality team leader for Perry’s. The IDFA awards honor the top ice cream innovations in the dairy industry. This year’s competition was sponsored by Dairy Foods and featured contestants from around the country. A panel of 110 judges from across the dairy industry selected the winners; there were 18 entries in three categories. The conference also included presentations and discussion on key issues in the industry, such as sensory evaluation and product concept testing, implementation of the Food Safety Modernization Act, ice cream’s place in a healthy diet, new and traditional sweetener options and sustainability in the frozen dessert industry. “This annual contest provides a unique opportunity to spot new trends,” says Cary Frye, IDFA vice president for regulatory and scientific affairs. “From unusual combinations such as strawberries and peppercorns to more traditional flavors like coconut cream pie, the annual contest showcases the creativity of our ice cream and frozen dessert makers.”

WA S H I N G TO N WATC H

News & Trends

Dairy Leads Participation in EPA Energy Star Challenge In January 2010, the International Dairy Foods Association (I DFA), Washington, D.C., entered into a partnership agreement with the U.S. Environmental Protection Agency, also in Washington, D.C., to promote energy efficiency in the dairy processing industry. Among the envisioned activities are the Energy Star Challenge, a national call-to-action to improve the energy efficiency of America’s industrial facilities and the development of an energy management guide and energy performance indicators. The challenge launched in May, and since then, 97 dairy facilities have enrolled in the program, representing nearly half of all manufacturing companies currently participating in the program. “The challenge is open to all industries, not just the beverage or food in-

dustry, so our participation stands out and is very much appreciated,” says Clay Detlefsen, IDFA vice president of regulatory affairs. Because the program operates on a rolling enrollment, new facilities are welcome to participate at any time. The Energy Star program also will be featured during a panel discussion at the IDFA Sustainability Symposium, May 25-26 in Chicago. The session will demonstrate how companies are leveraging the Energy Star program to meet company goals. For instance, one company will explain how it achieved a 10% energy reduction, while another will discuss how it succeeded in getting all of its facilities to participate. Both will share best practices for implementing energy-saving techniques and making the most of their successes within their companies and their customers.

To learn more about the Energy Star program, contact Detlefsen at cdetlef [email protected]. Also check out Detlefsen’s column “Spotlight on Sustainability” on page 84. Upcoming Events from the IDFA May 10-11 Dairy Cost Accounting Workshop Rosemont, Ill. May 25-26 Dairy Sustainability Symposium Chicago June 22-23 Washington Conference Washington, D.C. Find details about all of these events at www.idfa.org

Continued on page 14

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MilkPEP Partners with Oreo Cookies

adding any taste, aroma or unwanted viscosity of it’s own. Fibersol®-2 is the ﬁber you want so your consumers and your dairy products can reach their FULL potential!

For the second year, The Milk Processor Education Program (MilkPEP) will team up with Oreo cookies to offer the Milk & Oreo promotion, reminding consumers that the Nabisco cookie brand and milk go hand-in-hand. Throughout the month of June, consumers are encouraged to enter to win free milk and cookies by logging on to www.oreoandmilk.com and sharing their favorite milk and cookie moment. This campaign also is an opportunity for processors to leverage a national brand to increase milk sales during the summer months, while encouraging sales outside the dairy aisle for retailers. It also allows the unique opportunity to maximize their brands by adding individual logos to the customizable point-of-sale that will be available mid-April at www.milkpep.org. In addition, processors should also consider developing a loyalty program with a key retailer to incentivize consumers to purchase milk and Oreo cookies; feature a branded ad in a retail circular to promote the offer; incorporate a dynamic ad on processor consumer-facing websites; host a milk and cookies display contest; sample new and enhanced flavors instore; and establish a relationship with local Nabisco representatives to explore partnership opportunities. “Milk and cookies are behind many of life’s special moments,” says Julie Buric, vice president of marketing for MilkPEP, Washington, D.C. “By participating in this promotion, processors can raise their brand’s visibility and increase sales by partnering with a national and well-respected brand.” The sign-up deadline is May 4. Go to www.milkpep. org or call 800-945-6455 to register and receive free, downloadable materials.

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Dairy Foods | April 2011

News & Trends

General Mills Picks up Half of Yoplait General Mills Inc. said in March it is buying 50% of Yoplait, the French yogurt maker, from PAI Partners, a French private equity firm. News reports pegged the price at $1.1 billion. The other half of Yoplait is being retained by Sodiaal, a French dairy cooperative. Yoplait ranks 21st on the Dairy 100, Dairy Foods’ list of the largest dairy processors in the United States. The U.S. marketing license for Yoplait has been in General Mills’ hands since 1977. Observers expect General Mills to expand Yoplait market share in western Europe, China, India and other emerging markets. Other recent acquisitions in the yogurt and dairy industry include the purchase of YoCream by Danone subsidiary Dannon and PepsiCo’s purchase of Wimm-Bill-Dann of Russia. (See the January Dairy Foods for additional details.)

satiety lower calorie

sugar-free digestive health

Two Vermont Processors Expand Facilities The Vermont Farmstead Cheese Co., South Woodstock, Vt., is expanding its Windsor cheesemaking and maturation facility, located in Windsor Industrial Park on Route 5. It will provide for the increasing demands of Vermont artisan cheeses, as well as aging and distribution functions. The facility will house 600 square feet of retail space with a viewing to watch cheese production and will offer economical aging, custom packaging and distribution services. In March, Commonwealth Dairy, Brattleboro, Vt., a joint venture between Ehrmann USA, a subsidiary of Ehrmann AG of Germany and Commonwealth Yogurt, held a grand-opening ceremony for its new facility. The company broke ground in March 2010. The $32 million, state-ofthe- art, LEED-compliant, Class II dairy IFT Booth processing facility #2737 includes alternative energy sources. It accepts milk from the open market as well as segregated milk streams, such as organic and local. Commonwealth sells its own branded yogurts and manufactures or copacks for others.

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News & Trends

PEOPLE Wisconsin Center for Dairy Research, Madison, Wis. John Lucey, professor of food science at University of Wisconsin-Madison, has been named director. Over the past 20 years, he has worked in food science departments or research centers in Ireland, the Netherlands, New Zealand and the United Sates, each with an emphasis on dairy technology and products, including cheese texture/chemistry, gelation of milk, cultured products and the production/functionality of milk protein ingredients. California Milk Advisory Board, South San Francisco, Calif. Richard Michel, a third-generation dairyman and agri-businessman, has been elected to serve as chairman. Meanwhile, Domenic Carinalli Jr. has been elected vice chairman. Essie Bootsma has been re-elected to serve as secretary. Frank Ferreira has been elected treasurer. Lastly, Dante Migliazzo, James Netto and Richard Wagner have been elected to serve as members-at-large. Swiss Valley Farms, Davenport, Iowa Jeannie Kenevan was named regional sales manager, responsible for retail blue and specialty cheese sales in the Midwest. Meanwhile, Kelly McNamara joined on as regional sales manager, responsible for retail blue and specialty cheese sales in the Western region, as well as select national accounts.

Dean Foods Co., Dallas Joseph Scalzo, president and COO, has resigned. Chairman and CEO Gregg Engles is assuming Scalzo’s operating responsibilities. The company says it does not intend to name a replacement. Meanwhile, Scott Vopni took on the role of vice president and CAO, replacing Shaun Mara who was named chief financial officer. Vermont Farmstead Cheese Co., South Woodstock, Vt. Rick Woods has been appointed vice president of creamery operations, responsible for the production and research of the creamery and the new Windsor, Vt., production and affinage facility. Woods comes from Grafton Village Cheese where he was cheesemaker, plant manager and regional sales manager. MCT Dairies, Inc., Millburn, N.J. Niall Foster has been named vice president of international sales. He came from Lactalis, Socius Ingredients, and most recently as chief operating officer of Dairy America. Research Chefs Association, Atlanta Susan Edwards, manager of foodservice and corporate chef at Sealed Air’s Cryovac division, Duncan, S.C., has been elected to the board of directors. A member of RCA since 2005, Edwards has served on the nominations and board development committee for four years.

think think DONALDSON *OEVTUSJBM"JSt 4UFSJMF"JSt $VMJOBSZ4UFBNt 5BOL7FOUJOHt Process Liquids

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© 2010 Donaldson Company, Inc. Minneapolis, MN. All rights reserved.

16

Dairy Foods | April 2011

Member of

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Tel 800.543.3634 Fax 952.885.4791 processﬁ[email protected]

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Donaldson Company, Inc. Compressed Air and Process Filtration PO Box 1299 Minneapolis, MN 55440-1299 U.S.A.

9001:2008

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Standard No. 10-04* * PF-EG & PG-EG single ﬁlter element housings meet 3-A Sanitary Standards.

News & Trends

IN MEMORIAM Stan Bennett, Oakhurst Dairy Stanley Taylor Bennett II, president of Oakhurst Dairy, Portland, Maine, passed away Feb. 23 in Scarborough, Maine, from pancreatic cancer. Bennett graduated from Tufts University, and went on to receive his law degree from Boston University School of Law in 1972. Shortly thereafter, he began working for Oakhurst Dairy, which was founded in 1921 by his grandfather, Stanley T. Bennett. In 1983, he became president, and in 1999, became chairman of the board after the passing of his father, Donald H. Bennett. Four of his siblings and a brother-in-law also work at the dairy. Over his lifetime, Bennett devoted countless hours to many organizations. He was truly passionate about many, but perhaps most particularly, the environment. And like both his father and grandfather, he was committed to giving back to his community. Friends of Casco Bay, Boys and Girls Club of Southern Maine, Gulf of Maine Research Institute, The Maine Historical Society, the Portland Tree Challenge, the Maine Audubon Society and the Iris Network and the Tidewater Farm Project were among some of the more recent recipients of his enthusiasm and energy. His other involvements included work with the Greater Portland Chamber of Commerce, the Maine Medical Center, the Portland Club, the Woodfords Club, the Maine Bar Association, the Maine Dairy and Nutrition Council, the International Dairy Food Association, the New England Milk Dealers Association, Greater Portland Landmarks, Maine Genealogical Society and the Mayflower Society. He was also twice a republican convention delegate and served on both the Falmouth Zoning Board of Appeals and the Falmouth Planning Board. He also recently completed and published a 400-page book chronicling the Bennett family history. Bennett will be remembered for his extreme generosity and kindness. He was an avid boater and loved his time

on Casco Bay on the Lucia II with his close friends and family. More recently, he discovered the joy of bird watching. Bennett is survived by his three children, Theodore, Colby and Sara Jane, and his former wife, Chris Arlander, all of

Falmouth. Also surviving him are his six brothers and sisters, Priscilla Doucette, Althea McGirr, William Bennett, Jean Driscoll, Mary Ellen Tetreau and John Bennett, their spouses and many nieces and nephews. Continued on page 18

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Our ingredients in your foods and beverages Add the taste, texture, nutrition and functionality that consumers demand in your foods and beverages with highquality ingredients from Tate & Lyle. We work side-by-side with you to create valuable, innovative solutions driven by our passion for food. Everyday, millions of consumers around the world enjoy products made with our ingredients. It’s the Tate & Lyle difference. Experience it today.

MIRA-CLEER® – Cook-up Starches Range SPLENDA® Sucralose KRYSTAR® Crystalline Fructose PROMITOR™ Soluble Corn Fiber STA-LITE® Polydextrose Fiber STAR-DRI® Maltodextrines INSTANT TENDER-JEL® X-PAND-R SC® Natural Starches MIRA-THIK® Cold Water Swelling Starch MIRA-SPERSE® Agglomerated Instant Starch STA-CAP® Lipophillic Starch TATE & LYLE Stabilizer Systems

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News & Trends

B R I E F LY … Wells’ Dairy Changes Company Name Wells’ Dairy Inc., Le Mars, Iowa, changed its legal company name to Wells Enterprises, Inc. to better represent its ability to move forward as a manufacturer of ice cream and frozen novelties. Cowabunga Sells Probiotic Frozen Yogurt Online Cowabunga Ice Cream, Forked River, N.J., debuted its super premium “designer” ice cream and made its probiotic frozen yogurt offerings available for online purchase with the re-launch of its website, www.cowabungaicecream.com. Cowabunga Ice Cream offers a wide variety of perennial and seasonal flavors, with many that are exclusive to the brand. Stonyfield Names Grant-a-Wish Winners The Teagues of North Carolina are the winners of the Stonyfield Organic Farmers Grant-a-Wish Program, which will fund a total of six innovative organic farming projects. Consumers voted online after watching short videos about each one. They received a $10,000 grant, which will be used to build a new, energy efficient feed mill to process organic grains for other organic dairy farmers in the southeast, as well as livestock growers and small farmers looking for local, organic feed. The Beidlers of Vermont and the Mahaffys of Oregon tied for second-place grants of $7,500 each. All recipients are farmer-

18

Dairy Foods | April 2011

owners of Organic Valley/CROPP Cooperative, the cooperative that has supplied Stonyfield with organic milk for more than 15 years. Roberts Dairy Showcases New Name, Logo, Packaging Roberts Dairy Foods debuted a new company logo and packaging that reflects the symbol of quality from Quality Chekd – the Blue Q Red Chek. The Omaha, Neb.-based processor’s products undergo bacterial and chemical product testing and certification of milk containers to ensure that they meet the Quality Chekd top standards for freshness and flavor. In addition, Roberts Dairy officially changed its name to Roberts Dairy Foods to represent its ever-expanding product line beyond milk. Beemster Partners with Arbor Day Group Beemster Cheese, Jersey City, N.J., makers of premium, gourmet Dutch cheeses, is partnering with the Arbor Day Foundation to plant trees in America’s forests. Beemster will donate 50 cents to the foundation for each pound of cheese sold under the Farmers Choice label from April 1-June 30. The donations will go to the foundation’s Replanting Our Nation’s Forests campaign to add trees to forests that have been devastated by wildfire, insects and disease.

News & Trends

SUPPLIER NEWS Sensient Colors LLC made a capital investment to add aseptic packaging capabilities, allowing its customers to receive preservative-free colors that deliver maximum shelf life and enhance sustainability. Delkor received a new U.S. government patent for its Intelligent Positioning technology for carton closing. This new technology can make the precise correction on an individual carton basis at speeds up to 150 cartons per minute. DSM Nutritional Products introduced Bright Science. Brighter Living., a new brand created to better symbolize the transition from a chemical company into a life, sciences and materials sciences company active in health, nutrition and materials.

Innophos Holdings Inc. expanded its Port Maitland, Ontario, facility for the production of potassium phosphates. At its Chicago Heights, Ill., facility, Innophos plans for a 25% increase in tri-calcium

phosphate capacity. This expansion uses new process technology, which achieves a significant improvement in throughput and a broader product range by optimizing existing production lines.

There’s more on the line than your bottom line. To us, it’s elementary.

Chr. Hansen opened the doors to its probiotic production facilities for “Microwarriors: The Power of Probiotics,” a TV documentary on probiotics. For more information, to order a copy of the DVD or to view the trailer, go to www.microwarriorsmovie.com. Kraft Foods expanded the deployment of EPS Corp.’s xChange Point real-time energy management and carbon reduction solution to all manufacturing facilities in its grocery business unit. The xChange Point solution monitors and curtails energy use and carbon emissions, identifies the most compelling options for achieving target reductions and tracks the results. Kraft Foods has already cut energy use in its manufacturing plants by 15% and energy-related emissions by 17% through the end of 2009.

Your customers depend on you to provide a safe, high-quality product that tastes great. That’s what you can give them with SPLENDA® Sucralose from Tate & Lyle. We refuse to compromise when it comes to setting the standard

CP Kelco received the Frost & Sullivan 2010 North American Food Ingredients Technology Innovation of the Year Award for its patent-pending triple-layer, selfseparating dessert gel concept, which is said to give manufacturers the ability to process two or three layered desserts effectively and efficiently.

for quality, reliability and consistency. Our customers wouldn’t have it any other way. Would yours? To see all our elements in action, visit www.splendasucralose.com

© Tate & Lyle 2011

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19

New Products & Marketing

DAIRY MARKET TRENDS

Shelf Pleaser Marina Mayer

Executive Editor

he updated 2010 Dietary Guidelines for Americans pose a tremendous challenge for some dairy processors, as they scurry to reformulate certain product lines to meet the call for healthier foods. Between lower-sodium offerings and SKUs making fat-free label claims, these hot-button issues present a host of hurdles for the food manufacturing community. For cheesemakers, though, this so-called “problem” may just be one of the already-in-place steps in delivering premium, topquality products time and time again. That’s why the cheese category continues to increase sales, according to Chicago-based SymphonyIRI Group.

T

Quarterly Sales of Natural Cheese Reporting Period 13 weeks ended

Dollar Sales (millions)

% change vs. yago

Unit Sales (millions)

% change vs. yago

12/26/10

$1,996.1

+4.5

663.7

+0.9

9/26/10

$1,848.2

+2.5

616.6

+0.8

6/27/10

$1,782.2

-1.1

598.7

+0.3

3/28/10

$1,902.3

-5.2

640.8

+2.3

12/27/09

$1,910.3

-8.1

658.1

+6.2

$1,803.5

-6.2

611.7

+8.3

9/27/09 Maintaining naturalness The natural segment raked in $7.6 billion in sales (up 1.1%) thanks to its top-grossing segments — shredded ($2.6 billion) and chunks ($2.4 billion), SymphonyIRI sales figures show for the 52 weeks ending Jan. 23. Shredded sales (as measured in dollars) were up 2.5%, but chunks declined 2.4%. Other natural cheese categories showing gains were crumbled (6.2%), slices (5.3%), string (4.7%), “all other forms” (3.8%) and refrigerated grated cheese (1.8%). Besides chunks, other natural cheese categories showing a decline in dollar sales were cube (12.6%), shelf-stable grated (2.7%) and ricotta (0.1%). Certain Kraft SKUs experienced roller-coaster results: sales of some soared while others plummeted. For instance, in the “all other forms” category, Kraft Cracker Barrel brought in 365,368.7% change in sales from last year due to its limited-edition lineup of Holiday Reserve cheese. Sales of the company’s Deli Fresh slices rose 121.4% and Cracker Barrel slices sales increased 14.7%, SymphonyIRI sales statistics show. On the other hand though, the Northfield, Ill., company recorded a 51.3% dip for its Kraft brand slices, a 25.6% drop in sales for its Snackables and a 20.1% decline in sales for its Cracker Barrel string cheese SKUs. The grated cheese segment also displayed up-and-down results, SymphonyIRI says, with sales for Bella Famiglia brand increasing by 252.5% since last year. But for Crystal Farms, a Lake Mills, Wis.-based division of Michael Foods Co., sales plummeted 37.5% for its pair of grated cheeses in Romano and parmesan kinds. The crumbled category saw more positive marks with Alouette Cheese, New Holland, Pa., scoring 114.2% in sales for its Alouette brand cheese. This gluten-free crumbled cheese is ideal for salads, omelets, pizza and pasta, comes in blue, goat, gorgonzola and feta flavors and is equipped with a patentpending resealable shaker top container that allows consumers to shake out the right amount of cheese each time. Processed cheese melts away The processed sector eked out a small gain of 0.04% to $2.1 billion in sales, with processed/imitation slices accounting for $1.3 20

Dairy Foods | April 2011

Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Wal-Mart)

Quarterly Sales of Processed Cheese Reporting Period 13 weeks ended

Dollar Sales (millions)

% change vs. yago

Unit Sales (millions)

% change vs. yago

12/26/10

$545.9

+2.6

174.9

-0.9

9/26/10

$522.3

+0.5

179.7

-2.6

6/27/10

$512.0

-1.6

173.8

-2.8

3/28/10

$525.4

-5.6

173.5

-0.7

12/27/09

$532.1

-10.0

176.5

+1.1

$519.7

-8.6

184.5

+4.6

9/27/09

Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Wal-Mart)

billion in sales, according to SymphonyIRI data. However, sales in the processed/imitation slice segment fell 4.1% overall. For example, sales of Land O’Lakes SKUs dropped 43.6% since last year, whereas Borden and Veggie Slices from Galaxy Nutritional Foods, North Kingstown, R.I., saw a 9.7% and 6.4% dip in sales, respectively. For its part, sales of Kraft and Kraft Deli Deluxe dropped 31% and 13.9%, respectively. However, where Kraft faltered, it also made up for it in other areas of the processed cheese category. For instance, sales for its shredded cheese products raked in a whopping 335,651.7%, 69,832.1% for the “all other forms” avenue and 56.3% for its lineup of loaf SKUs. Other noteworthy sales increases include: Ortega aerosol/ squeezable cheese spreads (479.7%); American Accent shredded (110.5%); Shullsberg brand of “all other forms,” produced by Shullsberg Creamery, LLC, Shullsberg, Wis. (38.1%); and Whitehall Specialties brand shredded cheese (40.6%). Regardless of the issue at hand, the cheese category remains a shelf pleaser for all occasions.

