Dairy Foods January 2011

UNDERSTANDING FIBER | NESTLÉ’S ASEPTIC PLANT | NEW X-RAY EQUIPMENT

January 2011

Innovative Ideas for Dairy Processors

SPOTLIGHTS

www.dairyfoods.com

Your Product. Our Systems Know-How.

Bringing a new product to market? Today’s food, dairy, and beverage lines need modern technology that is innovative, efficient and reliable. GEA Process Engineering has the engineering solutions to help carry you from initial concept through design, installation and training. Whether it is a retrofit of an existing system or developing a complete new plant, our technical expertise and years of engineering solutions can bring your vision to fruition. Specifications tricky? GEA Process Engineering works closely with your product developers to custom engineer the best solution. • drying and particulate processing systems • thermal concentration and separation • liquid processing • membrane filtration • powder packaging and conveying systems • bottling and aseptic filling lines • controls and automation . . . complete engineering solutions.

Engineering Excellence. GEA Process Engineering 1600 O’Keefe Road • Hudson, WI 54016 • Tel 715 386 9371 • Fax 715 386 9376 9165 Rumsey Road • Columbia, MD 21045 • Tel 410 997 8700 • Fax 410 997 5021 E-mail [email protected] • Website www.niroinc.com

SUPPLIER CAPABILITIES SPOTLIGHT

GEA Process Engineering Inc. Liquid and Powder Processing Equipment and Systems GEA Process Engineering Inc. is a full-service engineering company offering systems and solutions for powder and liquid processing. GEA Process Engineering Inc. is a member of the GEA Group, a global technology group specializing in mechanical and plant engineering. GEA Niro – Evaporation, Drying and Agglomeration Niro is the world leader in evaporation, spray drying, agglomeration, and fluid bed processing. We offer a full range of dryers and particulate processing systems including our own unique Integrated Filter Dryer IFD™ which features an integrated fluid bed and filter arrangement. GEA Filtration – Membrane Filtration Systems GEA Filtration provides custom-designed cross-flow membrane filtration systems to the food, food ingredients, dairy, beverage, and nutraceutical industries. The company has expertise in pilot trials and application development, systems scale-up, project engineering, process integration, fabrication, installation and start-up, service, and membrane replacement.

GEA Liquid Processing – Process Units, Process Integration and Process Automation GEA Liquid Processing is a business group dedicated to supplying process units (such as pasteurizers and UHT plants, CIP Systems, mixing and blending systems, product recovery systems, standardization systems, etc.), process integration services and liquid processing solutions. The necessary know-how to design and manufacture hygienic and aseptic plants for the production of liquid and paste products are the hallmarks of GEA Liquid Processing - competencies range from quotations/pre-engineering, design and planning, CAD, automation, installation, test/commissioning, qualification, documentation, components and spare parts, to after-sales service.

GEA Powder Systems GEA Powder Systems offers the complete range of sanitary high-accuracy powder packaging, handling and conveying systems. Including dense phase low velocity convey systems, filling of super sacks in a sanitary and dust free systems, filling of open mouth kraft paper or plastic bags 10-55lb, filling of rigid retail containers for food and pharmaceutical powders. GEA Procomac The core business of GEA Procomac is to design, manufacture and install complete aseptic and traditional filling lines for juices, teas, isotonics, still soft drinks, milk, dairy products and water.

GEA Atlas – Freeze Drying Systems GEA Atlas is the world’s leading supplier of freeze drying systems for the sanitary process industries. Atlas freeze dryers set the world standard for design, operation and quality. The delivery program includes plant sizes ranging from pilot scale to large industrial batch and continuous plants. GEA Process Engineering Inc. 1600 O’Keefe Road Hudson, WI 54016 USA Tel.: 715 386 9371 Fax: 715 386 9376 GEA Process Engineering Inc. 9165 Rumsey Road Columbia, MD 21045 USA Tel.: 410 997 8700 Fax: 410 997 5021 E-mail: [email protected] Web: www.niroinc.com

www.dairyfoods.com

3

SUPPLIER CAPABILITIES SPOTLIGHT

Chr. Hansen, Inc. What is important to you? At Chr. Hansen we strive to understand our customers on the most basic level. Strong working partnerships are the key to understanding our customer needs which drives our future innovation efforts.

Innovative Solutions Inspired by You, for You… YieldMAX® PL Same milk, more cheese CHY-MAX® M The best now better EASY-SET® Simply dependable FlavorControl® Signature cheese flavor at your speed YoFlex® Drinking YoFlex® Mild, YoFlex® Classic, YoFlex®Twist – The next generation of cultures for drinking yogurt YoFlex® Stirred YoFlex®Advance - Same texture, less cost YoFlex®Harmony – Same texture, more control YoFlex® Cup set YoFlex®Express – Same texture, less time FRESCO® The new standard for cottage cheese Probiotic Solutions PCC® -Clinically documented to support the immune health of active people BB-12® - Clinically documented to aid in digestion L.Casei-431® – Clinically documented to support the Immune system Call us to start your journey today. www.chr-hansen.com 800-558-0802

4

Dairy Foods | January 2011

New innovative yogurt solutions YoFlex® Culture System YoFlex® Drinking YoFlex® Mild, YoFlex® Classic, YoFlex®Twist A new line of drinking yogurt cultures which provide a thicker texture, while reducing stabilizers, allowing for cost-effective and clean label solutions. YoFlex® Stirred YoFlex®Advance, YoFlex®Harmony Very high texture and mild flavor cultures allow you to increase the quality of low and full fat yogurt, offering clean label solutions, while still staying cost-effective. Going hand in hand with increased end product quality these select line of cultures ensure perfect harmony and stability of your yogurt quality from production to consumption. YoFlex® Cup set YoFlex®Express Set yogurt with high texture, medium yogurt flavor and minimal post acidification. Call on us today to start your journey. www.chr-hansen.com Chr. Hansen Inc. - 9015 W. Maple St. - Milwaukee, WI 53214 - Toll free: 800-558-0802

January 2011 Vol. 112, No. 1

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

2011 Supplier Capability Spotlights On our cover: If you are wondering, “Who moved my cheese?” from lunchtime to breakfast perhaps, don’t fret. It’s a new strategy by the dairy industry to add protein to Americans’ diets throughout the day instead of just at dinnertime. With shoppers seeking more non-meat protein sources, dairy foods can be suitable alternatives. Read “Inside Perspective” for more. Page 156.

Look for these special pages throughout the magazine. Dairy Foods advertisers tell you more about their companies and the products and services they provide. Dairy processors need more than just a good idea and hard work. They need valves, vats, pumps, packaging, ingredients, services and other supplies. To find a specific supplier, see page numbers in the index of advertisers, page 155.

Features News & Trends 24 Newsline Danone acquires YoCream International; Yoplait is in play; U.S. Dairy Export Council looks at global prices; U.S. Senate passes food safety bill

Departments

New Products & Marketing 60 New Product Review

Ingredient Technology 72 Understanding Fiber

Yogurt

68

Product development editor Donna Berry leads a virtual roundtable on dietary fiber in dairy foods.

Dairy Market Trends Ice cream comes out of hibernation

80 86

16 144 150 152 155 156

Editorial Cheesemaking showcase Buyers Mart Classified Ads Index of Advertisers Inside Perspective

Dairy Detective Sharon Gerdes explains Greek yogurt.

Wellness Watch The weight-management industry touts “plus” foods that make you feel full.

REPORTS

93

A Milk Toast Nestlé USA sells the No. 1 brand of flavored milk and the No. 1 brand of juice for children. The U.S. division accounts for about 10% of the sales of its Swiss-based parent.

104 Nestlé’s aseptic milk plant 114 Behind The Scenes 120 Sayler on Safety 124 Spotlight on Sustainability 126 X-ray, metal detection, checkweighing equipment 136 Secondary packaging equipment

Peggy Blitz of the Dairy Council of Calfornia focuses on protein.