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New Products & Marketing

NEW PRODUCT REVIEW ries, dependri ing on variety. Shake packages tout the packag that a servfact th ing is an excellent source of calcium and vita vitamin D, while smoothies are a the smo source. good sou

Dreyer’s Grand and Ice Cream Inc., nc., Oakland, Calif., lif a division of Glendale, Calif.-based Nestlé USA, which is owned by Nestlé S.A. of Vevey, Switzerland, introduces Slow Churned Shakes and Smoothies. These parlor-style treats are sold frozen in single-serve containers. Consumers simply add milk to the 8.1-ounces (shakes) or 7.6-ounces (smoothies) of dairy base and stir to desired consistency. The consumer controls thickness and richness by how much milk and the type of milk they add. The shakes come in Chocolate, Cookies n’ Cream, Strawberry and Vanilla varieties, while the smoothies come in Mixed Berry, Strawberry Banana, Sunrise Blend and Tropical. Before the addition of milk, the shakes range from 190 to 240 calories and the smoothies from 160 to 170 calo-

Bakersfield, Calif.Bakersfiel Bolthouse based adds Parfait Farms ad Smoothie to its popular Protein Smoo ein Plus beverage line, joining the he chocolate and mango flavors introh oduced about six months ago. The he new variety is the only parfait prootein drink in the ready-to-drink premium smoothie category. Each smooth sip delivers an equal measure of strawberries, yogurt and granola, according to the company. Made with Bolthouse Farms’ proprietary whey and soy protein blend, the company packs 25 grams of protein into each 15.2-ounce bottle, along with 180 calories and 3 grams of fiber, making it a satisfying, healthful choice for breakfast, for a refreshing afternoon snack or for postworkout recovery. The suggested retail price is $3.19.

Dan-o-nino is now drink-able. The Dannon Co., White Plains, N.Y., extends this cultured dairy children’s brand to mini drinks that resemble the popular Danimals drinkable yogurt line. Promoted as being “power packed” with “two times the calcium of milk,” Dan-o-nino dairy drinks come in two fruity flavors: strawberry and strawberry banana. Each bana h 3.1-fluid-ounce bottle is a good source (13% of bott the Daily Value) of protein and an excellent source (20% of the Daily Value) of vitamin D. D The company touts the fact T that the formulation does not include high-fructose corn syrup or any artificial colors or flavors. The bottles are sold in four-packs in select introductory markets. This past holiday season, T ffans of the famous Buddig beef and cream cheese b rrecipe were treated to an aall-in-one kit containing tthe ingredients to make tthis tasty appetizer. Third-

NOTEWORTHY I NTROD UCTION S Campo Lindo Queso Blanco from Advanced Products Inc., New Holland, Pa., is a rich, velvvety, mild cheddar cheese sauce available in an easy-open 15-ounce can. a Lancaster County, Pa.-based Turkey Hill Dairy L iintroduces limited-edition flavors to its top-

22

Dairy Foods | April 2011

selling line of refrigerated drinks. From January to June, Light Wildberry Green Tea and Light Raspberry Lemonade will be available. In July, Light Blueberry Tea and Light Peach Mango Punch will appear on store shelves. A new Fruit Punch Drink flavor will also be available throughout the year.

New Products & Marketing

c cheeses. One variety has six light mozzzarella strings and six reduced-fat colby JJack sticks. The other has six light Swirls (string mozzarella blended with cheddar) and six Superstrings. The latter is mozzarella fortified with calcium and m vvitamins A and D. Also in the Lovers lline is Cheddar Lovers, which contains ssix mild and six sharp cheddar sticks, aand Jack Lovers, which contains six pepper Jack and six colby Jack sticks. p SSubscribe to Dairy Product Innovations ((www.dairyfoods.com/dpi), an e-newsletter ffocused on new dairy products and new pproducts and services from dairy industry ssuppliers. Subscribers receive Dairy Product IInnovations monthly with the occasional special installation or themed issue focusing sp oon specific niches such as artisan cheese or oorganic and natural foods. To subscribe, visit www.dairyfoods.com. w generation family-owned lunchmeat company — Carl Buddig & Co., South Holland, Ill. — created the Buddig Cheeseball & Pinwheel Kit. Each reusable container includes enough smoked chopped pressed beef, cream cheese and seasoning to form a 10.7-ounce cheeseball or 24 pinwheels. Product retailed for about $5. Packs of new Frigo Fit & Fun F Lovers String Cheese from Canadabased Saputo Inc., contain 12 individuallyy wrapped snackingg

I N T E R N AT I O N A L The popularity of almond milk has exploded in the United States. Billed as an alternative to dairy milk, this nut-based beverage carries a powerful healthful halo. In Taiwan, consumers are no longer forced to choose between cows milk and plant-based milks. The Fresh Delight brand from Standard Food Co. now offers a fresh cows milk supplemented with a combination of milk from five nuts: almond, cashew, macadamia, pistachio and walnut. While a milk-and-nut drink won’t appeal to the lactose intolerant, it could be an interesting proposition for health-conscious consumers. Belgium’s Mercer’s Dairy brings the essence of wine to the frozen dairy case. Mercer’s Chocolate Cabernet Wine Ice Cream is Cabernet-flavored ice cream blended with rich chocolate ice cream. Like Cabernet Sauvignon wine, w the Cabernet ice cream features fe notes of dried cherry and an blackcurrant. Mercer’s four fo other wine ice cream flavors vo are: Ala Port, Peach White Zinfandel, Zi Red Raspberry Chardonnay and Royal White Riesling. The Laughing Cow process cheese brand from France-based Fromagerie Bel celebrates its 50th anniversary with the introduction of a special flavor combination pack of Apéricube, a line of individually wrapped cheese cubes. The limited-edition variety pack contains the brand’s best flavors — blue cheese with walnuts, ham, onion and scallop — as chosen by French consumers. With 48 pieces per pack, the product is more reminiscent of a box of specialty chocolates than a dairy snack.

Contributed by Krista Faron, director of innovation and insights, Mintel Research Consultanc y, Global Ne w Products Database (GNPD). For more information call 312-932-0400 or visit www.gnpd.com. Continued on page 24 www.dairyfoods.com

23

New Products & Marketing

NEW PRODUCT REVIEW: FOCUS ON ICE CREAM Even before Santa came down the chimney, ice cream marketers had been hustling and bustling to perfect their summer 2011 ice cream introductions. Product is now being manufactured, and some retailers have already received their first shipment.

Premium appears to be the name of the game for many ice cream marketers. For example, Turkey Hill Dairy, Lancaster, Pa., says it is going back to its roots of premium ice creams based on homemade flavors, and recently introduced Double Dunker and Homemade Vanilla premium ice creams. Double Dunker features mocha ice cream swirled with chewy cookie dough and crunchy chocolate cookie swirl. The flavor was one of Turkey Hill’s limited-edition options in 2009 and 2010, but following strong consumer demand, it has now been added to the full-time premium flavor lineup. Homemade Vanilla builds on the company’s success in the vanilla category. Homemade Vanilla sets itself apart by featuring a unique vanilla taste that harkens back to more traditional vanilla ice creams. “I’m proud that we are focusing on these two new flavors this year,” says Turkey Hill Dairy president Quintin Frey. “While Homemade Vanilla showcases our 80 years of experience making truly homemade-tasting ice cream flavors, the Double Dunker also allows us to showcase how we like to mix some of the newer, more popular mix-ins for ice cream. I think all of our fans will be pleased.” Smith Dairy Products Co., Orrville, Ohio, adds Vanilla Orange Cream (vanilla-flavored ice cream and tangy orange sherbet) and Chocolate Peanut Butter (chocolate ice cream with a creamy peanut butter swirl) to its halfgallon premium ice cream line. The suggested retail price is $4.99. “These two tried-and-true flavors complement our other Smith’s premium ice creams,” says Penny Baker, director of marketing. “They’re a natural fit to our product line, and, of course, Smith’s premium ice creams are still 24

Dairy Foods | April 2011

our customers’ best value since they’re offered in a full halfgallon size.” For Brenham, Texas-based Bluee Bell Creameries, the focus is on n chocolate. Chocolate Mud c d Pie is a creamy chocolate ice ce cream loaded with mixed-nut nut shortbread, a smooth milk ilk chocolate sauce and a whipped c ped topping swirl. to “Our ice cream has all the flavorful ingredients you would expect to find in a chocolate mud pie,” ing says say Paul Kruse, CEO and president. “One taste of Chocolate Mud Mu Pie ice cream and you’ll agree it’s as smooth as the pie itself. itse And if you love chocolate, I have a feeling this will quickly become beco your new favorite flavor.” This is the first new flavor released from Blue Bell this year. “We have a great lineup of new flavors we’re very excited to introduce to you,” Kruse adds. “Each year we spend countless hours in our research and development lab creating ng and perfecting recipes. Many are suggestions from our very own employees. The inspiration can come from anywhere; sometimes it’s as simple as another dessert.” And for G.S. Gelato & Desserts, Fort rt Walton Beach, Fla., that dessert would ld be the king cake, a traditional sweet et treat consumed in New Orleans during ng Mardi Gras. Just in time for this year’s ar’s festivities, the company rolled out pints ts of King Cake gelato, a biscotti-flavored base with cinnamon and dark Italian cherryy swirls. The packaging is designed with traditional Mardi Gras flair and even includes a sugar “baby” iinside to keep with the tradition of king cake. “Being a major manufacturer in the Southeast, we wanted to merge our Italian background with a custom that is dearly loved in our rregion,” says Cynthia Harrison, national grocery account director. n ““Mardi Gras is a tradition that is unmatched in terms of spirit and u ffestivity, so King Cake was a naturral choice.”

JUNE 8-10, 2011 TECHNOLOGY SHORT COURSE

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Refresh yourself on fundamentals and learn the latest new membrane applications and technologies! The Practical Membrane Technology Short Course will be broken up into two days with the ﬁrst day focusing on fundamentals of membrane technology and the second day focusing on new membrane technologies and applications. For an additional fee, plant tours to local OEMs will be offered on the third day of the program. WHO ATTENDS?

Technicians, Chemists, Scientists, Processors, Plant Engineers, Product Formulators, Equipment Manufacturers, Sales & Marketing Specialists and anyone else interested in learning about new methods to eliminate process bottleneck, enhance efﬁciency, and increase proﬁtability in the ﬁltration and membrane industry.

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Here are just a few reasons why you should attend the Practical Membrane Technology Short Course. • Learn from industry experts who will cover fundamentals of membranes, process design, cleaning, economics and new applications • Participate in case studies dealing with process design, optimization and practical problems in membrane applications and fouling • Get a better understanding of membrane technology, chemistry, process development, conditions, modules and systems • Discover new energy saving strategies in process reverse osmosis & nanoﬁltration plants • Explore UV and ozone disinfection technologies for membrane systems used in water treatment and food related processes

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Membrane Chemistry, Basic Membrane Terminology and Basic Membrane Mathematics (MF, UF, NF, RO)

9:00 am

Module Design & Options: Spiral, Tubular, Hollow Fiber, Plate & Frame

9:30 am

Pre-treatment & Post-Treatment Technologies

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Marriott Minneapolis West M 9960 Wayzata Boulevard St. Louis Park, Minnesota 554265 For overnight accommodations please call the Marriott directly at 866-268-1280 or 952-544-4400 and ask for the "Membrane Short Course" group discount of $139/night + tax. Room reservations at this rate will only be accepted until May 13, 2011.

12:00 pm Use of Process Scale-up Software 12:30 pm Networking Luncheon 1:30 pm

Membrane Selection Process

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How to Perform Pilot Plant Study

2:30 pm

Pilot Plant Data Analysis

3:00 pm

Afternoon Break

3:30 pm

Membrane Performance Testing, and Data Normalization

4:00 pm

Electrodialysis: Principles of ED, BPED, EDI and System Design and Applications

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New Developments and Directions in Membranes and Membrane Chemistries

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Applications Update on Chemical Industries: Waste Water, Catalyst, Cleaning Solutions etc.

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Water RO Pretreatment: Water Chemistry and How to Operate a Water RO System

10:00 am Morning Break 10:30 am Energy Recovery in High Pressure Applications 11:00 am How to Develop Cleaning Program for Reverse Osmosis Applications 11:30 am An introduction to MBR technology and its Growing Role in Water Treatment 12:00 pm Critical Parameters in Using Membrane Technology in Milk and Dairy Applications 12:30 pm Networking Luncheon

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Update on the Use of Microﬁltration for Production of ESL Milk, and Total Protein and Casein Standardization of Cheese Milk

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New Membrane Products for the Beverage and Food Industry

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New Applications of Caustic/Acid/Solvent Stable Ultraﬁltration and Nanoﬁltration Membranes

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Current Applications of New Nanoﬁltration Membrane for High Temperature/ High pH Performance

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An Inorganic Tubular Membrane for Demanding Applications

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New Energy Saving and Efﬁcient Membrane Technologies from GE

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Texturants manage the flow of melting cheese and slow the breakdown of sour cream exposed to heat.

Suppliers discuss ingredients that influence the texture of dairy foods. Donna Berry Product Development Editor

he average consumer typically does not realize the role texture plays when deciding if they like or dislike a food. Most will say something tastes good or bad, but few evaluate the mouthfeel and visual appeal of foods, or at least to the extent that food scientists employ when evaluating product quality. In the lab, mouthfeel descriptors include creamy, grainy, sheer, slippery, slick and smooth, while terms used to describe the apparent texture are cohesiveness, ice crystals, melt, synereis and watering off. Numerous ingredients are available to dairy foods product developers to manage and manipulate food textures. Usually carbohydrate or protein-based texturants impact appearance and mouthfeel without contributing much in terms of calories and flavor. Dairy Foods interviewed 14 suppliers of texturant ingredients to better learn about the role texturants play in dairy foods, as well as recent innovations available to product developers. Here’s what they share.

T

Dairy Foods: What role do texturants play in dairy foods formulations? Peterson: Flavor and texture are the two attributes that ensure a dairy product provides a unique experience for consumers. But, however good the flavor, if the texture is wrong, consumers won’t 28

Dairy Foods | April 2011

Dairy Foods talked to: Ivan Gonzales, category marketing manager-cultured foods, Fonterra Amanda Higgins, laboratory technician, Gum Technology Corp. Donna Klockeman, dairy food scientist, Tic Gums Mindi McKibbin, specialist-edible technical services, Gelita USA Cathy Miller, technical applications director, Danisco USA Joseph O’Neill, executive vice president-sales and marketing, Beneo Inc. Vince Patti, marketing associate, Fiberstar Inc. Darrin Peterson, assistant vice president-functional systems product manager, Cargill Texturizing Systems Declan Roche, commercial director of new technology platforms, Kerry Ingredients & Flavours-Americas Region Jane Schulenburg, global marketing director, CP Kelco Bill Shazer, director-research and development, Tate & Lyle Jennifer Stephens, marketing manager, Penford Food Ingredients Teresa Yazbek Pereira, vice president/technical sales director, Colloides Naturels Inc. Erhan Yildiz, business scientist-dairy applications, National Starch Food Innovation/Corn Products

Ingredient Technology

be back. Well-designed texturizing solutions offer much more than stabilization. They can affect sensorial attributes, provide a broad array of functionality, deliver health and wellness support, reduce ingredient costs and offer formula optimization. O’Neill: The texture of dairy foods formulations can be modified by the addition or removal of fat, carbohydrates and/or protein. The technical attributes of these ingredients may be used for additional functionality from mouthfeel and syneresis control to freeze-thaw stability. The specific nature and digestibility of the ingredient may influence the nutritional value of the product, including fiber content and caloric value. Patti: In our experience, customers want to improve the eating qualities of their products. This can be done by preventing syneresis and oil and water separation or improving texture, mouthfeel and taste. A second use of texturants in dairy products is fat reduction. Manufacturers are using our ingredients to replace fat and thereby either reduce formula costs or improve their product’s nutritional profile. Roche: Texturants interact with the major components in a food or beverage — proteins, fats, carbohydrates and moisture — sometimes acting on specific ingredients such as proteins or at the interface between the major components. They work synergistically with the ingredients to set up a stable structure within the product that allows ease of processing in the short term and maintains that stable structure over the life of the product, delivering the desired organoleptic experience when the product is consumed.

under otherwise unforgiving conditions such as low pH or high temperature. They also can play a role in the nutrition of dairy foods and beverages, as they allow for a reduction of high-fat ingredients without losing the texture or mouthfeel of the full-fat product. Gums contribute to the fiber content of a food and also help lower the glycemic index. This comprehensive improvement of texture, stability and nutrition shows how vital a role gums and starch/gum blends can play in both improving dairy products while also reducing the total cost of ingredients. Gonzalez: Each texturant has different functional characteristics and contributes to the body and texture of dairy foods in different ways. Milk proteins, for example, which are naturally found in dairy products, play a major role in the nutritional profile of the finished product, as well as help define final structure, taste and texture. The use of dairy proteins, whether whey protein concentrates or milk protein concentrates, when properly utilized, not only increases the protein content of the formulation but also can bind moisture to prevent syneresis. In cheese products, these ingredients can assist with increasing yield and in cultured products, they provide thickness. McKibbin: Gelatin is a protein-based hydrocolloid often used as a texturant in dairy products. Its melting point is near body temperature, thus it simulates milkfat’s meltin-your-mouth experience.

Shazer: Texturants have multiple functions in dairy products and come in many forms, ranging from components such as maltodextrins and polydextrose, which add body and build total solids, to starches and modified starches, which add viscosity plus body/mouthfeel, to hydrocolloids, which build viscosity and prevent phase separation, and finally, to emulsifiers, which bind fat and aqueous phases. Miller: Although no one hydrocolloid or emulsifier can provide fat mimetic properties, a combination of the two can be used to provide a creamy mouthfeel and build a creamier texture when fat is reduced in dairy applications. This is particularly important in products that are typically higher in fat, such as sour cream, cream cheese, ice cream, whipping cream and coffee creamers. Texturants also prevent serum separation in resale ice cream mixes, soft serve, flavored milks, buttermilk, whipping cream and smoothies.

Schulenburg: A texturant’s role in a food differs by application. Even within the beverage category, functions can be quite varied. An increasingly popular beverage sector is what we call “healthin-a-bottle.” This includes drinkable yogurts, fermented milk, smoothies and milk-, whey- and soy-juice drinks. Not only do they deliver a good source of protein, they can often serve as a healthy and refreshing meal-replacement or snack option. Unfortunately, for the beverage manufacturer, formulating low-pH drinks that contain protein can be a bit of a challenge. Technical hurdles can also be exaggerated via fortification with insoluble particulates. Formulation challenges include protein aggregation, gritty or chalky mouthfeel, thinness, settling of insoluble ingredients and visual separation. Hydrocolloid texturants assist with stabilization, suspension and thickening. They make it possible to produce consumer-appealing acidified protein beverages with a consistent and uniform quality and nutrient delivery. Continued on page 30 To maintain the integrity of pudding, whipped cream and yogurt in the increasingly popular pre-made fruit parfait, formulators use texturants designed to prevent melt and synersis while maintaining foam structure.