More features at Dairyfoods.com Dairyfoods.com reaches beyond the pages of our monthly print content. For Web-exclusive content, great interactive features and recent articles from Dairy Foods, visit www.dairyfoods.com. DAIRY FOODS (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

7

SUPPLIER CAPABILITIES SPOTLIGHT

Urschel Laboratories, Inc. Urschel Introduces New Grating Heads for the Models CC, CC-D, CC-DL, and CCX-D Through new Urschel engineering developments, Urschel now offers a wide variety of grating heads that offer cuts from coarse granules to different types of shreds. Grating heads present added flexibility to slicer/shredder Models CC, CC-D, CC-DL, and CCX-D. Grating heads incorporate a simple design of four posts with corresponding fasteners, upper support ring, locking lower support ring, and a grating screen. A multitude of interchangeable grating screens are available to easily switch from one style to another. Applications include cheese, coconut, nuts, and carrots. “The Model CC series of machines continues to grow. We offer several different types of CC slicer/shredders to suit different applications. New grating head options significantly increase existing cutting capabilities,” stated Tim O’Brien, vice president of sales at Urschel. Urschel offers complete Product Test Cutting Facilities throughout the world. Product Test Cutting Facilities feature extensive, complete analysis by experienced technicians to determine the best Urschel machine suited for each application, and assist customers in discovering additional cutting options. For more information, contact Urschel Laboratories, Inc., E-mail: info@urschel. com, Phone: (219) 464-4811, http://www. urschel.com, PO Box 2200, 2503 Calumet Avenue, Valparaiso, IN 46384-2200 U.S.A.

8

Dairy Foods | January 2011

22.8" Enclosure 26" Enclosure 32" Enclosure

Through Urschel Engineering advancements, Urschel now offers the new Model CC-DL Shredder with a large 32 inch cutting zone enclosure. The U.S.D.A. accepted Model CCX-D has also been revamped with the 32 inch option. A larger cutting zone enclosure enables an increased product flow area to promote higher throughputs. As a further benefit, Urschel also offers retrofit kits for existing Model CC-D Shredders already in production lines. Contact Urschel to explore these new developments.

Increase Your Cheese Shredding Capacity NEW

32"

Model CCX-D • U.S.D.A., Dairy Division Accepted. • Available 5 or 10 HP motor. • Fully enclosed motor compartment. • Swing-away feed hopper. • 24 inch or NEW 32 inch cutting zone enclosure. • Produces a wide variety of shreds, slices, strip cuts, and NEW grating options.

NEW

!

2" " OR 3 6 2 IT NEW OFIT K RETR

Model CC-D • Available 5 or 10 HP motor.

Model CC-DL • Powerful 10 HP motor. • Swing-away feed hopper. • Large 32 inch cutting zone enclosure. • Produces a wide variety of shreds, slices, strip cuts, and NEW grating options.

• 22.8 inch cutting zone enclosure standard. • Retrofit kits enlarge cutting zone enclosure to 26 or 32 inches. • Produces a wide variety of shreds, slices, strip cuts, and NEW grating options.

URSCHEL LABORATORIES, INC. Email: [email protected] • Phone: (219) 464-4811 PO Box 2200, 2503 Calumet Avenue Valparaiso, IN 46384-2200 U.S.A. ®Urschel is a registered trademark of Urschel Laboratories, Inc.

SUPPLIER CAPABILITIES SPOTLIGHT

A.T.S. Engineering Inc. A History of Innovation In the field of rigid plastic packaging, it takes a combination of skill and experience to provide tailor-made solutions for each customer’s individual requirements. A.T.S. Engineering Inc. knows this well. A.T.S. had its beginnings many years ago redesigning and modifying other dairy product filling machines to run faster and more efficiently. As the number of satisfied customers grew, A.T.S. began to receive requests to build new equipment from the ground up. Custom Design & Manufacturing A.T.S. Engineering designs and manufactures high-quality filling, sealing and overcapping equipment that suits a wide range of applications. Our durable rotary and straight-line machines can package a variety of liquid and viscous products including juices, sauces, dips, salads, sour cream, cottage cheese, ricotta, yogurt and ice cream. Adaptable for either single or multiple filling operations, our affordable machines meet or exceed USDA, FDA and 3A standards. Since we believe long-term performance is absolutely paramount, all of our products are rigorously tested prior to being shipped to our customers’ plants. Commitment to Excellence Over the years, we have worked hard to earn our reputation as single-source specialists in high-speed filling, sealing and overcapping machines for this demanding market. Our ability to deliver reliable machines that can be counted on for years of trouble-free operation comes from merging technical expertise with an understanding of what our customers need in their plants. Total Packaging Solutions At A.T.S. Engineering Inc. we do more than simply build equipment. We are your packaging machine consultants. From installation to startup and training, we use our long history of applications 10

Dairy Foods | January 2011

experience to ensure that customers get optimum results every step of the way. Our manufacturing staff and engineers are ready to support your needs at any time with technical assistance and expertise, while our service technicians are available at a moment’s notice. Our installation goes beyond simply setting up the equipment in your plant; we are present during your initial start-up to insure your equipment is running as flawlessly as possible. All installation and training is provided by us at no extra cost with the installation of all new equipment. From concept to completion, we consider ourselves part of the process - and are never satisfied until you are.

A.T.S. Engineering Inc. 104 Hedgedale Road Brampton, Ontario L6T 5L2 Canada Phone: 905.457.2871 (toll-free: 1.800.263.6416) Fax: 905.457.6131 Website: www.atseng.ca

Automated Milk Component and Somatic Cell Testing Engineered for dairy laboratories and dairy processing facilities that require highly reliable and accurate instrumentation.

January 2011 Vol. 112, No. 1 www.dairyfoods.com

• Fat, protein, lactose and solid analysis by FTIR spectroscopy • Up to 500 samples per hour

• Somatic cell count by flow cytometry • Extensive remote diagnostic capabilities

CALL: 952.448.7600 (USA) EMAIL: [email protected] VISIT: www.bentleyinstruments.com

Also available: IBC-M: Rapid enumeration of individual bacteria and somatic cells BactoCount Series: Real-time analysis of total Flora

Sign Up To Receive Your Free DIGITAL Edition of Dairy Foods Today! Innovative Ideas for Dairy Processors

Audience Development Manager Kourtney Bell Multimedia Specialist Katie Jabour Audience Audit Coordinator Carolyn M. Alexander

No special reader software to download! Use your standard browser to view the Dairy Foods Digital Edition. Get the Digital Advantage NOW at www.dairyfoods.com/digital. Customer Service (847) 763-9534.

12 Dairy Foods | January 2011 DFDigitalAd-Quarter.indd 1

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] Senior Group Publisher Peter Havens [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 Petra Cady [email protected] Editorial Reprints Jill DeVries 248-244-1726; [email protected] List Rental Postal: List Rental Manager Robert Liska 800-223-2194 x726; [email protected] Email: Account Manager Shawn Kingston 800-409-4443 x828; [email protected] Audience Development

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 Information Technology: Scott Kesler Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Breanne Rozek 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

2/4/10 3:22:51 PM

SUPPLIER CAPABILITIES SPOTLIGHT

Fristam Pumps USA Fristam is a leading manufacturer of high-performance stainless steel pumps, blenders, and mixers with design and production facilities in Middleton, WI and Hamburg, Germany. Fristam products are designed for precision and durability to outlast and outperform all others and provide the highest lifetime value. With unmatched knowledge and experience, we partner with you for custom innovative solutions. Positive Displacement Pumps • Fristam’s new FKL A positive displacement pump series features a clean, rounded exterior; split-style gearbox for easy access to bearings and shafts; and customizable port-to-port dimensions for easy drop-in replacement of other PD pumps. The FKL A is built for no-disassembly-required “True CIP”. Its design allows CIP flow to reach all areas of the pump, including the seal. Nothing is ever removed and cleaned “out-of-place”. Other manufacturers increase clearances for rotor-in CIP, reducing efficiency. With the FKL, clearances remain tight and efficiency remains high. FKL A pumps have large diameter shafts, balanced rotors, and a heavy-duty gearbox. They are rated for up to 500 PSI standard on most models. An optional stainless steel gearbox is offered for difficult environments. • Standard-duty FL II series pumps maintain product integrity with their gentle handling. They are CIP-able and handle viscosities to 100,000 cps. Centrifugal Pumps Fristam centrifugal pumps serve as the industry benchmark for quiet, efficient, low-maintenance operations. They include: • Easy-maintenance FPR series pumps, built with a front pull-out seal. • Heavy-duty FP series pumps for demanding applications such as vacuum

withdrawal from evaporators, viscous, hot, or abrasive products. • Standard-duty FPX series pumps for products with viscosities up to 600 cps. • High-pressure FM, FPH and FPHP series pumps for discharge pressures to 1,250 PSI. Self-Priming Liquid Ring Pumps For CIP solution and foamy or aerated products, Fristam’s FZX series pumps reduce waste by completely removing product from equipment. Able to lift water up to 23 feet, FZX pumps maintain their prime when other pumps become air-bound. Powder Mixers Fristam’s Powder Mixer blends dry and wet ingredients into a fluid stream. This quick and efficient mixing method maintains performance even as product viscosity increases. The Fristam Powder Mixer is customizable and provides consistent batch-to-batch repeatability and reduced blend times.