Higgins: In addition to the obvious — providing texture — many texturants protect proteins from denaturing Photo courtesy of Rich Products

www.dairyfoods.com

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Ingredient Technology

Dairy Foods: Describe one or more of your texturant ingredients, including specific applications, usage level and functionality. Schulenburg: CP Kelco offers labelfriendly pectin derived from either citrus peel or sugar beets. In acidified protein drinks, our application-specific pectin protects the proteins from aggregation

during heat processing and stabilizes the beverage over shelf life. Via protein protection, a smooth and palatable beverage is obtained, since sedimentation and serum formation — that watery layer on the surface of the beverage — is prevented. In beverages with live and active cultures, the pectin is added to the milk prior to fermentation to add body and mouthfeel to the finished beverage. In this process, the

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pectin is pasteurized with the milk prior to culturing so that no additional process steps are required. The pectin interacts with the milk proteins to build viscosity, reduce protein sedimentation and minimize serum separation to help create a smooth, stable drinking yogurt. Klockeman: Tic Gums provides texturant systems for all-natural sour creams, which can be used for light and full-fat formulations using cultured or acid-set processing methods. The ingredients include a combination of starch, gum Acacia, guar gum, locust bean gum and carrageenan, with a recommended usage level ranging from 1.5% to 3.25%, depending on the desired finished product characteristics. This combination of ingredients provides a thick, heavy bodied sour cream with good tolerance to temperature stress, both in foodservice applications and as an ingredient in baked goods. We also provide 100% certified-organic texturant systems for cupset and tank-set yogurts, which is based on 100% organic-certified agar. The recommended usage level range is 0.05% to 2.25%. These systems provide excellent texture after stirring in combination with increased control of syneresis throughout the shelf life of the yogurts. McKibbin: Gelita markets an array of gelatin ingredients, including a recently introduced Orthodox Union kosher-certified product we distribute for Geliko. Dairy processors rely on gelatin for many functions. For example, gelatin can prevent whey from being expelled in yogurt, curd and cream cheese, as it binds and stabilizes the whey. The gelatin molecules form a sort of lattice in the casein gel structure during the gelling process, and this is stabilized by hydrogen bonding. This prevents the protein from clumping and expelling the whey. Gelatin assists in freeze-thaw stability, specifically in frozen dairy products, as it influences the size and distribution of ice crystals. Gelatin also has the ability to generate and stabilize foams, and is therefore a great option for whipped dairy desserts. Yazbek Pereira: Colloides Naturels markets Acacia gum, which can be organic and kosher. It is a purified, instantized ingredient so it is easy to use. Acacia gum is 90% soluble fiber and different from other texturants as it has a low viscosity. Continued on page 32

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Dairy Foods | April 2011

Ingredient Technology

In addition to providing mouthfeel, stabilizing systems and contributing fiber, it is able to mask the bitterness and aftertaste of low-calorie sweeteners. We also have developed a co-processed Acacia gum and gluten-free wheat fiber. It functions as a fat replacement in ice creams. In fact, at a use level of 2%, fat can be cut in half and still maintain the same texture, stability and creaminess.

Higgins: Gum Technology offers a tara and guar gum blend for ice cream. When used at 0.15%, it can provide freeze-thaw stability by preventing the formation of ice crystals. These gums can also be blended with modified starches at 1% to provide a similar stability. Another example is an acidified beverage. A pectin and tara gum blend at 0.7% helps to protect the protein from denaturing

in the low pH solution. In another application, a blend of guar gum, xanthan gum and alginate allows for the amount of cheese in a cheese sauce to be greatly reduced without compromising texture. Yildiz: National Starch offers starchbased texture systems that are specifically optimized to deliver a customer-preferred texture in blended yogurt products. Further, we can optimize texture systems to create the texture and eating experience of higher-fat content products in low- and no-fat yogurt applications by providing creaminess and opacity. Dairy co-texturizers, which are unique combinations of modified starch, maltodextrin and tapioca maltodextrin, can enhance creaminess in cultured dairy products, dairy desserts and milk drinks. Our proprietary maltodextrins contribute to the creaminess and firmness of cultured products and dairy desserts. Stephens: Penford offers rice starch, which is recommended for creaminess and as a fat replacement in dairy, cheese and ice cream food products. When native rice starch is used, it can be labeled as natural and appears as rice starch on the ingredient declaration. Usage level is formula specific, but generally it is in the 1% to 10% range. All of our products are kosher. Gonzalez: Fonterra offers many functional dairy proteins for cultured applications. For example, one ingredient is designed to deliver a thicker texture and shiny appearance to high-protein yogurts, such as the increasingly popular Greek-style yogurts. Our dairy ingredients offer clean-label options and are simply declared as either “whey protein concentrate” or “milk protein concentrate” in the formulation. Fonterra’s range of ingredients includes rBST-free, Grade A, kosher-certified and manufactured in the USA options. Miller: Emulsifiers keep water and oil in suspension, and this contributes to a smooth, creamy mouthfeel, as well as prevents visual separation. Danisco offers a number of emulsifiers that are ideal for dairy applications, including mono and diglycerides, distilled monoglycerides, lactic acid esters and DATEM. The primary function of hydrocolloids is to bind water; however, each has its own set of unique functionalities. A popular hydrocolloid for dairy products is guar Continued on page 34

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Dairy Foods | April 2011

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sugar. Inulin is available in powdered and liquid forms with fiber contents ranging from 85% to 95%. Highly soluble inulin is designed to offer the solubility of oligofructose and the textural properties of inulin without causing crystallization issues in fruit preparations for yogurt. High-performance/long-chain inulin forms gel at lower concentrations than standard inulin and is therefore twice as efficient for fat replacement. It is typically used at levels ranging from 1% to 6%. Beneo also carries a wide range of clean-label rice starches that specifically cater to the following needs: creamy mouthfeel, syneresis prevention, freeze-thaw stability and calorie reduction. Dairy Foods: What is the future for texturants in dairy products?

In multi-layered desserts, texturants bind water to prevent breakdown between layers. If the dessert is frozen, they can assist with freeze-thaw stability by reducing undesirable ice crystal development.

gum, which is considered to be natural for label claims. It is one of the more inexpensive hydrocolloids and can build viscosity and enhance a creamy texture in ice cream, water ices, sherbet, sour cream, cream cheese, buttermilk, flavored milks and smoothies. Microcrystalline cellulose is used in lower-fat ice cream applications to provide a creamy mouthfeel at the same time it protects against heat-shock damage and altitude abuse. Polydextrose can be used to increase fiber content and can also be used as a bulking agent in reduced-sugar and/or reducedcalorie dairy products. Patti: Fiberstar’s citrus fiber-based ingredients are used to partially replace fat, stabilize emulsions, prevent syneresis and improve texture. Our ingredients have an amorphous cell structure and the ability to bind fat as well as water. This allows them to give reduced-fat formulations excellent texture, mouthfeel and taste. Customers typically use our citrus fiber products at 0.5% to 2% of formula weight. When replacing formula fat, our citrus fiber products often reduce the per-unit cost of the product. One of the newest applications is in ice cream. We have tested reduced-fat ice cream formulas that have truly excellent mouthfeel, texture and flavor delivery with reduced-formula costs. O’Neill: Inulin is a natural plant ingredient that provides fiber enrichment without negative organoleptic effects. It can replace all or part of the fat in cheese, ice cream, mousse and yogurt, where it also improves texture and mouthfeel. Low-fat spreads and mousses, fluid milk and dairy desserts are just a few of the applications where inulin shines, typically at usage levels ranging from 2% to 10%. Inulin can also be used to partially replace 34

Dairy Foods | April 2011

Roche: There will always be a need for the unique properties delivered by texturants to dairy products. They are the scaffolding around which many dairy products are constructed. For some traditional dairy products, texturants are not needed. They are self-sustaining. But for the majority, in the drive for enhanced efficiencies, both in processing and in product formulations and the drive to reduce calories, fat and sugar, texturants are key to enabling the processor to successfully formulate, manufacture and expand market share for a product. Ultimately, all products have to deliver the desired experience during consumption. If not, its life cycle will be short lived. Texturants enable long product life cycles because they allow companies to formulate products that deliver on promise without breaking the bank. Gonzalez: Several dairy product manufacturers are formulating or reformulating dairy products with functional dairy proteins in order to offer consumers products with a cleaner label, while benefiting from the texture-building properties of the dairy proteins. Yildiz: Texturants derived from starches are versatile ingredients that are easy to formulate with, provide a wide range of benefits and are recognized and accepted by consumers. This should help continue to drive their utilization in dairy products. Further, starch-based texture systems offer excellent cost/ performance benefits. With the continued consumption of clean-label, vegetarian, halal and kosher foods and sometimes the price pressure on dairy ingredients, the use of starch-based texturants will keep growing. Stephens: Texturant technology within the dairy category will continue to evolve to solve processors’ future needs, which include cost effectiveness with quality, allergen-free labeling and natural/ clean ingredient declarations. Shazer: The highly functional nature of hydrocolloids at relatively low-use rates, and the synergies observed between various hydrocolloids will make their use attractive in simple-label foods. Similarly, starches and maltodextrins will find favor with simple-label products and will provide function and cost efficiencies across a wide range of food applications. Higgins: Scientists will continue to discover synergies between the different texturants. This will allow for replacement of highcost or calorie-rich ingredients, while also improving texture and allowing for cleaner and more natural flavors.

Ingredient Technology

THARP & YOUNG

The Unsung Frozen Desserts herbet, water ices and sorbets can very well be forgotten or misunderstood. Often, they sit in the shadow of classical standardized ice creams or even non-standard frozen desserts (for example, frozen yogurt, non-dairy foods, generic frozen dairy desserts, etc). However, demands on new product development, new flavors, innovative applications and approaches, cost reduction or cost avoidance make these frozen dessert workhorses more capable of meeting consumer needs and preferences. They fill voids that ice creams and other products simply may not be able to. Given this, the value of sherbets, water ices and sorbets to any given product line cannot be understated.

S

The properties of sherbet Sherbet is a frozen dessert that, compared to ice cream, has much lower levels of fat (1-2%), milk solids not fat (2-4%, all of which can be whey solids), lower overrun (minimum weight 6 pounds per gallon) and higher levels of sweetener (typically 28-32%). See the table for a comparison of sherbet to sorbets and water ices. Sherbet can be produced in any flavor; however, fruit flavors are predominate. In fruit flavors, organic acids are added to enhance flavor — a level of acidity of at least 0.35% (calculated as lactic acid) is required by the Food and Drug Administration’s Standard of Identity. The standard also includes minimum requirements for the quantity of fruit: citrus — 2%; berries — 6%; and other fruits — 10%. The body and texture properties of sherbets range from the traditional icy, cold style to a smooth, creamy product with a mouthfeel close to that of ice cream. Initially, sher-

Typical Composition Ranges for Sherbet, Water Ices and Sorbet Component

Sherbert

Water Ices/Sorbets

Fat

0% to 2%

None

MSNF*

1% - 4%

None

Total milk solids

2% – 5%

None

Sucrose

17% – 23%

19%-21%

Corn syrup solids

7% – 13%

9%-11%

>0.35%

>0.35%

30% – 60%

0% - 50%

Acidity (fruit flavors, as lactic acid) Overrun

*Milk solids not fat, Source: Bruce Tharp and Steven Young

bet was considered to be a refreshing frozen dessert, particularly appropriate for consumption during warm seasons. Its refreshing qualities were provided by a dense, low overrun structure that provided more mass per spoonful than ice cream and, therefore, more cooling effect. The inclusion of typical ice cream emulsifier systems and advanced stabilizers make it possible to produce a sherbet with eating properties more like those of ice cream. Emulsifiers produce stronger, more stable and smaller air bubbles that add to creaminess, while alternative stabilizer systems provide enhanced control over ice crystal growth. It is now possible to produce sherbet products over a broad range of properties, including the achievement of overrun in the normal ice cream range. Such products would fall below the weight limitations of the standard of identity; however, they would have legal acceptance if identified by a fanciful name other than “sherbet.” If properly formulated, more mainstream flavors may be possible,

Understanding Frozen Desserts For more on the nuances between frozen dessert types and the opportunities that are possible when considering sherbets, water ices and sorbets, join Bruce Tharp and Steven Young at their Tharp & Young On Ice Cream Technical Short Course, Workshops and Clinics, Nov. 30-Dec. 2, in Las Vegas. Course size is limited and tuition discounts are available. Go to www. onicecream.com or call 610-975-4424 or 281-782-4536.

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Dairy Foods | April 2011

Tharp & Young

thus, compounding the subtle differences between “sherbet” and ice cream. Water ice goes upscale Water ices are frozen desserts that consist of mainly water, sweetener, acidulant, flavor, color and stabilizer. They can be considered as sherbets in which no dairy ingredients are present. They are sometimes produced as quiescently frozen novelties. They may or may not have added air whipped into them and may or may not have added emulsifiers as well. If air is whipped into the mix, special formulation considerations are necessary. Sorbet is marked by fruit solids No regulatory definition for “sorbet” exists. Thus, it is conventional wisdom that defines it as an upscale water ice. The basis for the upscale characterization is the added quality that comes from the fact that products identified as sorbet usually derive at least part of their sweetening from bland fruit juice concentrates (often apple or pear), fruit juice concentrates of the select characterizing flavor (e.g., strawberry) and often contain discrete fruit pieces. As a result, sorbet contains more fruit solids than water ice (which usually has none). The overrun level in sorbet is generally less than 15-25%. Bruce Tharp is principal of Tharp’s Food Technology, Wayne, Pa. Steve Young is principal of Steven Young Worldwide, Houston.

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Donna Berry

Donna Berry Product Development Editor

t the recent Natural Products Expo West show in Anaheim, Calif., I was amazed by how many companies promoted new products on the basis of not containing high-fructose corn syrup (HFCS). I managed to converse with a few company representatives about their deliberate omission of HFCS; and the stories they could tell…none of which were based on sound science. (My favorite, but also the most pathetic, was the baby food manufacturer who said that studies have shown HFCS stunts growth.) Here are the facts. Sucrose (table sugar) and HFCS have the same number of calories as most carbohydrates; both contribute 4 calories per gram. They are also equal in sweetness and contain nearly the same 1:1 ratio of two sugars — fructose and glucose. Sugar is a 50-50 blend; while HFCS typically comes in two blends: 42% and 55% fructose. The balance is made up primarily of glucose with a few other natural sugars. Further, once these sugars are absorbed into the blood stream, research shows that they appear to be metabolized similarly in the body.

A

In terms of chemical structure, yes, there are some differences. This is why they have different names. The two differ by how the sugars bond. Table sugar is a disaccharide, in which fructose and glucose are linked by a chemical bond; whereas, the fructose and glucose in HFCS are not bonded. In other words, they are free sugars. The other obvious difference is that HFCS, as the name suggests, comes from corn, and sucrose comes from sugar cane and beet sugar plants. Functionally they differ in product applications, with HFCS often providing benefits beyond sweetness, which is why so many manufacturers have used it in the past. For example, in yogurt, HFCS enhances flavors, rounds out tartness and even assists with water binding to prevent syneresis. Data presented at the American Heart Association’s (AHA) Scientific Sessions 2010 meeting in Chicago shows that consuming fructose from added sugars at levels found in the average American diet does not lead to weight gain or an increased risk for heart disease when part

All types of sweeteners can satisfy our sweet tooth. The secret is to consume in moderation and keep calorie counts down.

of a weight-stable diet. The results mark the first time researchers measured the effects of added sugar consumption on various metabolic markers. In this double-blind study, researchers followed 64 overweight and obese people who were placed on a weight-stable diet for 10 weeks. The diet incorporated sucrose or HFCS-sweetened low-fat milk, at 10% or 20% of calories, which represent the 25th and 50th percentile for adult fructose consumption levels (two to four times greater than AHA recommendations). After 10 weeks, there was no change in body weight in the entire group. In addition, there were no changes in total cholesterol, triglycerides, low-density lipoprotein (LDL, or bad cholesterol), apolipoprotein B (elevated levels of APO Protein B represent an increased risk for heart disease), or mean LDL particle size. Group assignment also had no effect on high-density lipoprotein (HDL, or good cholesterol). The AHA recommends that women and men consume no more than 100 and 150 calories, respectively, of added sugars Continued on page 40

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Dairy Foods | April 2011

Ingredient Technology

What’s Luo Han Guo? Monk fruit, the translation for the Chinese luo han guo, is a fruit grown in Southeast Asia, which is now available in a concentrated form for zero-calorie, all-natural sweetening of all types of foods and beverages. The unique zero-calorie sweetness of monk fruit concentrate comes from naturally occurring compounds in the fruit that are up to 300 times sweeter than sugar. In recent years, the monk fruit industry was industrialized with technological advancements in plant varieties, seedling cultivation, growing methods and fruit processing, creating a vertically integrated monk fruit supply chain. FDA’s no objection GRAS letter in 2010 was the final step in bringing monk fruit into mainstream America food formulating. “Our consumer research in the [United] States shows that moms and their families want natural, healthy choices for everyday food and beverage items such as cereals, juice drinks and yogurts. The same research shows that moms trust fruit for healthy nutrition,” says the New Zealand-headquartered supplier with Chicago-based offices. “We have conducted extensive sensory profiling that shows our monk fruit concentrate possesses a clean taste profile without the off notes found in some other sweeteners. Further, this testing has also shown cost and taste benefits for blending monk fruit concentrate with other natural sweeteners such as those based on stevia.”

each day, which is the equivalent of about 25 and 38 grams per day. However, data show that more than 90% of Americans consume more than that amount with an average consumption rate of 345 calories of added sugar, or about 86 grams per day, with less than half coming from added fructose in any form. (In addition to being a component of sucrose and HFCS, fructose is available as a stand-alone sweetener.) “Although this study is not license to overindulge, it does inform us that we can enjoy sugar in moderation as long as we are following a healthy lifestyle,” says James Rippe, a cardiologist and the study’s chief investigator. “That’s an important take-away for people like moms who may want to use added sweeteners to make healthy foods more attractive to their children.” Rippe is right. Sweeteners make many foods more palatable for picky eaters. Sweeteners (with chocolate) make milk more appealing to school children. Formulators have to remember that it’s the calories that count, not the sweeteners. And, not all sweeteners contribute calories. Earlier this year, Milford, Conn.-based Iskream Inc. introduced the first low-fat, no-sugar-added ice cream made with a stevia-based sweetener.

40

Dairy Foods | April 2011

Photo courtesy of BioVittoria

Monk fruit, also known as luo han guo, is the most recent natural, high-intensity sweetener to enter the U.S. marketplace.

Consumer desire for sweet foods is not going to go away, but formulators can help by blending sweeteners to obtain the best sweetness with the fewest calories. Many formulators are finding luck with stevia-based sweeteners. It’s been about two-and-a-half years since FDA first recognized the self-affirmed GRAS status of Stevia rebaudina plant extracts. Leaves from this plant, which is grown in Central and South America, have long been recognized as sweet. Numerous ingredient companies are extracting the sweetest compound from the leaves, the steviol glycoside known as rebaudioside A (reb-A), which is non-cariogenic, contains no calories and has a zero glycemic index, making it safe and suitable for diabetics. FDA has not actually permitted the stevia plant itself to be used as a food ingredient, only the reb-A extract, and only ingredients that contain 95% or more pure reb-A. With reb-A being one of about a dozen sweet-tasting compounds in the stevia plant, suppliers are differentiating themselves by reb-A content, as up to 5% of a steviabased sweetener can be something other than reb-A. Another emerging option is monk fruit, also known as luo han guo, which FDA recognized as GRAS in 2010. Monk fruit has been used for its sweet taste and healthy qualities for hundreds u of years. The small, vine-grown, subtropical fruit, which is indigenous to Southeast Asia, is packed with antioxidants and vitamins. The calorie-free sweetness of monk fruit is derived v from fro unique natural antioxidants in the fruit called mogrosides. (See (Se related story “What’s Luo Han Guo?”) At A Natural Products Expo West, the monk fruit sweetener ene supplier sampled a whey protein-based no-sugar-added orange cream smoothie. An 8-fluid-ounce serving contained ora 120 calories and 15 grams of sugar primarily from orange juice concentrate. Also at the show, the Kellogg Co., Battle Creek, conc Mich., Mich debuted Kashi Honey Sunshine cereal, which contains monk mon fruit and other sweeteners, including, as the name suggests, honey. The company touts the goodness of the product. No HFCS HF lambasting here.

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Innovations in Marketing, Merchandising & Technology

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Cover Story Photo courtesy of National Starch Food Innovation

Donna Berry

Product Develpment Editor

emember when yogurt only came in a cup and cream cheese in the form of a brick? Or when consumers made their own spinach dip by stirring dried vegetable soup mix and thawed frozen spinach into sour cream? And who would have thought Greek yogurt would be made in the United States, and by so many companies? Dairy’s healthful halo coupled with an incessant drive by processors to innovate has made today’s refrigerated dairy case the most dynamic it has ever been. And as the lyrics go, “you ain’t seen nothing yet,” as more than a dozen cultured dairy innovations have been introduced since the beginning of the year, and more are primed for a summertime roll out.

R

Greece is the word Without a doubt, Greek yogurt continues to drive innovation in the cultured dairy category. Enough so that Kraft Foods Inc., Northfield, Ill., a company that exited the yogurt business in 2005 with the sale of its Breyers brand, jumped back in with the introduction of Athenos Greek yogurt in November. “Adding a Greek yogurt to the Athenos family is an exciting next step for the brand,” says Marshall Hyzdu, brand manager. “Greek yogurt has become one of the fastest-growing food categories since its introduction into the United States about five years ago. Volume has doubled every year, with sales reaching approximately $500 million in 2010. Additionally, household penetration has already reached nearly 20%, surpassing many other food categories. It seemed only natural that Athenos, a leading line of authentic Greek foods in the marketplace, take 44

Dairy Foods | April 2011

their offering to the next level of taste and convenience by introducing a rich and creamy, authentic Greek yogurt. “We believe the category will continue to grow,” says Hyzdu. “U.S. consumers will continue to develop a palate for a larger range of global foods, while looking for foods that are nutritious, versatile and convenient. Consumers will also be moving toward foods with cleaner labels, including those without preservatives, artificial flavors or high-fructose corn syrup. (For a discussion on the latter, see page 38.) Clean and simple ingredient legends are what many authentic Greek yogurt manufacturers tout, as the straining process used to thicken the yogurt reduces or eliminates the need for stabilizers. Straining also increases protein content, another consumerappealing feature, as high-quality proteins such as those found in milk are associated with satiety. When consumers feel full, they eat less, and with many Americans carrying too much weight around, the concept of satiety-inducing foods is increasingly appealing. Hence, the time is right for Greek yogurt. To create a point of differentiation in what is becoming a crowded category, national players are putting a spin on their marketing efforts, as well as their product line. (See “It’s Love and War for Greek Yogurt Marketers” about TV commercials for Athenos and Chobani, page 46.) For example, Stonyfield Farm, Londonderry, N.H., will show Americans this summer that Greek yogurt can be consumed in a drinkable format. That’s right. The company’s organic Oikos brand will now include a smoothie format sold in four-packs of 6-fluidounce bottles. Marketed as being thick and creamy with 50%

Cover Story

Oikos is the first U.S. brand to offer a drinkable version of high-protein Greek yogurt.

more protein than traditional smoothies, Oikos Organic Drinkable Greek Lowfat yogurt comes in two varieties: Honey Vanilla and Pomegranate Berry. “With the growing popularity of Greek yogurt among athletes, foodies and people on the go, we recognized the need for a thick, creamy, proteinrich drinkable Greek yogurt that’s easy to take with you,” says Gary Hirshberg, president and CE-Yo. “Oikos Organic Drinkable Greek yogurt combines the portability of a smoothie with the high-protein nutritional benefits of Greek yogurt.” Stonyfield is also expanding its Oikos cup line with Honey Fig joining the smooth and creamy lineup, and Peach Mango, now part of the fruit-onthe-bottom range. Another national player, Sun Valley Dairy, Sun Valley, Calif., makers of Voskos Greek Yogurt, one of the first Greek yogurts to enter the U.S. marketplace, now offers YoGreek, the only dual-compartment cup of side-by-side Greek yogurt and granola. All consumers do is “lift & crunch,” an instruction that is cleverly imprinted on the YoGreek product lid. YoGreek comes in four different yogurt flavors: blueberry, honey, strawberry and vanilla. At the beginning of the year, Fage, Johnstown, N.Y., rolled out the Fage Total 0% Flavors line. This is the first time that the company’s nonfat Greek yogurt has been made available with flavors, which are: Blueberry-Acai, Cherry-Pomegranate, Honey, Mango-Guanabana and Strawberry-Goji. To support the introduction, the company recently launched a 45-second TV spot entitled: Plain. The commercial has a voice-over take the viewer through a poetic journey from “plainly plain” to “plain extraordinary,” the latter of which has become the brand’s new positioning line. Using live action and computer animation,, the viewer is held captive until the very p end, when it is revealed that the artistic display of milk, fruit and beautiful women is for Fage yogurt. wo To view the comm commercial, visit www.fageusa. com. On the regio regional side, Auburn Dairy Products, Auburn, Wash., is introAu ducing customers in d the Pacific Northwest to t Zoi Greek Yogurt. In select Midwestern markets, sel Y YoGreek offers consumers an interactive i package that allow allows them to control the amo amount of granola mixed into the yogurt.

Anderson Erickson Dairy, Des Moines, Iowa, now offers its own version of this Mediterranean delight. And other regional dairies have Greek yogurt in their plans. “We are always looking into new product introductions and listening to what retailers want when considering expanding their product line,” says Ted Barlows, assistant general manager/general sales manager, Hiland Dairy, Springfield, Mo. “Of course, the Greek yogurt trend is very hot and Hiland will be introducing a Greek yogurt line in the near future.” More than a cup “Because of Greek yogurt’s versatility, consumers will most likely begin to see it packaged in ways that allow for on-the-go snacking, as well as incorporated into food offerings such as dips, dressings or beverages, and integrated into the foodservice channel more prominently,” adds Hyzdu. This is already happening in the dip category. At the end of 2010, T. Marzetti Co., Columbus, Ohio, introduced Otria Greek Yogurt Veggie Dip in five varieties: Chipotle Cheese, Cucumber Dill Feta, Garden Herb Ranch, Salsa Cilantro and Spinach Artichoke. Santa Barbara Bay Greek Yogurt Dip made with Voskos Greek Yogurt now comes in a club store-size (24 ounces) container. The original retail product line from Santa Barbara Bay, Buellton, Calif., debuted about a year ago in 12-ounce tubs in five varieties: Cucumber Dill, Thai Three Pepper, Roasted Red Pepper & Asiago Cheese, Zesty Ranch and Spinach. The new variety — Garden Vegetable — is what comes in the club store pack. The dip is loaded with large pieces of fresh vegetables (artichokes, asparagus and carrots), dehydrated vegetables (carrots, leeks, onions, mushrooms and red bell peppers) and an array of savory spices. The company is also in the process of transitioning its 12-ounce tub product into a sleek, clear container that functions as an attractive serving dish. Continued on page 46 www.dairyfoods.com

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Cover Story

It’s Love and War for Greek Yogurt Marketers As more Greek yogurt brands enter the retail channel, manufacturers have had to turn up the heat in their marketing efforts. From putting passionate customers to discriminating grannies in the spotlight, here are two national Greek yogurt marketers who have taken very different approaches with onscreen advertising. Read more about these campaigns and Fage’s advertising efforts on page 10. On Valentine’s Day, Agro Farma Inc., Norwich, N.Y., debuted its first national advertising campaign for Chobani Greek yogurt. Entitled “Real Love Stories,” TV commercials feature true stories from “Chobaniacs,” the yogurt’s greatest fans who often share their Chobani love with the brand via social media platforms. To view the commercials and fan-submitted stories, visit chobani.com. Less than two weeks after Chobani’s love story campaign hit the air, Kraft Foods Inc., Chobani brings to life the stories fans have shared on social media regarding the Northfield, Ill., rolled out three commercials for great lengths they have taken to show their love for Chobani. the Athenos brand, with one focusing on Greek yogurt and the other two on hummus. The campaign is centered logue. Each yiayia brings her unique personality and approach on the simplicity of the product formulations, with respect for to the shoot. What all the yiayias have in common is their oldtraditional ingredients and yiayia’s approval of them. school beliefs, which they convey in blunt and honest opinions Who is yiayia? Greek for grandmother, the three yiayias of modern situations. To view the commercials, visit www. in the spots were cast in Athens, adding authenticity to the dia- athenos.com.

This Greek grandma approves of the Athenos yogurt this young couple is enjoying, but she lets them know that she is not too happy with their unmarried, cohabitating status. This is one of three commercials promoting the Athenos product line.

Larger-sized containers of Greek yogurt are becoming increasingly common, as this encourages use as something more than a grab-and-go snack. For example, because of its thick, rich, dense nature, it can be used as a bagel spread or fruit dip. This is what The Greek Gods brand, which was acquired by The Hain Celestial Group, Melville, N.Y., in July 2010, is likely hoping for with its two new flavors (honey blueberry and vanilla honey), which are only available in a 24-ounce multiserving cup size. To educate consumers about Greek yogurt’s cooking performance, Agro Farms Inc., Norwich, N.Y., developed a “CHO Conversion Chart” to make it easy for consumers to substitute Chobani for other cooking ingredients. For example, plain Chobani can be a direct replacement for sour cream, mayon-

naise or cream cheese in most recipes. To reduce the amount of fat used in some applications, one cup butter can be reduced to a half cup when one-fourth cup Chobani is also added. One cup oil can be replaced by three-fourths cup Chobani. The plain variety comes in 6-, 16- and 32-ounce containers. Yogurt for children Chobani is also into little portions for little tummies. Chobani Champions come in two kid-pleasing flavors: Honey-Nana and VeryBerry. Sold in four-packs, the 3.5-ounce cups are said to better accommodate a child-size appetite. After all, Greek yogurt is more satiating and nutrient dense. According to the new Packaged Facts report Kids’ Foods and Beverages in the U.S. 2011, yogurt designed just for chilContinued on page 48

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Dairy Foods | April 2011

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Cover Story

dren is a booming business, and one that will continue to thrive in upcoming years. “Retail dollar sales of kids’ yogurt products — cups, tubes and even containers that you squeeze and slurp — grew 12.7% annually from 2005 to 2010 thanks to an influx of innovative products,” says Don Montuori, vice president-publishing, Marketresearch.com, Rockville, Md. “We project growth will continue to be double-digit every year from now until 2015, with retail sales reaching about $1.3 billion in 2015.” And it’s no wonder, as market research firm NPD Group, Port Washington, N.Y., identified yogurt as the No. 1 food eaten as a snack by children 2 to 17 years old. It is also quite popular with babies, thanks to the extensive line of YoBaby products from Stonyfield Farm. The Hain Celestial Group is now ready to give Stonyfield some competition. Hain is a leader in frozen and shelf-stable foods and beverages targeted to kids, but has yet to take a stab at the refrigerated dairy category. That is about to change thanks to last year’s acquisi-tion of The Greek Gods Greek Yogurt. t. The first innovation scheduled to roll ll out sometime this summer is Earth’s Best st Organic Baby Yogurt, which debuted at the Natural Products Expo West show in March. Real sour cream functions as a base for dips, which are also now being promoted as cooking ingredients.

This new whole-milk yogurt is loaded with nine live and active cultures, including probiotics, and has been formulated for a baby’s nutritional needs, with each 4-ounce cup delivering 25% of the Daily Value for calcium, vitamin D and zinc, 2 grams fiber, 5 grams protein, and other important vitamins and minerals. Made with no refined sugars, the yogurt gets its sweetness from the addition of organic fruit and fruit juices. It will come in four-packs of four different varieties: Apple, Banana Mango, Peach Pear and Vanilla Prune. Easy on the tummy There’s more going on in yogurt than just Greek and kids’ innovations. For example, there are a growing number of lactosefree options for those who are intolerant to cows milk’s inherent sugar but want to reap the benefits of the live and active cultures and other nutrients that yogurt delivers. Bellwether Farms, Sonoma County, Calif., has So been selling its five-flavor bee (blackberry, blueberry, plain, (bla strawberry and vanilla) line stra of 66-ounce cups of sheep milk yogurt regionally for about yogu three years. At the beginning of this yyear, in response to consumer requests, the company made re product available for national the pr distribution. distrib

We put the squeeze on the cost of testing cheese LactoScope: the only milk analyzer that also works with cheese. Forget the expense of buying two dairy analyzers. The innovative LactoScope™ FTIR Advanced ﬁnds component levels of numerous dairy goods: raw milk, ice cream, and more. Add its application to liquefy cheese products, and you can even determine composition and quality of soft and hard cheeses! You can also squeeze out the industry’s lowest cost of ownership, because this analyzer is faster, simpler, and less expensive to maintain. Test all your preconceptions about dairy analysis with the amazing double-duty LactoScope.

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Dairy Foods | April 2011

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“Sheep milk yogurt can be enjoyed by many people who are intolerant of cows milk,” explains Lenny Rice Moonsammy, education and marketing coordinator at Bellwether. The same is true of goat milk yogurt. Sierra Nevada Cheese Co., Willows, Calif., just started rolling out 6-ounce cups of Capretta Goat Yogurt in four flavors: blueberry, plain, strawberry and vanilla. Redwood Hill Farm, Sebastopol, Calif., has been marketing goat milk yogurt for some time. The company recently decided to enter the cows milk yogurt business, with one key point of difference: the yogurts are made with lactase enzyme so that they can be labeled as lactose free. The products are branded Green Valley Organics, and in addition to yogurt, kefir and sour cream are also available as lactose free. “The Green Valley Organics products were developed with the same intent as our goat milk yogurts: to bring peace to the stomach,” says Ken Strunk, chief executive officer. And as a result of France’s Groupe Danone owning approximately 85% of Stonyfield shares, Stonyfield was able to license the Activia brand and is in the process of rolling out Stonyfield Organic Activia. The initial launch will be in four-packs of 4-ounce cups in either strawberry or vanilla flavors. According to Stonyfield research, 73% of its customers currently do not purchase Activia, yet 58% said they would buy it if it was available as organic. The product launch is an opportunity to reach 6.8 million new households for incremental sales. “We’re pleased to have the opportunity to offer a great product to organic consumers that they didn’t previously have access to,” says Hirshberg. Beyond yogurt Without a doubt, yogurt is the most replenished perishable product in the majority of supermarkets across the country. But cultured dairy product innovations are not limited to the yogurt category. For example, Smith Dairy Products Co., Orrville, Ohio, recently added Smith’s Buttermilk Ranch Dip to its product line-up. Made with real sour cream and a blend of ranch seasonings and spices, including garlic and onion flavorings, the dip is positioned not only as an accompaniment to chips and veggies, but also as a cooking ingredient. “Buttermilk ranch is a top-selling salad dressing, and it was a natural fit for us to use as a dip flavor,” ssays Penny Baker, director of marketing. “What I like about the flavor is that it can be used with snacks, but it b also works as a versatile ingreals dient in different recipes — die from soups, to wraps and casseroles.” To promote its use in sero cooking, the company develcook oped a number of recipes that consumers can access through consu the w website. Formulating with sea salt allows for a 15% reduction in sodium in Anderson Erickson’s low-fat cottage cheese. Continued on page 50

Cover Story

Barlows agrees that using dips in recipes is a growing trend, and one that is driving innovation in the refrigerated dairy dip category for Hiland Dairy. “We are noticing more and more customers contributing recipes using our dips to make their own unique side dishes like pinwheels and seven-layer dips,” he says. “Unique dips, such as our new Jalapeño Fiesta dip have quite the loyal following. Hiland recently added this new spicy dip and it has been onee of our best sellers ever since.” Hiland also recently added sini gle-serve cottage cheese to its retail lineup. “Several schools and institutions expressed a need for a single-serve cottage cheese, so we first developed this product to serve their needs,” says Barlows. “Due in part to the success at the schools, we expanded distribution to retail. The single-serve cottage cheese snack cup is sold to consumers in a four-pack, as we found our customers are always looking for convenience. They’re perfect for lunches, picnics or just as a snack on the go.” Anderson Erickson developed a cottage cheese with 15% less sodium than its original product. This is accomplished through the use of sea salt, and is appropriately called AE Dairy Lowfat Cottage Cheese with Sea Salt. This product was in development for several years and included side-by-side taste testing. “Because the sea salt grains we use are finer, we were able to get more salt flavor coverage even though we were reducing the amount of salt we used,” says Miriam Erickson Brown, president and CEO. The introduction of AE Lowfat Cottage Cheese with Sea Salt coini cides with the new Dietary Guidelines recommending Americans reduce their sodium intake drastically. If that sea salt comes from the Mediterranean, maybe there’s a Greek connection that can carry over to cottage cheese as well other cultured dairy products that contain added salt. Anything is possible in this dynamic category.

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Dairy Foods | April 2011

Noteworthy Recent Introductions In February, Walmart stores became the exclusive distributor for enLiven low-fat yogurt manufactured by Ganeden Biotech Inc., Cincinnati. “Yogurt has long been touted as a healthy breakfast and snack food,” says Carl F Freund, vice president of consumer products aat Ganeden. “We believe Walmart shoppers w will enjoy our tasty new enLiven yogurt with b beneficial probiotics, as it is not only good for yyou and your whole family, but it is affordably priced to he help p save yyou money. y”

The Dannon Co., White Plains, N.Y., takes its unique crush cup concept to the next level with Double Crush Cup. Each 4-ounce cup contains two kidfriendly flavors of yogurt that come togeth-er when the cup is crushed.

Ontario, Canada-based S Skotidakis Goat oat Farm has developed R Ranch Yogurt Dip, which is made with strained Greek probio biotic yogurt based on both cows and goats milk.

In p private label, Safeway Inc., Ple Pleasanton, Calif., now offers 6 6-ounce ou cups of Lucerne Greek yoogurt in honey, plain, strawberry and vanilla varieties.

W White Wave Foods, B oululder, Colo., a business of Dean an Foods Co., Dallas, is rolling ing out Horizon Organic Cream am Cheese in 8-ounce bricks. Prevviously only sold as a spread in tub fformat, the new bricks can be used in baking and cooking applications. Varieties are original (full fat) and reduced fat (30% less fat than original).

Heluva Good!, a brand of HP Hood LLC, Lynnfield, Mass., adds Limited Edition Buffalo Wing to its sour cream dip line. The dip features fiery hot buf-falo wing sauce blended with cool, l, creamy blue cheese that functions not ot only as a veggie and chip dip, but also so as a condiment.

We look at things a little differently. Because we’re not just a flavor company, we’re your product development partner. And when that happens, anything is possible.

Food Safety

New or improved analytical systems save time and ensure quality. Donna Berry

Product Development Editor

2010 consumer study sponsored by the Produce Safety Project at Georgetown University, Washington, D.C., found that health-related costs of food-borne illnesses total $152 billion a year, which includes the costs of medical bills, lost wages and lost productivity. That total is more than four times that of earlier estimates calculated by USDA and does not take into account food industry costs associated with a product recall. Recalls occur not only for safety issues, but for quality reasons, too, and can be detrimental to a company’s bottom line. For example, a little less than a year ago, the Kellogg Co., Battle Creek, Mich., recalled 28 million boxes of select cereals after consumers complained that the boxes had an unusual smell and flavor, which the company blamed on a chemical in the box liner. Fallout from the massive recall resulted in a decline of 5% for North American retail cereal internal net sales in 2010. Kellogg might be able to handle this loss, but many small dairies would have to close up shop.

A

Parameters to monitor There are several critical safety and quality control points that should be monitored within all dairy processing facilities. Some tests (i.e., antibiotic, somatic cell, adulteration, composition, etc.) are performed on each tanker delivering milk and also for each supplier on a regular schedule. Other tests (i.e., allergen detection, vitamin levels, etc.) are performed only within the context of production at regularly scheduled intervals. A few tests are performed throughout the dairy supply chain (i.e., milk composition, alkaline phosphatase, pathogens, etc.) to ensure quality, safety and sound nutritional value from farm to table. With an increasing number of consumers reading product labels, it is imperative that a product deliver what it promises. For example, dairy foods manufacturers must continuously monitor product composition of both raw materials and finished product.