It offers repeatable results and reduces raw material usage and processing times.

Fristam Pumps USA 2410 Parview Road Middleton, WI 53562 800-841-5001 www.fristam.com/usa

Shear Blenders FS Shear Blenders improve product consistency by removing agglomerates and preventing lumps and masses in product.

www.dairyfoods.com

13

SUPPLIER CAPABILITIES SPOTLIGHT

SensoryEffects® Flavor Systems Our Approach At SensoryEffects®, we touch the senses. We do this by working collaboratively with our customers to develop a wide range of innovative food and beverage products with customized ingredient solutions that meet their specific needs. Being privately held and focused on customer responsiveness, we pride ourselves on being able to make quick decisions, offer flexible scale from bench to plant scale-up, as well as provide personalized customer service and sales representation. We strive to make it very easy to do business with us and make sure that we deliver clear value in our product and service solutions. Our Capabilities To support our unique and personalized business approach, SensoryEffects has a

cepts (see products highlighted below with

• Coffee Creamers and Syrups

wide range of capabilities that help us to

an asterick *).

• Hot Beverage Bases • Smoothie Syrups

deliver on our value proposition and continually exceed customer expectations. We

Our Products

• Vitamin Emulsions

bring many strengths into play while devel-

Here is a list of our current product offer-

• Complete Hot Cocoa and Hot Beverage

oping new products and servicing our cus-

ings by end use market/applications:

tomers including:

Frozen Dessert Systems

• Lean and flexible equipment

• Flavor Bases

• Unique processing equipment

• Variegates (both regular and textured)

• Developmental / Formulation expertise

• Solid Pack Fruit Preparations

• Technology collaboration with our

• Toppings and Syrups

Systems* • Complete Branded Juice Beverage Programs (Juice Pac ™) • Complete Branded Milk Alternatives (Vitamite ®)

other two facilities (Powder Systems

• Coatings

Bakery Systems

and Cereal Systems)

• Chocolate Flakes / Inclusions

• Inclusions (Browns, Fruits, Dairy, and

• Applications labs / Pilot plant

• Novelty Bases and Cores

Savory)

• Sensory capabilities

• Alkalized Cocoa Blends

• Toppings

• Regulatory support

• Complete Branded Ice Cream Feature

• Fillings

• Quality programs – SQF Level 2 Certified

Flavors*

• Coatings

• Personalized customer service • Innovation support / Marketing guidance

Beverage Systems • Milk Flavors (including Chocolate

In addition to our traditional ingredient

14

Dairy Powders)

Please contact us to discuss your specific needs and to put our unique resources and approach to work for you. You can contact

systems, we also now have many products

• Fruit Drink Bases (0 to 100% juice)

us at 800-422-5444, email info@sensory

that could be considered “turn-key” and

• Iced Tea Concentrates

effects.com, or visit our website at www.

retail ready formulations and product con-

• Eggnog and Cordial Flavors

sensoryeffects.com.