This is to ensure that the dairy foods consumers purchase deliver on the parameters specified on the Nutrition Facts and defined by the ingredient legend. This is particularly important for bone-building nutrients that many consumers trust they are receiving from dairy foods, as not only is milk an inherent source of calcium, but FDA mandates vitamin A and D fortification of fluid milk. With vitamin A and D deficiencies recognized as serious medical concerns in the United States, ensuring sufficient delivery of these nutrients is a dairy processor’s responsibility. Quality control testing is essential to ensure that milk delivers the right amount of these vitamins; too much is toxic and too little provides no benefit. An enzyme-linked immunosorbent assay (ELISA) testing kit that measures vitamin A and D content in fluid milk in as little as two hours is now available to quality control technicians. The testing of milk can now be completed before shipping, allowing adjustments to be made to prevent under- or over-fortification. The test is based on a proprietary rapid extraction process for the vitamins followed by quantification of vitamin content using proprietary monoclonal antibodies. To avoid violating state and federal government regulations regarding total solids content of dairy foods, a new rapid, efficient gravimetric moisture and ash analyzer can assist. Using the accepted Babcock method for determining percent butterfat along with a gravimetric solids analyzer, lab techs can determine percent total solids, percent butterfat and percent solids-not-fat. The latter consists mainly of minerals, protein and lactose. The new gravimetric analyzer tests for non-organic material, mainly minerals, which allows for verification of calcium, phosphorus and potassium content. Further, the analyzer also measures water content, which is an important quality parameter, as excess moisture not only negatively impacts product appearance (i.e., syneresis), but it also can promote microbial growth and premature spoiling. Thus, quantifying moisture content helps determine product shelf life. Continued on page 54

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Dairy Foods | April 2011

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Food Safety

Introduced last year, another supplier offers a process analysis system based on high-resolution diode array technology. It provides non-destructive analysis of a variety of products, including dairy foods, directly in the process line without bypass. The analyzer is housed in a cabinet mounted at the relevant location in the production area. Measurements are displayed in the control room and results can be fed into a regulation system for closed-loop automatic control. The solution helps to optimize the use of raw materials and to consistently run production closer to target specifications. Yet another supplier now offers an instrument designed for a wide range of component analysis, including fat, protein and lactose. The multicomponent analyzer uses an industrial Fourier transform spectrometer (FTIR) that captures the complete infrared absorption spectrum of the milk sample for component analysis. Collecting the complete spectrum allows the calibration to be based on all spectral characteristics of each particular component. The infrared spectrum is permanently stored so that at any time in the future, other calibrations may be retroactively applied to the data. Control is integrated into a single Windows-based software program. Extensive diagnostics are collected so the user can be assured that the instrument was performing optimally when the sample data was taken. And because a full set of diagnostic readings is stored with each sample run, an audit trail exists to validate the state of the instrument during data collection. The system is engineered for dairy plants and laboratories that require a highly reliable and accurate instrument for performing individual tests on a variety of milk products. Another new milk analyzer is designed for milk and cheese processors that require highly cost-effective dairy component analysis. The instrument uses a mid-infrared (MIR) filter to measure

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Dairy Foods | April 2011

specific bandwidths for the most commonly measured dairy components in milk. Through access to specific software applications, dairy processors can use the analyzer to quantify fat, protein and total solids. The instrument processes up to 150 samples per hour, offers auto-cleaning and sample heating capabilities, and can be ordered with a freezing-point depression option. A new low-cost, easy-to-use microprocessor measures both pH and titratable acidity. These two fundamentally different conventions for expressing acidity in dairy products are equally important to ensuring product quality throughout shelf life. Titratable acidity measures total acidity, while pH indicates the acid strength. This new microprocessor employs a titration method that has a potentiometric end-point determination at a pre-determined pH value. This eliminates the subjective end-point color-change detection determined by the human eye, and instead employs the sensitivity and accuracy of a pH sensor, eliminating the chance of error. Let’s not forget that proper sanitation is vital to ensuring food quality and safety. If not removed by thorough cleaning, allergens, microorganisms and food residues can affect product safety and shelf life, which can lead to ingredient cross-contamination and recalls. The presence of undeclared food allergens, in particular, has been the reason for numerous recalls this past year. A food allergy is typically an immune system response to a protein in food that the body mistakenly believes is harmful. Even minor exposure to a food allergen can cause symptoms from mild skin rashes to fatal anaphylactic shock. Cross contamination during production can occur, so that residues of food allergens from different products show up in the most unlikely places. Rapid tests are now available for in-house labs to continuously check for allergens to ensure that contami-

Going Clean, Lean and Green in the Lab Quality assurance and product safety professionals are increasingly turning to rapid microbial methods (RMMs) as a way to satisfy distribution deadlines while ensuring that only safe products are sent to market. A number of additional benefits of RMMs exist and should be considered in light of current industry trends toward sustainability, connectivity and the increasing conversion to aseptic packaging. Sustainability. Many food and beverage manufacturers overlook the micro lab when it comes to increasing their company’s sustainability profile. Many traditional testing methods generate large amounts of waste and can lead to increased water and energy usage. RMMs provide a sustainable alternative by completing tests faster and with less waste. RMMs allow products to be incubated, tested and released in as few as 24 hours — resulting in reduced inventory and warehouse space. And, a faster production cycle means products get to market faster. Connectivity. Advanced software enables manufacturers to access test results for any product at any testing site with a network computer. This provides departments with the ability to view test results around the clock, improving visibility and increasing productivity. The software works by incorporating a multi-user interface that enables multiple RMM instruments to send results to a centralized location. In addition, the software that supports some of today’s new RMM systems helps companies simplify and streamline USDA and FDA compliance by allowing manufacturers to track and trace products and access data onsite or remotely. Aseptic packaging. Many food and beverage manufacturers are embracing aseptic packaging in order to meet increased consumer demand for products that are natural, organic and free of preservatives. Compact and space-saving aseptic packaging also facilitates sustainability by utilizing less shelf and warehouse space, cutting shipping costs, reducing energy expenses, allowing delivery to more locations and even enabling the regular delivery of certain products to remote areas for the first time. Because the goal is to produce a sterile product, goods are far less likely to have any microbial bioburden present, meaning there is rarely a need to identify any organisms. A rapid screening, which quickly indicates the presence or absence of microbial contaminants, makes it easier to safely release the production run, while also enabling a faster response to contamination events. Food and beverage manufacturers have relied on RMMs to deliver products to market safely and quickly for more than a decade. In today’s atmosphere of clean, lean and green, they make more sense than ever. Source: Celsis Rapid Detection

nated product does not make it out of the manufacturing facility. Easy-to-use, accurate and affordable food allergen detection systems can be used on incoming ingredients, prepared foods, equipment and cleaning supplies. In conclusion, suppliers are continuously working to develop increasingly sensitive tests to reduce the incubation time needed for end-product testing, as well as solutions that deliver the highvolume throughput required by large-scale processing facilities at an affordable price. Tests will continue to become more accurate predictors of safe, quality products for consumers.

Food Safety Photo by Vito Palmisano

The dairy industry continues to go for the long haul to uphold food safety measures and produce premium quality products. Marina Mayer

Executive Editor

ast year, in response to an outbreak of a rare strain of E.coli 0157:H7 reported in cheese samples sold at Costco Wholesale stores, based in Issaquah, Wash., the Food and Drug Administration, Washington, D.C., inspected the Bravo Farms Cheese processing facility in Traver, Calif. According to an FDA report, inspectors found: • Deficiencies in plant design. • Failure to manufacture foods under conditions and controls necessary to minimize the potential for growth of microorganisms. • No reasonable precautions being taken to ensure that production procedures do not contribute contamination from any source. • No effective measures being taken to exclude pests from the processing areas and protect against the contamination of food on the premises by pests. • Suitable outer garments were not worn to protect against contamination of food, food contact surfaces and food packaging materials. • Failure to provide hand-washing and hand-sanitizing facilities at each location in the plant where needed and wear beard covers where appropriate. Azteca Linda Corp. received an FDA warning letter as a result of federal inspectors finding Listeria in its Brooklyn, N.Y., cheesemaking facility. In July 2010, Azteca recalled its Queso Fresco (fresh white cheese) and Queso Hebra (fresh white string cheese) due to contamination, and recalled these same products again in August 2010. It also recalled its Queso El Azteca brand of ricotta cheese for contamination. Inspectors found: • Standing water in the cracked and pitted floor directly underneath the stainless-steel Queso Fresco table. • Standing water in the cracked and pitted floor beneath the pasteurizer and in front of the exit of the processing room. • Broomstick bristles and a black dust pan stored in the processing room. Industry observers say dairy processors, in general, run safe and clean plants. But many processors are going the extra mile to ensure they’re producing the safest products possible. Processors must comply with state and federal laws and follow general, good manufacturing practices. Marina Mayer, executive editor of Dairy Foods, talks to some organizations to find out what each law entails, how they impact the dairy industry and what processors are doing to follow the rules.

L

Making it a law On Jan. 4, President Barack Obama signed into law the Food Safety Modernization Act (FSMA), which modernizes the food safety system to better prevent illness and better respond to outbreaks. It’s designed to give the FDA and the Secretary of Health and Human Services, Washington, D.C., the authority to regulate food, suspend registration of a food facility and order a recall when necessary. It also gives FDA access to plant records during routine inspections and holds manufacturers accountable for assuring the safety and quality of the ingredients they use, says Clay Hough, senior group vice president and general counsel for the International Dairy Foods Association. “The biggest impact of the FSMA on IDFA member companies will be the new rules that impact daily operations,” he adds. “These include food safety and preventative controls plans, supply-chain management, record maintenance and access and food defense plans.” The scope of the FSMA FSMA is applied to all foods, including dairy, Hough says. “So, during the legislative process, IDFA worked with Congress to try to avoid duplication. For instance, language was included that authorizes FDA to coordinate with state inspection programs such as the state-based inspections under the Pasteurized Milk Ordinance (PMO) to meet the FSMA’s inspection requirements,” he adds. “Under the Memorandum of Understanding with the National Conference on Interstate Milk Shipments (NCIMS), we expect FDA will continue to rely on inspections for Grade ‘A’ milk facilities conducted by the states to ensure compliance with the PMO. The states have the needed expertise to conduct these inspections, so FDA can apply its inspection resources to other areas. The FDA should conduct audits of the state inspection programs to ensure nationwide consistency. IDFA supports FDA’s continued work with the NCIMS to be sure that the PMO is updated, as appropriate, to be consistent with FDA food safety standards under the new law.” In addition to the Grade “A” Dairy PMO programs, dairy plants must also adhere to strong, ongoing Good Manufacturing Practices (GMPs) programs, Hough advises. “These include maintenance of the plant surroundings and the integrity of the plant facility to prevent entry of pests, extensive training of processing personnel regarding personal hygiene and plant operations, detailed maintenance and cleaning of the processing facility and its equipment, correct storage and handling of food ingredients and packaging and proper temperaContinued on page 58

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Dairy Foods | April 2011

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Food Safety

ture control of the food product during processing and storage,” he notes. Because of all of these food safety measures, dairy products are among the safest and most regulated foods in the country, Hough adds. “Dairy farms and plants must meet stringent federal and local regulations, including those developed by the U.S. Department of Agriculture (USDA), the FDA and state reg-

ulatory agencies. Dairy plants are inspected frequently by state agencies, the FDA and USDA. Milk and dairy foods go through extensive and rigorous safety and quality protocols before they reach the grocery store. In fact, according to FDA, today less than 1% of foodborne illness outbreaks in the U.S. involve dairy products,” he notes. So then why the call for a national overhaul of dairy processing plants?

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Dairy Foods | April 2011

Food recalls have risen dramatically over the past three years, according to Hough, with the ice cream category experiencing some of the hit thanks to an increase in recalls of ice cream products that used potentially-contaminated peanuts, peanut paste and nuts for flavoring. However, other dairy products such as milk, yogurt and cheese were not impacted. “In fact, over the past three years, milk and cultured dairy products have had only a few recalls, but recalls in cheese increased in 2010 due to increased surveillance and testing for pathogens in soft cheese and cheese made from raw milk,” Hough states. Another act to follow When it comes to food safety in the dairy industry, there are two main causes for concern — biological and chemical contamination. That’s why the Federal Food, Drug and Cosmetic (FD&C) Act plays a significant role in controlling food safety issues by giving FDA the ability to oversee the safety of food, drugs and cosmetics. This act was introduced in 1938 and has since been amended several times. “By and large, the dairy industry does a good job of ensuring compliance with the FD&C Act, but there is always room for improvement,” says John Sheehan, director, division of plant and dairy food safety for FDA’s Center for Food Safety and Applied Nutrition. “The dairy industry should continue to work to ensure that the foods it produces are safe to eat and not adulterated within the meaning of the FD&C Act.” For instance, raw milk and raw milk products are of particular concern, as well as certain types of raw milk cheeses, such as fresh, un-ripened, soft, soft-ripened and even some semi-softs, due to the fact that they’re not pasteurized. According to the FDA’s website, most of the milk sold in the United States is pasteurized, where it is heated to 161°F for 15 seconds. But many of today’s consumers are getting “back to nature” by turning to products made with raw milk, including cheese and yogurts, because they are said to be more nutritious. The FDA says that’s not true. “Although the heating process slightly affects a few of the vitamins — thiamine, vitamin B6 and folic acid within the B-complex and vitamin C — the changes are not significant. Meanwhile, there is a risk that milk could be contaminated by environmental factors such as soil or animal feces, animal diseases or bacteria on an animal’s skin,” the site says.

Food Safety

“Manufacturers of dairy products generally must endeavor to ensure that their manufacturing environments remain free of environmental pathogens and that their products do not contain pathogens,” Sheehan says. Processors have to watch for allergens, too. Publix Super Markets, Lakeland, Fla., for example, issued a voluntary recall in January for its private-label Premium Light Tiramisu ice cream, which may contain coffee almond fudge ice cream bits, or an undeclared almond allergen. “One of the greatest reasons for recalls is undeclared allergens in ice cream,” says Gary Ades, president of G&L Consulting Group LLC, Bentonville, Ark., and chairman of the executive education council for the Food Safety Summit, a sister publication of Dairy Foods, Washington, D.C. “Dairies are working to assure that products are not contaminated after any biological ‘kill’ step (e.g., pasteurization).” Concerns also rise when dealing with raw milk, Ades says. “It is hazardous. The use of raw milk in cheesemaking is being reevaluated regarding the length of aging that is needed to mitigate biological risks,” he adds. As a result, dairy processors are kicking their food safety steps into high gear by enhancing raw ingredient supplier approval programs, reviewing and updating internal processes and procedures, implementing tighter documentation policies and upgrading software, equipment and traceability. “Any product is susceptible to contamination if proper processes and procedures are not in place,” Ades notes. “If a product does not have a kill step or may be contaminated from ‘add-ins’ that are incorporated after the kill step, they pose a risk.”

Dairy processors keep it safe Regardless of how many laws are in place, the dairy industry has been ahead of the curve in recognizing the need for real-time tracking and traceability, Hough says. “Companies know where their raw ingredients come from and where their products go when they leave the plant. Recording all ingredient lot numbers is industry practice for all stages of production and processing,” he adds. “[Plus], the advances in herd management and animal health coupled with advances in processing equipment design, installation, operation and a better understanding of product flow throughout the facility have contributed to a better business operation.” On the flip side, any regulation makes it more difficult for processors to market their products and find the financial means to develop new products that meet or exceed standards, says Jim Dimataris, director of processor relations for California Milk Advisory Board, South San Francisco, Calif. Yet, the dairy industry continues to go the extra mile in ensuring proper safety measures. “The dairy industry has always been the leader in cleaning and sanitizing its plants,” Ades says. “There are no magic bullets. The basics of good manufacturing practices, especially cleaning and sanitizing, temperature control, employee training and management commitment are the keys to food safety.” For more about the Food Safety Modernization Act, scan this image with your smart phone. Or, go to http://www.fda.gov/Food/FoodSafety/ FSMA/default.htm

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Guida’s Milk

REPORTS

uida’s Milk, New Britain, Conn., succeeds by co-packing, finding customers to buy its excess cream, developing new products and manufacturing non-dairy beverages, such as water, orange juice and iced tea. While the plant has been modernized, what hasn’t changed is Guida’s commitment to quality products and processing. Its new larger plant (see page 68) helps Guida’s service and acquire large-volume customers.

G

Pumps and Valves umps and valves are at the heart of any processing plant. They control the flow of fluid milk, cheese curds, ice cream mix and other dairy products through a facility. Makers of this equipment share their knowledge and what plant managers should look for in pumps and valves. Page 74

P

Equipment Showcase We focus on fillers. Page 86

SUPERCOW joins Guida’s executive team (from left): Alexander Guida, chairman of the board; Wesley Sliwinski, director of plant operations; James Guida, vp sales; David Drezek, director of distribution and customer service; Michael Young, executive vp; and Michael Guida, president and ceo.

Fogg Co.

It’s Not About Us By focusing on the dairy needs of its customers, Guida’s Milk has been able to grow its co-pack and private label business, serve food manufacturers’ needs and grow its own brands. Jim Carper Chief Editor

fast forward what’s coming in May… Dippin’ Dots, Paducah, Ky. Don Wilson on “Beyond the Filler” Labeling for dairy foods Caps and closures

ndependent milk processors have it tough. They are a dwindling breed. Their competition tends to be multistate conglomerates. Migration at the retail level from branded to privatelabel products have burned up brand loyalty by turning milk into a commodity, often selling the beverage as a loss leader. Then there is OPEC. It might not

I

be obvious to the consumer, but milk processors depend heavily on the price of oil. Not only do processors get socked at the gas pump when they refuel their delivery vehicles, but they also pay more for petroleum-based plastic resins to form bottles and containers. Despite these conditions, independent milk processors can thrive. Take

Maintenance equipment www.dairyfoods.com

61

Corporate Profile Among Guida’s branded dairy beverages is Healthy Moo, a school milk product made without highfructose corn syrup. The processor produces its own brand of Florida orange juice. Its line of flavored punch is called Exotico.

Guida’s Milk of New Britain, Conn. The company succeeds by co-packing, finding customers to buy its excess cream, developing new products and manufacturing non-dairy beverages, such as water, orange juice and iced tea. Guida’s is a family business. Mike Guida is president. His brother Al is chairman of the board. James Guida is senior vice president, and third-generation family members hold management positions in the company. Annual revenues were about $120 million in 2010. The company ranked No. 69 on the Dairy 100, Dairy Foods’ list of the nation’s largest dairy processors. Guida derives as much as 30% of its revenues from co-packing. Retail sales of its own dairy and non-dairy brands to supermarkets and convenience stores account for about 25% and foodservice sales are 15%. Guida’s supplies milk to in-state school districts and many of Connecticut’s state universities. Cross-border customers include the University of Massachusetts at Amherst and the University of Rhode Island. Additional revenue comes from milk and cream sales to food manufacturers and from broadliners that deliver dairy and other food products. The company is organized into three functional areas: administration (including sales, service and IT), plant operations and distribution. The management style is democratic, says executive vice president and treasurer Michael Young, the first non-family member to serve in an executive capacity. Executive committee members meet weekly. A board of directors, drawn from various disciplines, helps provide oversight, governance and direction. Young, who joined the company 20 years ago after working for 10 years in public accounting, says the board challenged Guida’s to write a strategic plan. Prior to the plan, the company was “plant driven and not customer focused,” Young says. Guida’s made a decision to grow by becoming a low-cost processor that could serve co-pack partners and private-label marketers, as well as

maintaining its own brand. Young says the plan showed the company that “it’s okay not to make your own products as long as you’re fulfilling the customer’s needs.” Processing non-branded and copack milk allows Guida’s to pump volume without any associated marketing expenses. Guida’s has more than 600 SKUs to manage. As a result of the strategic plan, the company planted its flag as a low-cost provider. Activity-based accounting helps Guida’s monitor efficiencies and to identify costs to drive out. The company benchmarks its performance against other processors tracked by Carl Herbein + Co., Reading, Pa. Guida’s co-packs national brands, including Organic Valley, based in La Farge, Wis., and regional ones, such as The Farmer’s Cow of Lebanon, Conn. “They take good care of us,” says Louise Hemstead, Organic Valley’s chief operating officer and a long-time customer. “They are very accommodating.” She says she likes the cold separation, especially for skim milk, because it gives the beverage a better mouthfeel. Guida’s was “a key component in us getting started,” says Robin Chesmer, the managing member of The Farmer’s Cow, a co-operative of six dairy farmers. “They let us get in the milk business,” he says. Guida’s processes the co-op’s milk in gallons, half-gallons and half-pint containers, and half-and-half in pints and quarts. The Farmer’s Cow also buys ice cream mix from Guida’s and uses the processor’s distribution services. Satisfying the customer By deciding to be a low-cost processor, Guida’s made a change to being customer-focused from plant-focused, Young says. Thus, it manufactures bulk containers, like the 320-gallon totes for food processors who don’t want a large tanker of cream but need quantities greater than 5-gallon bags. Guida’s processes more milk and creates more cream than it can use, so it has found ready buyers in food processors. Blount Seafood, Fall River, Mass., buys 320-gallon totes of cream for use in its soups and prepared foods. YoCrunch of Naugatuck, Conn., is a customer of fluid milk. Pie makers are buying Guida’s Sweet and Creamy topping. (That product was originally introduced at retail but consumers never took to it, so Guida’s reformulated the product and found takers among large-scale users.) Guida’s processes milk for most IGA grocers in Connecticut and sells its brand in convenience stores. James Guida describes the Continued on page 64

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Dairy Foods | April 2011

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Corporate Profile Guida’s Got Milk (and Orange Juice) Product