Dairy Foods | January 2011

The Ingenious Pursuit Of Flavor

)ODYRU6\VWHPV

$W6HQVRU\(IIHFWVŠ)ODYRU6\VWHPV

$VH[SHUWVLQWKHGDLU\EHYHUDJHDQG

ZHKDYHDSDVVLRQIRUFDSWXULQJWKH

IUR]HQGHVVHUWLQGXVWULHVZHDGGYDOXH

HVVHQFHRIWKHFRQVXPHU¶VGHVLUHIRU

WR\RXUSURGXFWDQGVHUYHDVDSDUWQHU

DXQLTXHH[SHULHQFH:HVHDUFKRXU

LQH[SORULQJQHZDQGXQFKDUWHG

LPDJLQDWLRQVZKLOHH[SORULQJWKH

WHUULWRULHVLQWKHXQLYHUVHRIIODYRU

ZRUOGRIIODYRUDQGLWVXQLTXHHIIHFWV

$VVFLHQWLVWVDQGPDUNHWHUVZHHQMR\

RQWKHVHQVHV2XUJRDOLVWRPDNH

XVLQJRXUFUHDWLYLW\E\WDNLQJWKHRUGLQDU\ DQGWXUQLQJLWLQWRVRPHWKLQJH[WUDRUGLQDU\

WKHH[SHULHQFHRIIODYRUDQHQOLJKWHQLQJ RQHWKDWOLIWVVSLULWVDQGWDVWHEXGV

&RQWDFWXVLI\RX¶GOLNHVRPHIRRGIRU WKRXJKWRQ\RXUVSHFLILFSURGXFWV

EH\RQGJUDYLW\WRQHZKHLJKWV

)ODYRU6\VWHPV_3RZGHU6\VWHPV_&HUHDO6\VWHPV 5RFN,QGXVWULDO3DUN'ULYH_%ULGJHWRQ02_S_I_LQIR#VHQVRU\HIIHFWVFRP ZZZVHQVRU\HIIHFWVFRP \

From the Publisher’s Desk

Success Through Partnerships hank you, partners.” Those are the words that Organic Valley’s CEO George Siemon and his management team spoke when we visited them last fall to prepare our 2010 Processor of the Year story (December’s cover story). They are passionate about recognizing their numerous processing partners — milk handlers, hard-working bottlers, cheese-cutters, butterchurners, suppliers, retailers and consumers — all the while being the voice of their 1,600-plus cooperative family farms. That same month we traveled to Ovid, Mich., to interview the executive team at Michigan Milk Producers Association and to tour their facility, the winner of our 2010 Plant of the Year award. This balancing plant operates seven days a week, 24 hours a day, in large part due to a very impressive two-year $62 million dollar expansion. You’ll have the chance to congratulate both teams at this year’s Dairy Forum awards luncheon, Jan. 24 in Miami. I hope to see you there. These two award winners help to demonstrate that while the recession has taken its toll on many industries, dairy processing has remained a bright spot the last few years. Across the nation we’ve been seeing growth and expansions such as, new cheese plants by Jerome Cheese Co. and Leprino Foods to new ice cream operations by Graeter’s and Pierre’s. In the yogurt sector, General Mills has been pouring millions into plants in Michigan and Tennessee. The slow economy has brought opportunities to expand while construction costs are low. And, the industry has benefited from making foods that consumers still buy (and want to buy), even in hard times. We are fortunate to be in the dairy foods business. Meanwhile, at Dairy Foods, we’ve ended our third full year of momentous change since the introduction of a special section called Dairy Field Reports. The results and the response continue

“T

16

Dairy Foods | January 2011

Tom Imbordino

to be beyond our expectations. The combination of Dairy Foods’ marketing, product development and formulation coverage, and Dairy Field Reports’ processing, operations, packaging, logistics, food safety and sustainability coverage continues to deliver the most complete media package serving the dairy processing industry. Speaking of sustainability, we’re proud to introduce a new column, Spotlight on Sustainability. This quarterly feature, written by Clay Detlefsen of the International Dairy Foods Association, promises to deliver keen insight. On page 124, he tells how processors are saving thousands of dollars by reclaiming waste heat. We were fortunate to visit with many of you last year, whether it was at your headquarters, in your plant, at the International Dairy Show or elsewhere. This access to your boardroom and your trust allows us to provide reporting and content unique to the market. Combined with dairyfoods.com — where you’ll find behindthe-scenes photos from our plant visits, videos from supplier partners, news feeds and more — and Dairy Product Innovations, our monthly e-newsletter focused on new products and trends, Dairy Foods is a formidable and indispensible source of industry information. And now you can stay connected with us wherever you are via Facebook, Twitter and our professional network on LinkedIn. Each January, we publish our Supplier Capabilities Spotlights, giving our advertisers a chance to tell you more about their companies and the products and services they provide. These companies are ready to partner with you to conquer today’s business challenges to achieve tomorrow’s business goals. Please continue to support our many advertisers. We hope Dairy Foods continues to be your go-to guide for success in the dynamic world of dairy food manufacturing. Thank you, partners.  Tom Imbordino, publisher of Dairy Foods, can be reached at 773/755-8990 or [email protected].

Our laboratory catalog isn’t everything to everyone.

Ou rs

irs e Th

Just inspiration for those seeking solutions for food and dairy analysis. Lost faith in dealing with a 3,000 page catalog that doesn’t know or care about your special testing needs? Restore your trust with our 265 page sourcebook devoted to products for food and dairy testing. Includes a true belief in simple and rapid methods.

CONTAINS MANY HARD-TO-FIND AND EXCLUSIVE ITEMS.

Weber DB™ pre-filled sterile dilution bottles have a quick-pull sterility strip that is much easier to open.

Insite™ environmental Listeria self-contained test device gives presumptive results in 24-30 hours.

Easygel™for rapid microbiology – a superior ready-to-use pour plate.

Colilert® and Colisure® for water results for coliform and E. coli in as fast as 18 hours.

Request your FREE catalog today. Legendary for great prices since 1959

Call 800-328-8378 or visit www.weberscientific.com

SUPPLIER CAPABILITIES SPOTLIGHT

Ampco Pumps Company Ampco stainless steel pumps have been in use in dairy and food processing plants since 1957 when a Z Series flanged unit was installed in a first generation CIP system. The initial acceptance of these units, based on reliability and outstanding performance, encouraged Ampco to offer sanitary connections. In the 1980’s Ampco’s D Series pumps set the standard for CIP and COP applications. Today we have considerably more to offer. **New in 2011** Complete ZP Series * Ampco has recently introduced our new ZP Series of positive displacement pumps • The ZP1 and ZP2 pumps are dimensionally and hydraulically interchangeable with competing brands • Both ZP1 and ZP2 models can be rebuilt with over-sized rotors to extend the pump’s useful life. We offer several rebuild options. • The ZP Series was designed to include the most popular features of leading pd pumps • Most significantly, all new ZP Series pumps include a stainless steel gear case and remain cost competitive to pumps with cast iron gear cases LC/LD Series * Heavy duty castings with high efficiency design • Standard stainless steel adapter • 100% interchangeable with competing FPX/FP pumps LF Series * Front loading seal for easy maintenance • Single or double seal options • Standard stainless steel adapter • 100% interchangeable with competing FPR pumps SP Series * Liquid ring pumps with self priming capability

18

Dairy Foods | January 2011

• Ideally suited for CIP return; drum unloading; and handling products with entrained air • 100% interchangeable with competing FZX pumps ZL Series * Rotary lobe pumps with unique front loading seal design for easy maintenance • Multiple rotor options including biwing, tri-lobe and multi-lobe • Mechanical seal, o-ring and lip seal options • Outstanding cleanability – EHEDG certified C+ Series * Improved shaft design with collar and impeller nut * Longer life for seals and backplates • Hydraulically and dimensionally interchangeable with traditional C Series style pumps Our expanded product line offers the same outstanding performance and reliability that we’ve demonstrated over the past 50 years. We’d like the opportunity

to introduce you to these new products while saving you money. We also offer a complete industrial line of pumps for your non-sanitary requirements.

Ampco Pumps Company 2045 W. Mill Road Glendale, WI 53209 www.ampcopumps.com (414) 643-1852

SUPPLIER CAPABILITIES SPOTLIGHT

Evergreen Packaging Equipment New

EQ-70

gable

top

packaging

machine from Evergreen Packaging ELL® features maintain product quality CEDAR RAPIDS, IA, USA – Evergreen Packaging manufactures a full line of filling equipment for refrigerated dairy, juice and liquid food products. Gable top packaging equipment, which forms, fills and seals paper gable top cartons, is ideal for pasteurized, ESL (Extended Shelf Life), ELL (Extended Long Life), and hot fill applications. These machines fill cartons from 4 oz. up to half-gallon (150ml up to two liter), at speeds from 30 up to 340 cartons per minute. SPOUTPAK twist-off closures are also available for most gable top cartons.

keep running efficiently, Run Time™, a

Evergreen Packaging Equipment intro-

serve food service and convenience store

comprehensive parts and service pro-

duced the new EQ-70 gable top packag-

markets. With fill volumes of 4 to 16 oz

gram provides genuine Evergreen parts

ing machine at IDS 2010, which will be

(125 to 500ml), the new Eco-Pak® machine

manufactured to OEM specifications

commercially available in 2012, designed

fills 4 to 8 oz. (125 to 250ml) cartons up to

to maximize production, reduce risk of

to serve liquid food markets.