Sales

Change

Units

Change

$10.5 M

15.2%

4.1 M

15.8%

Whole milk

$4 M

13.3%

1.7 M

14.9%

Orange juice

$662,099

5.4%

281,423

16.6%

Skim/lowfat milk

For the 52 weeks ended Feb. 20, 2011 Source: SymphonyIRI Group, Chicago

changes in the retail grocery industry that have had an impact on all milk processors. Limited-assortment stores like Aldi have come on the scene. General merchandise retailers and warehouse clubs have added food to their stores. Guida’s serves private-label customers in both of those channels: Family Dollar, based in Matthews, N.C., and Costco, Issaquah, Wash., (added in February 2011). David Drezek, director of customer service and distribution, says the customer needs and demands are “priority No. 1. We have invested financially and with personnel to become a customercentric company.” All customer issues are documented in a new customer retention management software program. Each issue is left open until the customer is satisfied with the resolution. “Customers love that we call them back several weeks after the issue has been resolved to ensure that they are satisfied and there have not been any reoccurrences,” he says. While Guida’s provides co-packing services, it is also a customer for other dairy plants. The company outsources the production

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Dairy Foods | April 2011

of its sour cream, cottage cheese, butter and single-serve waters. Guida’s bottles its own gallon containers of spring water. Products and introductions Mike Guida admits his company is not a new-product innovator. It does not have the staff or budgetary means to create new beverages. Guida’s does stay atop of food trends and reacts to the market. For example, school-milk product Healthy Moo is a sucrose-sweetened flavored milk. Guida’s replaced high-fructose corn syrup with sugar. Another new product, the aforementioned Sweet and Creamy pie topping, has found favor with dessert manufacturers. Guida’s sells a range of branded milk – whole, 2%, 1% and nonfat – in paper and plastic 4-ounce, 8-ounce, 10-ounce, 16-ounce, quart, one-half gallon and gallon containers. It sells a 5-gallon polybag dispenser for foodservice and a half-pint product for vending machines. On the flavored milk side, Guida’s processes low-fat chocolate milk (in paper half-pints and 5-gallon polybags), Dutch chocolate milk (in 16-ounce and quart plastic containers), low-fat Dutch chocolate milk (one-half gallon plastic containers) and 1% chocolate milk (in 10-ounce paper containers). Vanilla and chocolate soft-serve ice cream mix is available in 5% and 10% butterfat concentrations in 5-gallon polybags. Guida’s produces 14% and 16% butterfat ice cream mix in 5-gallon polybags. Exotico is the name of Guida’s punch brand, available in strawberry, pineapple, tropical and citrus flavors and sold in plastic gallon

Corporate Profile containers. Guida’s bottles Florida orange juice in 4-ounce, 8-ounce, pint, quart, onehalf gallon, gallon and 5-gallon containers. Some SKUs have calcium added. A line of 16-ounce non-dairy drinks is available in fruit punch, grape, lemonade and orange flavors, and Guida’s makes iced tea. Guida’s distribution arm delivers other dairy beverages, including Hershey’s milkshakes, Lactaid milk and International Delight flavored coffee creamers. Food items include eggs, cheese and lunchmeat.

ity. He is an opinionated and outspoken advocate for milk and milk products. The chairman is also fiercely supportive of Guida’s independent status. Customers need an alternative to large milk processors, he says. A key tenet of the company’s management philosophy is “treat customers right,” which is a competitive

Marketing Guida’s holds its own against larger rivals. Measured in dollars, its whole-milk sales rose 13% with units increasing nearly 15% in the fourth quarter of 2010. In a recent 52-week period, dollar sales of Guida’s whole milk rose 13.3%, while one major competitor’s sales rose 9.7% and the other’s dropped 3.8%, according to data compiled by Symphony IRI, Chicago. James Guida says the company has a small marketing and advertising budget. The milk processor piggybacks on MilkPEP campaigns, and while it does use supermarket circulars and television advertising, Guida’s takes advantage of cause marketing and community events. It supported Roses for Autism, a training and employment program based out of Guilford, Conn., by promoting the organization on specially marked gallons of 1% milk. The dairy regularly participates in Susan G. Komen For the Cure events. Guida’s Milk is the largest sponsor for the Brain Injury Association of CT (BIAC) and assists in coordinating its annual fundraising golf tournament. Sports tieins include promoting a family night package with the Connecticut Whale of the American Hockey League, promotions with the Rock Cats, a minor league baseball team from New Britain and sponsoring a race car for Gallo Racing. Its caped and masked SUPERCOW mascot makes personal appearances. Guida’s was the first milk processor to develop and print photos of missing children on milk cartons. Later, its anti-drug message campaign resulted in invitations to a lunch with President Ronald Reagan.

advantage, Guida says. He notes some of the company’s other advantages, including its flexibility to serve customers, the plant itself and the employees. Having family members involved at all levels of the company means that a customer who asks to speak to an owner can usually be accommodated, he says.

Continued on page 66

SQF Level 2 Certiﬁed

Industry involvement Chairman Al Guida, who no longer is involved in the day-to-day operations, serves the company in a consulting capacwww.dairyfoods.com DF-Croc-half-left.indd 1

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12/15/10 1:50 PM

Corporate Profile Guida serves on the Milk Industry Foundation board of the International Dairy Foods Association, Washington, D.C., and is an advisor to Milk Processor Education Program. Vivien P. Godfrey, ceo of the Washington, D.C.-based MilkPEP, says Guida brings the perspective of a small, independent processor from the East Coast. “It’s important to have that representation,” she says. Guida is not shy about sharing his opinions during conference calls or in-person meetings, Godfrey says. Guida says membership in these organizations is invaluable because he can stay current and informed on dairy-related issues by talking with legislators and milk industry peers. President Mike Guida feels as strongly about treating customers like family. Even non-family employees say they feel like a part of the family. “We have better help than the competition,” Mike Guida says. Asked to name what’s important, Guida mentions family and farmers. Size is important, but he adds, “it’s not everything. Bigger isn’t necessarily better.” Money isn’t everything, either. Cold separation of raw milk leaves behind a little more cream in the skim. Over the course of a year, that little bit of cream adds up to gallons of product that could be re-sold. But the retained fat produces a better-tasting skim, which is another example of treating the customer right. Guida says he heads to the production floor when he needs to clear his head. He can operate every piece of equipment, he notes with satisfaction. His children know how, too, having worked all the jobs in the plant. Daughter Ashley Davis, whose title is call order lead, also can drive a 10-wheeler, he says with pride.

All in the family: Al Guida (from left); Ashley Davis, call order lead; James Guida; David Zydanowicz, security; Mark Zydanowicz, sales representative; Michael Guida and Jonathan Guida, distribution manager.

Guida’s turns to other dairy processors to make its butter, sour cream and cottage cheese.

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Dairy Foods | April 2011

Looking ahead Ashley, her brother Jon (distribution manager) and their cousins Mark Zydanowicz (sales representative) and David Zydanowicz (security) are members of the third generation. They are spearheading the company’s sustainability project this year, which will touch on use of natural resources and recycling. Guida’s, as well as other milk processors, have been helped by the public’s interest in where their food is sourced, how it is made and the organic movement. Years ago Guida’s stopped taking milk from cows treated with rBST. Its commitment to manufacturing quality products is found in little things that all add up. It uses an inner-foil cap on plastic bottles that keeps milk safer, fresher longer and preserves the quality. Cold separation is a gentler way to handle milk and preserve its integrity. The company headquarters is in a quiet residential neighborhood. SUPERCOW sits atop the roof and the name GuidaSeibert is on the front door of the headquarters. Mike Guida’s father, Al Guida Jr., started delivering 13 quarts of milk out of the back seat of his car in 1929 and grew the business from there. In 1947, Al Guida Jr., acquired J.E. Seibert and Son, which was established in 1886. Al Guida’s brother, Frank, joined him at that time. Incorporated under the name The Guida-Seibert Dairy Co., the dairy is celebrating its 125th year anniversary in business this year. Guida says it is important to carry on the business for the next generation. With the changes the management team has made in customer focus, customer mix and plant improvements, the company is in a good position to continue to thrive.

Plant Close-up Photo by Kashif Chaudhary

Photo by Vito Palmisano

The plant developed a specialized process system to homogenize juice products and prevent the separation of juice solids. An on-site blow-molding operation produces plastic half-gallon and gallon containers.

three-story facility. The plant unloads from 20-27 trucks a day. Deliveries include raw milk, 100% juice products and orange juice concentrate. There are two receiving lines and multiple CIP’s that permit the unloading and cleaning of multiple trailers concurrently. Raw product is directed through a new receiving panel (installed in 2011) to any one of the six storage silos ranging in capacity from 40,000-50,000 gallons. Raw milk samples are sent by pneumatic tube from the receiving department to the third-floor lab. The lab screens the raw materials and tests for antibiotics, DMC (direct microscopic counts), added water, odor and chemistries, and puts the milk through various stress tests and microbiological analyses, says product quality manager Hugh O’Hare. Separation and pasteurization Guida’s uses cold bowl separation to separate the raw skim from the cream. A 5,000-gallon-per-hour separator is located in the receiving department and feeds skim to a dedicated 40,000-gallon silo. Raw cream is directed to one of three holding vessels for storage. The system pre-cools the cream exit-

ing the separator to 34°F to minimize the need for downstream cooling and agitation.Though not unique to Guida’s, cold separation is not common. The process leaves a little butterfat in the product. While some might consider this to be an inefficient process because it does not capture every last drop of cream, cold separation is a Guida’s signature. Director of plant operations Wesley Sliwinski says the cold process is gentler on the milk and improves the flavor and texture. Guida’s facility is unique in its ability to manage and segregate multiple streams of raw products to meet customer demands for conventional and organic products. A specialty line of Connecticutgrown products is processed on site from specially selected farms to meet the growing demand of the local products movement. Product standardizing and blending Guida’s uses four HTST (high-temperature, short-time) pasteurization systems with a capacity of 20,000 gallons an hour. These systems are equipped with a computerized ratio standardizing system for accurate blending of raw milk and skim at the balance tank that permits accurate custom blending to the target at the touch of a button. www.dairyfoods.com

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Plant Close-up Blending of creams, flavored milks and ice cream mixes are done using a Wonderware-based computerized control platform with a touch-screen interface that allows the operator to select any recipe from a list and instantly generate a formula based on the incoming test of the skim, milk and cream. The system also permits the operator to monitor the function of the pumps, valves and pasteurizer components in real time. Access to formulas and restricted functions is password protected. Process and CIP systems communicate through an interlock portal that restricts access to the cleaning system programs when a vessel or line are in process mode. The plant’s standard operating procedure requires that all CIP process charts are compared to a master file on an overlay transparency to ensure that the flow, temperature, pressure and chemical concentrations are within the permitted tolerances. Mixproof valves installed on the pasteurizer discharge lines maintain separation between the various product types from skim milk to chocolate ice cream mix. Nine pasteurized storage vessels equipped with HEPA air filtration on the vent line further protect the integrity of the product post pasteurization. An array of 86 3-inch valves in the pasteurization room allows for the flexibility to feed any packaging line from any pasteurized storage tank and permits multiple fillers to feed off a single source tank. The system’s design allows for products to be gravity-fed or pump-assisted to the fillers. Each pump is equipped with a pressure-monitoring system that varies the speed to meet a pre-set pressure setting, ensuring that the fillers are properly fed. This minimizes foam and shearing. The system also stops the pump when downstream demand ceases. Filling and labeling The facility has 10 packaging lines, consisting of three plastic bottle fillers that handle bottles from 10-ounce to gallon capacity; two paper half-gallon lines; two eco-pak fillers that handle 4- to 10-ounce cartons; a quart/pint/half-pint standard crosssection carton filler; a bag filler and a tote filling line. Several of these lines are equipped with HEPA filtration and auto-sanitizing features and one has extend-shelf-life capabilities, including a 250°F self-sterilization cycle. A tamper-evident foil seal liner to help preserve freshness is applied to Guida-label milk items in plastic bottles. Each filler bowl is equipped with a temperature-monitoring system to accurately track temperatures during product processing and sanitation-related activities. The plant produces products in many formats. These include: • Standard 16-quart milk cases • Nine one-half-gallon pack open corrugated boxes • 45- or 54-case bundles on a pallet • Flat-loaded bundles of 54 cases • 80-count stainless (Bossy) carts • 48-box-per-pallet corrugated gallons • 80-box-per-pallet corrugated half-gallons • 108-count tray pack pints per pallet and • Bulk format in trailers (capacity up to 6,000 gallons) Guida’s ships pasteurized cream, mix and milk products in bulk format to customers throughout the Northeast on its fleet of dedicated tankers. (President Mike Guida jokes that 70

Dairy Foods | April 2011

AT A GLANCE Total processing capacity: 1 million gallons a week (fluid milk, creams, flavored milks, 100% juices, drinks, ice cream mix and bottled water) Pasteurization type/units/capacity: Four HTST (hightemperature, short-time) pasteurizers Silos: Six, consisting of 40,000- and 50,000-gallon capacities Filling lines: 10, consisting of three plastic bottle fillers (16 ounce, quart, half-gallon and gallon capacity), two paperboard half-gallon fillers, two eco-pak cartons fillers (4, 8 and 10 ounce), one standard crosssection filler (quarts, pints and half-pints), one bag filler (2.5-, 3- and 5-gallon bags) and one tote filler (320-gallon bags using reusable or disposable totes) Storage capacity (raw, pasteurized, cooler): 270,000 gallons Refrigerated warehouse: 40,000 square feet. Temperature is maintained at 35-38°F and monitored by computer software that notifies plant personnel by fax, phone or e-mail of an alarm condition.

the company’s containers range in size from 4 ounces to 6,000 gallons.) The corrugated product offerings are fed to a robotic palletizing and wrapping system for direct loading onto trailers. The corrugated line opens up the distribution range for product to customers throughout the country. Juice room Frozen juice concentrate arrives in 4,200-gallon bulk tankers and is kept in a 25°F holding room to minimize the need for agitation during storage. A separate processing room contains blending and pasteurized storage tanks dedicated to juice products. Due to the fact that the majority of Guida’s juice products are sold in plastic bottles, the plant developed a specialized process system to homogenize juice products and prevent the separation of juice solids, which can lead to visually unappealing products on the grocer’s shelf (and lost sales). Distribution Guida’s, with its company-owned fleet of vehicles, does direct store deliveries serving convenience stores, schools, supermarkets, foodservice and institutions. The company has more than 100 power units and more than 150 trailers to meet the distribution needs of all types of customers. It owns its own trucks, performs the maintenance on them and buys fuel to keep distribution costs in check. “Our No. 1 asset within the distribution department is our people,” says David Drezek, director of customer service and distribution. “They are not just ‘milk men’ but well-trained customer service representatives. Our customers set their clocks daily when the ‘Guida guy’ arrives at their location.”

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Plant Close-up

Behind the Scenes A photo gallery of Guida's Milk facility in New Britain, Conn. Photos by Vito Palmisano

The refrigerated warehouse holds Guida's brands and those of other companies, which Guida's delivers. Director of plant operations Wesley Sliwinski (left) guides Dairy Foods editor Jim Carper through the facility.

Photograph this mobile tag with your smart phone to see more photos online.

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Dairy Foods | April 2011

Plant Close-up

The plant produces products in many formats, including 80-count Bossy carts. Gallon containers (below) come off the line.

Above: As many as 27 tankers a day deliver raw milk to the facility, which has six silos. Guida's also sends out tankers of milk and cream to bulk customers. Top: Pasteurized storage vessels are equipped with HEPA air filtration on the vent line to protect the integrity of the product post pasteurization.

PLUS For more photos, visit www.dairyfoods.com/ behindthescenes. Or, take a picture of the mobile tag (opposite) with your smart phone to go online now.

www.dairyfoods.com

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Processing Technology

Getting Pumped Pumps and valves control the flow of fluid milk and other products in processing plants. They also play a big role in maintaining a hygienic facility.

Fristam’s FKL closeclearance positive displacement pump is designed for CIP. he Food Safety Modernization Act has heightened interest in food safety. Dairy processors have always been keenly aware of the importance of maintaining a clean and hygienic facility. Pumps and valves are at the heart of any processing plant. They control the flow of fluid milk, cheese curds, ice cream mix and other dairy products through a facility. Dairy Foods wanted to know what plant managers should look for in pumps and valves. We invited makers of this equipment to share their knowledge. (See the end of the article for contributors.) Here’s what they told us: Any pump or valve considered for a processing system should bear the approval of 3-A Sanitary Standards Inc., McLean, Va., a non-profit organization that develops uniform standards and practices. A well-designed pump or valve allows for complete and efficient cleaning in place, or CIP. That means all surfaces, including wetted elastomers. When evaluating pumps and valves, look for designs that have no dead zones, sharp corners or other places where organic materials can set up unmoved. It is important to choose proper seal materials and elastomers. In fluid milk plants that also process juices and other non-dairy beverages, a plant manager needs seals that are compatible with all product ranges. The manager should choose the seal that stands up to the most demanding product. A silicon carbide double seal may be necessary for abrasive or sticky products. For example, a specifier might recommend a silicon carbide/silicon carbide seal for concentrated whey. But for fluid milk transfer, a carbon single seal might be suitable. EPDM (ethylene propylene diene Monomer) is said to be the most versatile elastomer for pumps and valves because the material is resistant to most fluids used in a dairy processing plant, as well as to ozone. EPDM has a wide temperature range, which makes it very good as a standard. Exceptions to the standard include combinations of high temperatures, fat content over 30-40% and highly abrasive or acidic products. There are several options when choosing elastomers and it’s always a good idea to consult an application specialist about a specific process or product parameters. Because of thermal expansion and contraction and pressure changes in a processing system, select pumps and valves that are designed with

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metal-to-metal contact around seal surfaces for defined compression of elastomers. This will limit expansion and contractions of the elastomer and provide maximum seal life. The right pump for the application For basic transfer of product and moving product through a process line, a centrifugal pump is often the best solution when the product is of low viscosity and has a very-low percentage of solids (or solids that are very small in size). With the rise in energy costs and the push for environmentally-friendly products, many processers use high-efficiency centrifugal pumps for these applications. The more efficient the pump, the less energy is consumed. With the Energy Independence and Security Act of 2007 now in effect, dairies have a heightened awareness of pumping efficiency. A rotary positive displacement pump with a circumferential piston is well-suited to move fluids and solids with minimal damage. Because the circumferential piston pump can handle very thin liquids, it is used in lines with multiple different products. The ability for the circumferential piston pump to handle low viscosities without losing efficiency also translates into energy-cost savings. Most fluid milk applications can be handled with a centrifugal pump, sometimes using an inducer for tough suction conditions. Other applications can be handled using a positive displacement pump. The majority of cheese and butter applications require a positive displacement pump. A large inlet port mounted to an auger feed will minimize restrictions of entering the high-viscosity liquids into the pump. Normally, a positive displacement pump also is used to handle ice cream mix. Cultured product requires gentle handling, so a large pump with increased pump inlets is the general rule of thumb. Continued on page 76

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Dairy Foods | April 2011

Processing Technology 10 Things to Know About Valves 1. Know how valves work, how to install them and how to maintain them. 2. Choose valves with a sanitary design, meaning they are easy to clean. 3. A mixproof valve should allow no possibility of cross-contamination, even with damaged gaskets or no seat gaskets. 4. Look for valves that require minimal CIP liquid for cleaning. This will reduce demands on the environment. 5. Select low-maintenance valves and develop a preventativemaintenance schedule. 6. Have spare parts on hand or know that they are readily available from the manufacturer or its distributor. 7. Reduce the number of parts you need to stock by choosing valves with modular designs, including those with interchangeability of control modules, actuators and housings. 8. Selecting PMO-compliant mixproof valves allows for more flexibility in processing and cleaning. 9. Stay up-to-date with new valve technologies. 10. Ask the manufacturer about its support and warranties.

Sorting out valves Economics, function and planned maintenance requirements are important when choosing a valve. The best valve is one that is reliable, easy to maintain and has a low total cost of ownership. An

unreliable valve can result in line stoppages, thus requiring cleaning and sterilization, which takes time away from producing salable product. There are many valve options, and they are all process dependent. Aseptic and hygienic process valves are used in applications where the highest of sanitary requirements are needed. These valves allow for the ability to sterilize and run a completely aseptic process. The valves also have the benefit of being easy to maintain and are highly modular so that they adapt to multiple application requirements. The different configurations of rising-stem valves (including single seat, mixproof and double seal) are all used in the dairy industry. Regulatory agencies write regulations around this valve design. The flexibility of the different configurations, their cleanability and their serviceability are the main reasons why some call this the best valve for the dairy processor. Look for a valve design that does not allow product to be trapped and become stagnant. Valves should not have any crevices or deadlegs in their housing design. Product specifiers should avoid seat and stem gaskets with an O-ring type design because these are prone to rolling as the valve stem moves, which allows product to get behind the gaskets, making the valve harder to properly clean. As for gaskets, a metal-to-metal V-ring design is the optimum because wear is greatly reduced, even when there are large temperature differences across the valve. This ensures longer life of the gasket. To ensure against cross-contamination, use a mixproof valve. This valve is designed so that CIP fluids in one hous-

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Bredel Watson-Marlow

Dairy Foods | April 2011

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Processing Technology ing cannot contaminate product in the opposite housing. Mixproof valves are generally used where automation and numerous product changeovers are critical to the system design. Processors of multiple fluid products (such as milk, juice and tea) benefit from using mixproof valves because they allow for the running of many products simultaneously without the fear of any cross contamination of products or product and CIP. Some vessels can be filled, some emptied and some cleaned, all at the same time. Mixproof valves in a multiproduct environment allow for a fully sanitary, flexible and automated process design solution. They protect against the mixing of unlike products, including allergens. For processing fluid milk, consider a single-seat mixproof valve. Cheese processors use a long-stroke single seat valve or PMOapproved long-stroke mixproof valves with a larger valve opening to allow for the gentle processing of cheese particulates and curds. Aseptic and single-seat PMO mixproof valves are suitable for cultured products. (PMO is the Pasteurized Milk Ordinance.)

1. Choose the right pump for the application. Ask an application specialist to size pumps. 2. Specify pumps that meet all current standards and regulations. 3. The more efficient the pump, the less energy it will use. 4. Do not run a pump dry. It will ruin the seals. Automatic control systems do not always catch this in time. 5. Buy a pump that is designed to be easy to clean in place. The more cleanable a pump, the less product risk. 6. Watch out for pressure shock, especially from a downstream valve closing. It can bend shafts, rub impellers or rotors and blow off covers. 7. Know who to call if the pump fails or if your applications and needs change. 8. Make sure spare parts are readily available. 9. Serviceability is critical. How easy or difficult is it to service by your personnel? Do you need special tools to service the pump? 10. Ask the manufacturer how long it has been in the sanitary pump business.

or maintenance intervals. The ability to communicate with valves from a central location and in a recorded database gives plant managers the advantage of increasing production efficiency and enhancing the safety of the product and operators.

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Accessories for valves Valve feedback units help control the valves through the plant’s PLC. This allows a central location to control the valves in a system, further increasing efficiency. Feedback is required for PMO mixproof valves. Control technology is a smart choice for single-seat valves because it allows an operator to confirm valve actuation and that the process is ready to start. New designs provide options such as local visual indication, valve speed controls

10 Things to Know About Pumps

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Continued on page 78

Processing Technology Best practices for cleaning After a product run, valves should be cleaned-in-place as quickly as possible to prevent product residue from drying or hardening. During the CIP sequence, the valves seats should be pulsed repeatedly to allow the solution to clean underneath the seats and inside the vent cavity of mixproof valves. Mixproof valves provide complete product protection at all times (including during seat lifting), so operators can receive maximum security when there is product and CIP liquids in opposite lines. The rule of thumb is to have a flow velocity of a minimum of 5 feet per second of CIP liquid. CIP pumps can save maintenance time and prevent equipment damage. Continual disassembly of a pump for cleaning not only costs valuable downtime, but it also can damage pump parts to the point where they are no longer sanitary and need to be reconditioned.

EXTRAS Aseptomag NA ..................................................... www.aseptomag.us Fristam Pumps USA ........................................www.fristam.com/usa GEA Mechanical Equipment US ..................www.tuchenhagen.us Lee Industries ............................................................. www.leeind.com Ross Controls ................................................ www.rosscontrols.com SPX Flow Technology ................................................ www.spxft.com Südmo North America ....................................... www.sudmona.com Tetra Pak .............................................www.tetrapakprocessing.com

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Dairy Foods | April 2011

The W75CP PMO mixproof valve from SPX Flow Technology is used for continuous processing.

A process engineer can determine the proper CIP regimen in terms of times, temperatures and chemical concentrations based on the type of product being processed, the run time and the frequency of cleaning. This is periodically tested when the installation is commissioned to ensure proper cleaning is achieved. This is normally monitored by QA results. Once the CIP regimen is determined, controls on valves make the process repeatable. There are control modules that can reduce the amount of water and chemicals needed to clean the valve, which are useful in areas where water is scarce. Sanitary single-seat valves and PMOapproved mixproof valves are designed to process fluid milk products as well as other beverage products. It is critical to have a stringent CIP regimen when switching the production run to a different product in order to avoid cross-contamination from leftover product residue. Buy new or rebuild? Rebuilt and reconditioned equipment is available from manufacturers and third-party providers. Manufacturers advise against rebuilding a valve from third-party parts. If such parts were not accurately manufactured, they can cause premature failure. Use of third-party parts can also lead to a loss of warranty from the manufacturer. Plant managers should be careful when considering buying used equipment. It might not meet the latest 3-A requirements and parts may be difficult to find. Managers are in the dark about how that product was used and maintained during its first life. Equipment makers do offer their own rebuilt and remanufacturing programs. This allows a facility manager to reduce the cost of ownership and extend the life of the equipment. The manager might want to use a reconditioned pump or valve as a backup. Ask the manufacturer if it warrants (and for how long) rebuilt products. A preventative-maintenance schedule should be developed for the high-wear parts of valves. This proactive approach will prevent downtime in production if a valve part fails and the spare parts are not in stock. Another approach is to have a few complete valve inserts as spares so that these can be dropped into the line right away if a part fails. The production line keeps running, and the failed valve can be repaired later. This article was written by Dairy Foods chief editor Jim Carper from information supplied by Jonathan Clem, Aseptomag NA; Randy Verges, Fristam Pumps USA; Dave Medlar, GEA Mechanical Equipment US; John M. Weaver, Lee Industries; Eric Cummings, Ross Controls; Jim LeClair, Chris Sinutko and William Rice, SPX Flow Technology; Jeremy Hauser, Südmo North America; and Keith Ortman, Tetra Pak.

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Sayler on Safety

Tools for a Functional Dairy HACCP Program

Allen Sayler

ACCP (hazard analysis critical control point) systems Software. Developing new or updating existing HACCP have been utilized by the U.S. dairy industry since programs can be simplified using a HACCP software program the mid-1980s, when everything was a critical con- with a good track record. The advantage of using HACCP trol point. The International Dairy Foods Association, software versus paper and pen or internally developed softWashington, D.C., and other dairy-based organizations popular- ware programs is that, similar to income tax software, making ized the use of HACCP during the early-to-late 1990s. However, changes in a plant’s HACCP program using a fully integrated truly functional HACCP programs for most dairy plants did not HACCP software program requires only one entry of a piece come of age until the first decade of the 21st century. of information; the software makes all other required changes. Five major “drivers” caused the maturation of U.S. dairy plant Fully integrated electronic HACCP record system. Data HACCP programs: used to support the HACCP written program is commonly 1. The 2001 U.S. Food & Drug Administration Juice HACCP captured on written paper documents, either by operators regulation required all plants processing juice beverages to have a using manual logs or through instrumentation producing viable and operational HACCP program. paper records. Both the Grade A Pasteurized Milk Ordinance, 2. The 2002 IDFA “Dairy HACCP Manual” and its subsequent states and FDA accept electronic data capture systems. These updates (latest edition is 2010) provided 21 dairy product models systems reduce records burdens on operators and are more and extensive recommendations on functional prerequisite pro- effective in identifying unacceptable operating conditions. grams. Detailed process flow diagrams. Product flow diagrams 3. Final adoption of the National Conference on Interstate Milk are the foundation for any effective HACCP hazard analysis, Shipments voluntary HACCP-based regulatory program in 2004 yet too many have been simplified (see the “bad” example) to for Grade “A” dairy plants. where they no longer include all ingredients, storage of ingre4. Popularization of the Global Food Safety Initiative third-par- dients or packaging, screens or filters, components of the pasty certification concept and the Safe Quality Foods scheme with teurization system or key processing steps addressing physical HACCP as a core requirement (2003 to the present). product changes. The result is a weak HACCP program. 5. The January 2011 FDA Food Modernization Safety Act Intense internal HACCP audits. Effectively trained plant (FSMA) with its 18-month deadline for all food plants to have a HACCP team members need to develop strong internal HACCP hazard analysis and “preventative measures.” audits that are conducted a minimum of once every six months, These five drivers provide insight for developing functional testing the on-going implementation of the plant’s HACCP dairy HACCP programs. Six state-of-the-art HACCP tools are written program. SQFI has a thorough internal assessment tool listed below. (audit form) that can be downUse of widely accepted forms. loaded from its website (www. By using common HACCP formats sqfi.com/documents) for $25 and for documenting and recording used to building strong internal HACCP operational information, HACCP audit program. such as the Randolph HACCP Learn more about food Incoming Materials model forms (www.randolphcon safety at Randolph Associates sulting.com) and/or the NCIMS Inc.’s HACCP training workHACCP model forms (www.ncims. shops scheduled for June 20–22 org/HACCPDocuments.htm), (Kansas City, Mo.), Sept. 12–14 Processing internal or external audits can be (Boise, Idaho), Nov. 14–16 shortened and reduce an auditor’s (Chicago) and Dec. 5–7 (New learning curve in understanding Orleans). Contact Kristy Clark Packaging unfamiliar HACCP forms. at 205-595-6455 or Kristy.clark@ Up-to-date staff training. The raiconsult.com. minimum goal should be HACCP training every four years for HACCP Allen R. Sayler is vice president, Storage team members. Also, the new FDA food safety, technology and regFood Safety Modernization Act ulatory solutions of Randolph requires dairy plants to document Associates Inc. He can be reached Distribution food safety training programs. at [email protected].

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A Bad Example of a Basic Flow Diagram

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Dairy Foods | April 2011

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Packaging Technology Packaging Points

Time for Dairy to Shed the Status Quo ith all the food safety scares going on globally across product categories, we need to be concerned about safety and security across the food chain. Consumers buy products and assume the consumer packaged goods (CPG) marketer or brand owner (often a retailer’s private label) are ensuring consumer safety and are responsible parties. That assumption makes sense. And, there has been quite a bit of technical work over the years in the areas of time/temperature sensors, radio-frequency identification and quick-response codes, but there seems to be little traction in food and dairy. Why aren’t we prepared? Food and dairy continue to be pretty status quo and follow the old Food and Drug Administration’s pharmaceutical guidelines for tamper-evident packaging. Remember, these are not tamper-resistant or tamper-proof guidelines. Typically, on dairy products, one sees breakaway closures on milk, shrink sleeves/labels on bottles and tubs, and sealed membranes on yogurts and dips. Most ice cream has no tamper-evident feature, but consumers believe and trust it to be secure. In fact, shoppers prefer to have features referring to “freshness keeping” not tamper evident. Certainly bar codes and code dating help us to be able to know when the product was made (or when it should be used by), but there is still much confusion about this terminology by CPGs and brand owners. This often results in consumers throwing away products needlessly. Beyond safety and security, just think of the negative impact on sustainability efforts. As supply chains grow more complex, both globally and locally, manufacturers need to look again at what they are doing across the entire ingredient/package value chain. Consumers want more fresh-

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Dairy Foods | April 2011

like products, so companies are continuing to develop new technologies such as high-pressure processing. Also, the growth of private label and private brand are leading to more premium products, more natural foods (with fewer ingredients and more wholesome ones) and organic products, including some raw products. Ultra-clean facilities are delivering longer shelf life and fresher dairy products. Other new processes and package technologies are in development, including micro-oxygen, pressureassisted thermal sterilization.

Mike Richmond

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response) code like this from Arla in Denmark could be used to deliver freshness information to shoppers.

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As you know, there have been a variety of food and beverage safety and security packagingrelated incidents and dĂŐϯϲϭ recalls in the past. They ^ E'TZh͗ ^D^͞ƌůĂ͟ƟůϭϮϯϭ͘,ĞƌĞŌĞƌŵŽĚƚĂŐĞƌĚƵ include pallet and priĞƚůŝŶŬ͘ŽǁŶůŽĂĚŝŶĚŚŽůĚĞƚ͕ƚĂŐ ĞƚďŝůůĞĚĞĂĨŝŬŽŶĞƚŽǀĞŶŽǀĞƌŽŐ ŚƆƌ͕ŚǀĂĚŽƉĮŶĚĞƌdŽŵdŚĞƐƚƐŝŐĞƌ mary package/odor and ŽŵĚĞŶŵĂŐŝƐŬĞŽƉĮŶĚĞůƐĞ͗TŬŽĨŽŶĞŶ͘ taints, the discovery >čƐŵĞƌĞƉĊĂƌůĂ͘ĚŬͬŽŬŽĚĂŐ of metal shavings and glass pieces in foods, improperly cured inks, deliberate tampering, and under-processed retort and canned foods. We can’t Six questions to ask yourself even count the number of recalls due to There are lots of changes coming. Are improper labels. you prepared? How would you answer All this makes you wonder who is these six questions? watching the store. These incidents have • Do you feel your company is looking resulted in many millions of dollars in hard enough at the changing supply/ recalls as well as (in certain cases) severe value chain? illness and death. • Have you looked across your packagConsider the questions above. Then ing, starting at the incoming ingre- ask: Are you feeling good about the dients packaging, intermediate bulk safety and security of your packaging? containers, etc? Remember, consumers expect your prod• Do you know the climate and envi- ucts and brands to be safe and secure. A ronmental conditions that these brand is a very fragile thing. The sense at products or ingredients have traveled our company is that there are more safethrough to get to your facility? ty and security issues hitting packaging • What was the distribution and ware- than ever before. housing environment like en route to It is often said “I would rather be lucky your facility? than good.” But when it comes to food • Have you done complete value-chain packaging, safety and security, I would audits of your contract manufactur- rather be good than lucky. ers to ensure you have a track-andtrace program in place? Mike Richmond is the president and ceo • Have you done technology searches of Packaging & Technology Integrated and looked at cost/need/viability Solutions, Shelbyville, Mich. Reach him at models for your products? [email protected]. ΎůŵŝŶĚĞůŝŐƐŵƐͲƚĂŬƐƚ

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Spotlight on Sustainability

The Time Has Come for Integrated Plant Assessments ustainability has many strange bedfellows and eccentricities. Not too long ago, the buzz was all about creating a carbon footprint, and as folks pursued carbon footprinting, the question became “do I conduct it as a Scope 1, 2 or 3 assessment?” For those of you that don’t know, a Scope 1 accounts for all of the direct emissions coming from the entity being studied — generally a fairly straightforward evaluation. Scope 2 takes it a bit further by accounting for the emissions that are associated with the indirect emissions, which relate to purchased electricity, heat and steam. Scope 3 is more complex and tries to account for all indirect emissions of the entity being studied, which includes emissions from vehicles that are not owned by the studied entity (for example, commuting or air travel), emissions from disposed waste, embodied emissions associated with the production and transportation of purchased goods, and fuels and emissions from pretty much anything else that plausibly relates to the studied entity. Accounting for Scope 3 emissions can be a nightmare, to say the least. That is probably why I tend to focus time and attention on more palpable matters. With an integrated plant assessment, the boundaries are the processes that happen at the plant itself, namely things within our own direct control. How much energy was used? How much water was used? How much waste was generated? How do those factors relate to production? And what are the synergistic effects that really bring about the payoff that many are seeking?

S

An integrated plant assessment looks at what happens at the plant itself. How much energy and water were used? How much waste was generated? Ecolab, St. Paul, Minn., has emerged as a leader in integrated plant assessments — which covers all the influent-to-effluent processes — and has completed numerous assessments in a variety of plants. It is aggressively pursuing the concept of following the water and thermal energy throughout the plant and developing opportunities for efficiencies and cost savings. Its intensive approach involves bringing in a variety of expert teams with specialized experience in boilers, cooling towers, pre-treatment solutions, cleaning and sanitation (CIP systems) and wastewater solutions. In about a week or two, the plant work is done and the opportunities are compiled. One of the beauties of taking a total 84

Dairy Foods | April 2011

Clay Detlefsen

plant approach is that in many cases the dynamics and interplay of changes can negatively or positively affect the intended result. By taking the total approach, the best end-game result is achieved, and frequently, the sum is better than the individual contributions. Inroads in sustainable activities Why has the time come to take the total plant approach? The reason is simple — we are already part of the way there and new obligations are quickly coming at us. The U.S. dairy industry has made inroads with its sustainability activities, including the fluid milk carbon footprint and the cheese life-cycle assessment. And we are heavily involved with the Environmental Protection Agency’s Energy Star Challenge for Industry. Under the Energy Star Challenge, industrial facilities pledge to reduce their energy consumption by 10% over a 5-year time frame. The program is open to all industries, but it is the dairy processing industry that shines. With approximately 100 dairy plants entered out of 200 total industrial facilities of all types, it is clear that calculating and reducing energy per production unit is important to dairy. And, I am pleased to say that six Kroger dairy facilities and a Dreyer’s Ice Cream plant have actually already met the challenge. One of the recent obligations coming quickly is EPA’s new boiler rules, which may require plants to conduct a one-time energy assessment for boilers that burn biomass or oil, if the boiler has a heat input capacity of 10 million BTU per hour or greater. The rule calls for among other things: an evaluation of operating characteristics of the facility, specifications of energy-using systems, operating and maintenance procedures, an inventory of major systems consuming energy from affected boilers, a list of major energyconservation measures and a comprehensive report detailing the ways to improve efficiency. Both the Energy Star Challenge and carbon footprint analysis are each limited to only one aspect of plant operations. For the challenge, it is all about energy used; for carbon footprints it is about greenhouse gas emissions. However, once plant management seizes the opportunity and succeeds in one area, it is only natural to expand into other areas and seek new opportunities. So today’s Energy Star challengers will likely pursue water use and wastewater discharges tomorrow and, I suspect, many will use an integrated approach. Perhaps when that is done, they will be looking at transportation route efficiencies. While they are learning and growing from their experiences, they will be saving their facilities money and improving the environment. As with most things sustainable, it should make economic sense and contribute to the bottom line. Clay Detlefsen is vice president for regulatory affairs for the International Dairy Foods Association, Washington, D.C.

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New Product Showcase

Fillers Horix Flow Meter filler offers accurate volumetric and sanitary filling capability ideally suited for dairy and juice products. Its design allows for no contact with the neck of a container or intermixing of air in a container with fresh product in tank. It features all non-threaded contact parts to ensure easy cleanup and comes with rinsers and cappers. Horix Manufacturing Co. 412-771-1111 www.horixmfg.com The Model 80 is one of T.D. Sawvel’s most versatile machines, providing a highly flexible platform for makers of ice cream and other frozen desserts. The fully automatic Model 80 offers container denesting, indexing, filling and automatic lidding, and provides the ability to place tamper-evident, Mylar inner seals from roll stock or pre-cut seals. T.D. Sawvel Co. Inc. 877-488-1816 www.tdsawvel.com Harpak-ULMA’s line of G. Mondini fillers ranges from semiautomatic rotary and linear to fully automatic pocket, as well as various piston and lobe fillers. Pocket fillers offer the most simple and hygienic solution for filling low-viscosity product, which can be spread over a surface with minimum waste and no recycle. Piston and lobe fillers are used for pumpable products such as yogurt, sauces, etc. Harpak-ULMA Packaging, LLC 800-813-6644 www.harpak-ulma.com The Flex E Fill ice cream filler from Stanpac is said to be one of the most flexible fillers in the industry. It can fill 3- to 64-ounce containers in round or “scround” configurations. Plus, changeovers can be performed in 20-30 minutes. New this year is a wooden or plastic spoon-dispensing attachment for novelty size packages. Plastic film units are available on some models to allow for a freshness/ tamper-evident seal. Stanpac 905-957-3326 www.stanpacnet.com

Shibuya Hoppmann Shibuya is a leading supplier of aseptic beverage/dairy filling systems with more than 110 high-speed (400-1,200 bottles per minute) integrated aseptic filling systems installed worldwide. Its isolator-based systems are designed to meet FDA criteria for low-acid beverages with more than 10 billion products produced to date without spoilage. In addition to the line of conventional H2O2 sterilization aseptic systems, Shibuya produced the world’s first rotary E-Beam aseptic filling system. Shibuya Hoppmann 800-368-3582 www.shibuyahoppmann.com Evergreen Packaging introduced the new EQ-140 high-speed gable-top packaging machine for the dairy, juice and liquid food markets. Extended long-life components, including environmental control and carton decontamination features maintain product quality. With fill volumes of 8-32 ounces (250-1,000 milliliters), the EQ-140 fills quarts and liters up to 14,000 cph, 8 ounces (250 milliliters) up to 18,000 cph and 12-16 ounces (340 to 500 milliliters) up to 18,000 cph. Plus, integrated servo-driven functions provide consistency and repeatable package performance. Evergreen Packaging Equipment 319-399-3306 www.evergreenpackaging.com

Stanpac Continued on page 88

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Dairy Foods | April 2011

View videos demonstrating the newest dairy equipment by visiting www.dairyfoods.com/tv

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New Product Showcase The Microb-Blaster for bottles from Fogg Co. is a UV-HEPA bottle sanitizer designed to simultaneously sanitize bottles with UV light and exchange the air inside the bottles with HEPA air filtration. This patent-pending technology can achieve a 0.5 to 4 log reduction on the exposed surfaces of the bottles. With constant monitoring of the light source’s placement and density, operators can keep production running with confidence. Fogg Co. 616-786-3644 www.foggfiller.com

Fogg Co.

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Dairy Foods | April 2011

The Scholle SureFill 30 low-acid filler is a combination of advanced aseptic filling technologies in an operationsfriendly machine that delivers versatility and speed. The SureFill provides dairy, beverage and flavoring processors a range of bag size and fitment capabilities and fills speeds up to 15 1-gallon bags per minute. The SureFill also decreases operations downtime with automatic changeovers and allows for longer run periods between clean-up and enhanced product and operator safety. Scholle Packaging 888-224-6269 www.scholle.com Reiser and Vemag designed a variety of Vemag cheese cup filling systems. This automated system features a Vemag portioner and a Reiser-engineered dripless valve attachment to integrate portioning, depositing and filling. The system is an ideal solution for depositing exact-weight portions of processed cheese, cheese spread and cheese dip directly into cups, tubs, trays and packages of all types and sizes. It also can be easily integrated into existing production lines. The dripless valve attachment is an economical solution to easily fill containers with exact-weight portions. Reiser 781-821-1290 www.reiser.com

Reiser

New Product Showcase Oystar Hassia manufactures thermoform, fill-and-seal packaging machinery for deep draw cups with a maximum output of 40 cycles per minute for products such as yogurt. Available in hygienic and aseptic applications for extended shelf life, in-mold labeling (wrap-around, spot and shrink wrap), CIP/SIP equipped and different cup forming such as a dual chambered cup are just a few of the advantages. Oystar North America 732-343-7600 www.oystarusa.com/thmdeepdrawcups.html

The GWm weight filler from Sidel can handle a wide variety of pasteurized products dedicated to cold chain distribution, including flavored milk, drinking yogurts, probiotics, cream and more. The filler transfers various bottles up to 5 liters at an output rate up of up 60,000

bottles per hour. The GWm is available in different versions and comes with a neck trimmer, a rotary capping turret and a foil sealer or in Combi configuration with Sidel blower. Sidel Inc. 678-221-3000 www.sidel.com Continued on page 90

Oystar Gasti manufactures fill-and-seal packaging machinery for pre-made cups and tubs for the dairy industry. The Dogaseptic cup filler is a continuous motion machine with outputs up to 25,200 cups per hour for extended shelflife products such as yogurt. The Oystar Gasti offers CIP/ SIP, format flexibility and is capable of handling various types of closures. Oystar North America 732-343-7600 www.oystarusa.com/dogaseptic0.html Oystar Hamba manufactures fill-and -seal packaging machinery for premade cups and bottles. The Flexline bottle filler is ideal for yogurt drinks with fill volumes of 100-2,000 milliliters and outputs up to 60,000 bottles per hour. Other advantages include format flexibility with minimal adjustments needed for format changes, CIP/SIP capable and applicable for hygienic and aseptic applications. Oystar North America 732-343-7600 www.oystarusa.com/6086.html

Easy on the environment, easy on operational costs. The enviro award-winning ErgoBloc L lets you produce, label, ﬁll and cap PET containers in a single process.

Totally Turnkey – from Concept to Consumer Whether it’s plants or a production facility – one size ﬁts no one. Let Krones custom design a facility or line that ﬁts your product mix and operations to a T – or a PET. From product processing to bottling to ware house automation and distribution logistics, Krones’ total turnkey model removes all roadblocks on the route to greater efficiency and optimal total cost of ownership. Simply tell us what you want – Krones will custom-create a simple solution at a competitive cost. www.krones.com

Oystar North America

New Product Showcase ripple sauces injected into the ice cream flows before they are swirl-filled into cups or cones. This filling pattern gives a very exclusive appearance and is ideal for transparent plastic cups. Tetra Pak’s product development center allows customers to conduct specific product design tests and validate product specifications prior to the equipment arrival. Tetra Pak Inc. 847-955-6000 www.tetrapak.com

SIG Combibloc Inc.

Machines from SIG Combibloc are conveniently fast when it comes to filling drinks and liquid foods into aseptic carton packaging. With a capacity up to 24,000 carton packs an hour, SIG Combibloc fillers are also extremely efficient and flexible — a filler can be switched to any one of up to seven different package volumes in just two minutes. This means greater output with the usual high product quality, flexibility and low wastage rates. SIG Combibloc Inc 610-546-4200 www.sig.biz

The Elopak E-PS120UC Elopak Inc. is a flexible, high-speed filling system for pasteurized or ESL milk, juice and liquid eggs. It fills up to 12,000 gable-top cartons per hour at 8 ounces to 1 quart (250 milliliters to 1 liter), with automatic size changeover. It also fills PurePak, Pure-Pak Curve, Diamond and Diamond Curve cartons, and can run two styles or sizes at once. It has a user-friendly touchscreen, ergonomic blank feeders and a sterilization system that delivers the lowest recontamination rates available. Elopak Inc. 248-486-4600 www.elopak.com The new modular Flexline in-line filler from WCB Ice Cream breaks new ground in innovative filler design, flexibility and simplicity. Plus it is expandable. Servo drives and openframe construction make the Flexline simple to operate and easy to clean and maintain. The Flexline provides filling for any container from cones to 3-gallon cans and from sundaes to ice cream cakes. WCB Ice Cream 201-784-1101 www.wcbicecream.com

Tetra Pak

Tetra Pak developed a new and improved module for its Evolution Valve system for the Tetra Hoyer Comet C2 filling machine and extrusion lines. The latest addition is a combination of two-flavor swirl filling with two different color

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Dairy Foods | April 2011

WCB Ice Cream

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GEA Niro Soavi Model NS355 has the highest capacity available, running at a maximum flow rate of 60.000 l/h. NS355 is equipped with a touch-screen panel for operating parameters’ control and adjustment. It also is integrated with an on-board diagnostic system and is prearranged for remote control and process automation. Plus, this machine is equipped with the high-efficiency NanoValve and has a planetary gearbox, making it service friendly. GEA Niro Soavi 603-606-6060 www.geagroup.com The CS Series Process Control Modules from Omega Engineering offer PID loop control of any process, such as control of temperature, flow and pressure, without using a PLC, whereas the single- and dualloop temperature modules provide rampand-soak controls. Up to 16 modules can be attached to any CS series master to provide up to 32 independent control loops. Omega Engineering Inc. 203-359-1660 www.omega.com Neogen’s Soleris NF-TVC (total viable count) is a rapid assay that detects the growth of heterotrophic bacterial microorganisms in a wide variety of sample types. The optical assay measures microbial growth in test vials by monitoring biochemical reactions that generate a color change as microorganisms grow and metabolize. The Soleris line also includes quick, automated quality indicator system protocols for yeast and mold in 60-72 hours, coliforms in nine to 10 hours, E. coli in seven to 10 hours and lactic bacteria in 30-35 hours. Neogen Corp. 517-372-9200 www.neogen.com

The compact plastic case stack de-palletizing system from Westfalia Deam Systems de-palletizes three to four dairy pallets per minute, each with nine stacks of empty plastic dairy cases, for a maximum throughput rate of 180 cases per minute. Capable of handling palletized, unitized or a combination of stacks, the de-palletizer design utilizes a clamp and lift technology that maintains full stack control, thus eliminating stack tipping. Westfalia Deam Systems 800-673-2522 www.WestfaliaUSA.com Palmer Wahl

Palmer Wahl Instruments debuted the Palmer 3PC auto-ranging digital pressure test gauge, which ranges from vacuum to 3,000 psi, offers accuracy of 0.1%, and eliminates the need for many different gauges to span a large range. Meanwhile, the Palmer PP10K hydraulic calibration pump uses a patented fully-adjustable stroke control to allow for fast priming or filling of test systems, and is compatible with most hydraulic fluids, oils and water. The PP600 combo pneumatic calibration pump can create a range of vacuum 28 inches of mercury up to 6,000 psi. This pump also allows the user to choose slow or rapid pressure venting, and features a patented protective cage surrounding the vent knob for better control. Palmer Wahl Instrumentation Group 800-421-2853 www.palmerwahl.com Lantech presents a patent-pending Load Seeking Clamp 4.0, designed to reduce film breaks. At the beginning of the wrap cycle, the clamp goes out to the edge of

R & D INGREDIENTS A new clinical study shows that MixMe micronutrient powder from DSM offers hope of improving the nutritional status of populations whose diet is severely limited. MixMe, a multi-micronutrient powder launched in early 2008 in cooperation with the World Food Program, is designed to help combat iron and zinc deficiency. The new MixMe formulation used in the study contains a readily bioavailable form of iron (NaFeEDTA) plus an increased vitamin C dose along with a phytase. DSM Nutritional Products 41 (0) 61 815 83 54 www.dsm.com Gelita collagen proteins effectively prevent syneresis, the displacement of whey to the surface in yogurt. It also optimizes ice cream texture, stabilizes whipped cream, prolongs the shelf life of bakery products, is ideal for creamy and sliceable cake fillings and durable decorative coatings and is responsible for crystal-clear thermo-reversible gel formation in gummy candies and fruit chews. Gelita USA Inc. 712-943-1692 www.gelita.com

the load, creating clamp-to-load contact regardless of the width of the load. This eliminates sagging issues and maximizes containment at the bottom of the load. Lantech 800-866-0322 www.lantech.com Herbold Meckesheim SB Series Granulators employ a patented screwfeed mechanism, which makes them quieter and more efficient than gravity-fed, sizereduction equipment for pulverizing PET bottles and other recyclable plastics. Suitable for dry or wet operation, an SB Series Granulator is capable of processing up to 7 tons of plastic per hour. Herbold Meckesheim USA, Resource Recycling Center 401-232-3354 www.herboldusa.net www.dairyfoods.com

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ADVERTISING CLASSIFIED ADS To place a classified ad, contact Suzanne Sarkesian, Dairy Foods Classified Sales Representative at 248-786-1692 or fax to 248-283-6596, [email protected].

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Dairy Foods | April 2011

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Our Future As The Leader •In Dairy Auctions • • • • Was Clear From The• Beginning. And no matter how you spin it, we’re the right partner for you. Call 412.521.5751 or visit www.mdavisgrp.com more information. Call for CX R COMPANY Warsaw, IN

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Dairy Foods | Septem

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EMPLOYMENT

Sales Representative for the Midwest Territory Enzyme Development Corporation is seeking a person with a minimum 5 years sales experience to the food processing industry. The preferred candidate will also have some experience with hands on technical service. Experience should include selling functional chemicals/compounds to the food processing industry. A B.S. is required and an advanced degree is preferred. Dairy industry experience would be considered a plus. The position will be based in the Chicago area and working out of a home office. EDC will consider other Midwest locations but the Chicago area is preferred. The preferred candidate will have already had experience with working out of the home and reporting to an office in another state. Approximately 50% travel including some weekend travel for conventions (IFT, AACC).Travel may be higher during the first year. Please send a copy of your resume to the attention of L. Clark at [email protected]

JUDGE INC. J U D G E I N C I S A N I N D U ST RY L E A D E R RECRUITING FIRM SPECIALIZING IN FOOD AN D B EVE R AG E MAN U FACTU R I NG F OR OVER 35 YEARS. CONTINGENCY OR RETAINED SEARCH: VP ENG/MFG/OPERATIONS PLANT/PRODUCTION MGMT PLANT ENG/MAINT MGRS WAREHOUSE/DISTRB MGMT QUALITY/PROCESS IMP. MGMT MAINT/PROD/QC SUPERVISORS TO SUBMIT YOUR RESUME, OR ENGAGE SEARCHES, PLEASE CONTACT: TINA GANNON DIRECTOR, JUDGE INC. FT. MYERS OFFICE 4315 METRO PARKWAY, FT. MYERS, FL 33916 PH: (239) 332-0931 ext. 1004, FAX: (239) 332-4305 CELL: (813) 335-1515 EMAIL: [email protected] TO SEE A LIST OF OUR CURRENT JOB POSTINGS, CHECK OUT OUR WEBSITE AT

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HENSON PARTNERS, INC. SPECIALIZED EXECUTIVE SEARCH

EXCEEDING EXPECTATIONS AS YOUR SEARCH PARTNER Our mission is to earn the privilege of becoming our client’s exclusive recruitment resource for key search activity. We do this by LISTENING to our clients needs to develop an understanding of the ideal candidate. We FOLLOW-UP throughout the entire recruitment process with conscientiousness and a respectful sense of urgency. We reliably DELIVER freshly recruited, qualified and interested candidates to fill our client’s positions.

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Our pursuit of excellence and our dedication to the Food Processing Industry, has earned our firm a reputation we are proud to have, and one that you can trust. To learn how your business can benefit from our extensive industry knowledge and experience, contact us today.

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Dairy Foods | April 2011

Ad Index *Indicates Regional Advertising

Company Name

Page No.

Advanced Instruments ....................................................................................................48, 59 Ampco Pumps Co...................................................................................................................75 Bentley Instruments..............................................................................................................78 Blue California ..........................................................................................................................39 Brookfield Engineering .......................................................................................................88 California Custom Fruits & Flavors...............................................................................67 Charm Sciences Inc. .............................................................................................................54 Chr. Hansen, Inc. ....................................................................................................................... 3 Corn Products International .............................................................................................41 CP Kelco .......................................................................................................................................47 Dairy House Ingredient Systems ..................................................................................55 Danisco USA Inc......................................................................................................................33 David Michael & Co. ...............................................................................................................51 Donaldson Company, Inc. ..................................................................................................16 DSM Food Specialties .......................................................................................................... 7 Eriez Magnetics........................................................................................................................77 FOGG Company ......................................................................................................................18 FOSS North America ............................................................................................................. 4 Fruitcrown Products Corp..................................................................................................25 GEA Tuchenhagen North America ..............................................................................83 GEA Westfalia Separator, Inc. ..........................................................................................81 Gum Technology .....................................................................................................................32 H.S. Crocker Company, Inc................................................................................................65 Huhtamaki .................................................................................................................................IFC International Dairy Deli Bakery Association .......................................................42, 43 International Dairy Foods Association .......................................................................11 iTi Tropicals .............................................................................................................................12, 64 KRONES ......................................................................................................................................89

Company Name

Page No.

MasoSine .....................................................................................................................................76 Matsutani ADM .....................................................................................................................14, 15 Mettler-Toledo Safeline .......................................................................................................30 MilkPEP ........................................................................................................................................87 Mintel International ................................................................................................................97 Neogen..........................................................................................................................................53 Novasep....................................................................................................................................26 a-b Novozymes .................................................................................................................................. 9 Relco................................................................................................................................................ 8 Richmond Baking ...................................................................................................................37 Robertet Flavors, Inc. ............................................................................................................63 Rocket Products, Inc. ............................................................................................................71 Ross Controls............................................................................................................................58 rtech laboratories....................................................................................................................88 S&D Coffee .................................................................................................................................35 Scholle Packaging................................................................................................................... 6 Sensient Food Colors...........................................................................................................60 Spraying Systems Co...........................................................................................................79 SPX Flow Technology Segment................................................................................... IBC Sudmo North America, Inc. ...............................................................................................57 T.D. Sawvel Co. Inc. ................................................................................................................49 Tate & Lyle................................................................................................................................ 17, 19 Tetra Pak .....................................................................................................................................31 *Tetra Pak Hoyer ................................................................................................................. 10 a-b TIC Gums.....................................................................................................................................21 Tindall Packaging, Inc...........................................................................................................85 Virginia Dare .............................................................................................................................. BC Weber Scientific .......................................................................................................................13

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INNOVATION Mintel provides the most relevant, reliable & current market intelligence available. Flavor, ingredient & preparation trends Nationwide restaurant menu tracking Global new product monitoring & analysis

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97

Inside Perspective

A Technology Column That’s not Really About Technology airy technology” may sound oxymoronic, given the most common connotations of technology. After all, we are an industry that has to strategize about feeding animals and what to do with their byproducts. It doesn’t feel exciting enough to delve into technology. Undeniably, technology (in its non-electrical, broader sense) has made our industry more efficient, but that technology has been heavily at the farm level, focusing on reducing production costs rather than at the marketing level focusing on growing sales. But I think that’s going to change. I think it has to change. Oberweis Dairy is a small company in Illinois, and our sales are primarily directto-consumer. Therefore, keeping up with marketing technology is very important, but it has been challenging and undoubtedly expensive. Believing that successful marketing to consumers today requires new methods, we’ve invested in new technology that appears to be paying dividends. Here are several examples: Microsegmentation. We are fortunate to have direct-to-consumer sales giving us the ability to study buying habits of individual customers over time and break them down into tiny segments (even as small as one). Think of having SymphonyIRI data on a person-by-person level (rather than only store level). We’ve implemented sophisticated analytics software called SAS and have found great wisdom available from careful data analysis. We’re a small company and can do this; I know larger companies have many more people to mine and analyze their data. I believe companies unable to microsegment their customers will be at a competitive disadvantage over the next decade. Apps. The cost of software development is dropping, which is making automation of many administrative tasks within reach and allowing for exciting new capabilities that could not have existed years ago. For example, we’ve launched D2D-Pro, a new

“D

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Dairy Foods | April 2011

app built specifically for the iPad platform to manage a door-to-door sales team (who sell our home delivery service). We get great data with sales call dispositions, history by address and real-time, replevel, sales-funnel statistics. Our reps are given access to their own customers’ contact information and the ability to create a new customer account on the spot, wirelessly. Because they have entered address-specific dispositions, we give them credit for a new customer who starts our service within 10 days of the rep calling on their house.

Joe Oberweis

from 2011 rather than 1911. We’ve applied for patents on both, but we want to spread these innovations throughout the industry. These are just a few examples of the investments we’re making. Within the dairy industry, we are very small. However, within the home delivery industry, we’re relatively sophisticated. We believe that many of the systems and infrastructure we’re building today will enable us to more effectively serve our customers and leverage our systems by licensing technology to other companies.

Successful marketing today requires new methods. Our investment in new technologies (including analytics software, apps and social media) appears to be paying dividends. We believe this is pioneering technology in door-to-door sales management for the home delivery dairy industry. We anticipate licensing the software to companies with door-to-door sales teams. For us, the next step is a consumer-based app to allow our customers to modify their orders and update their Oberweis accounts. Social media. No matter how much I want to avoid the hype, it’s undeniable that so-called “social media” is becoming an important way to market brands. We’ve used Facebook as an express connection to our most vocal advocates. Measuring return on investment is incredibly challenging, but measuring ROI on many marketing initiatives is challenging. Simply having a channel of communication to our best customers is intuitively worthwhile. Better delivery. Although not electrical, our delivery methods certainly involve new technology as well. We’ve designed a method to safely deliver ice cream in the summer heat (safe for people and the product) in addition to a new porch box designed with know-how

The technologies I’ve discussed above are just examples of steps we’re taking to modernize. Dairy companies everywhere should develop custom apps or complex microsegmentation strategies. As an industry, we have to understand that we’re not in 1950 anymore, and we have to adjust for the world we live in today. We’re competing in a global economy. Right now, demand for milk outside the United States is pushing raw milk prices drastically higher. Yes, “global economy” also has become a buzzword, but that has happened for a reason. We truly are operating in a world where increased demand from developing economies impacts us. My ultimate thesis is this: as an industry, we have to come into the 21st century. If we don’t, we’ll be left behind and outpaced by other countries. Joe Oberweis is president and CEO of Oberweis Dairy, North Aurora, Ill. Dairy Foods seeks essays from dairy processors. Contact [email protected].

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