10,200 cph (170 cpm) and 10 to 16 oz. (300

product loss and protect equipment war-

to 500ml) up to 8,500 cph (142cpm).

ranties. The company stocks an exten-

ELL® (Extended Long Life) components include a self-contained CIP/SIP

The Q-70 serves the small to mid-size

sive inventory of critical parts and offers

system, environmental control features,

volume market. With fill volumes of 6

24/7/365 availability for emergencies. A

carton treatment and a hermetic filling

to 32 oz (180ml to 1.15L), the Q-70 fills

network of fully-trained, experienced

system to maintain product quality.

quarts/liters up to 7,000 cph (117 cpm)

technicians is established to handle any

With fill volumes of 6 to 32 oz (180ml to

and fractionals up to 9,000 cph (150 cpm)

size service request.

1.15L), the EQ-70 fills quarts/liters up to

to meet market demand for a mid-speed

7,000 cph (117 cpm) and fractionals up to

quart/liter cross-section machine.

9,000 cph (150 cpm) with a three-stage top down fill system. Servo driven technology provides repeatable package performance and automatically controls fill volumes and profiles based on product and carton size. Infinite fill adjustments allow for less down time with quick and easy changes to fill volume and carton height.

20

The N-100 serves the school milk, single

Dairy Foods | January 2011

To ensure that Evergreen machines

For more information, contact Evergreen Packaging Equipment at 319-399-3306 or visit www.evergreenpackaging.com.

Take a

FRESH APPROACH with The Shelf Life People. We deliver freshness in many shapes and sizes. The Q-70 (quarts/liters) and the N-100 (Eco-Pak®) gable top Ñlling machines help preserve the shelf life of a wide variety of products including milk, specialty dairy products, liquid egg products and still beverages. Maximize production: Servo-driven inÑnite Ñll system Gain Ľexibility: Quick & easy changes to Ñll volume, carton heights Reduce downtime: Easy to operate & maintain, autolube system standard Protect operators: Low infeed loading height provides ergonomic design Ensure freshness: Four levels of carton sanitization available

Want to apply our fresh approach to your next product? Call us today ... because we’re The Shelf Life People.

©2011 Evergreen Packaging Inc. All Rights Reserved. Eco-Pak is a registered trademark of Evergreen Packaging Inc.

Cedar Ceda Ce darr Ra da Rapi Rapids, pids pi ds,, Iowa ds Iowa • 31 319319-399-3200 9-39 939939 9-32 93200 32 00 www. ww www.evergreenpackaging.com w.ev w. ever ev ergr er gree gr eenp ee npac np acka ac kagi ka ging gi ng.c ng .com .c om

SUPPLIER CAPABILITIES SPOTLIGHT

Sensient Food Colors As the leading worldwide color supplier, Sensient® Food Colors continues to define the future of the food and beverage industry through superior capabilities, creative formulations, and extraordinary insight into what strengthens and protects brands. We combine color expertise and advanced science with secure sourcing to deliver customized solutions that are as innovative as they are healthy and safe. Because Sensient has a deep understanding of the fundamental connection between people and color, we work tirelessly to enhance the sensory appeal and product performance every day, all around the world. Through our strategic global presence, we are able to ensure safety throughout a product’s entire lifecycle, from harvest to manufacture, resulting in complete confidence and valuable market opportunities. In fact, Sensient has been leading the way towards advanced color systems for over a century. The authority in natural color, we use our unparalleled technical expertise to harness nature’s resources and create vibrant colors that grow brands naturally. Sensient’s mission is to help customers exceed consumer expectations for safe, preservativefree products with clean labels, consistently stable color and safe and secure ingredients. Our natural color solutions, Fusion Precise Natural Colors®, is at the forefront of the natural, environmentally friendly ingredient trend. With preservative-free and GMO-free options available, this unique natural color line is characterized

22

Dairy Foods | January 2011

by proven consistency and stability while delivering an extensive color spectrum. Customized to customers’ specific shade and attribute requirements, Sensient’s Fusion Precise Natural Colors brand delivers ultimate flexibility. Market research shows that consumers want simple, more wholesome ingredients in their products, and studies continue to reveal that natural colors possess compounds that promote health and wellness. To that end, Sensient expertly infuses natural color into key market segments, including beverage, dairy, bakery, confection, pet food, and processed food.

Sensient’s natural color building block line provides a comprehensive list of colors derived from nature, such as annatto, turmeric, beta-carotene, and anthocyanins, in the form of liquid dye blends, emulsions, dispersions, natural lakes, and powders. Furthermore, our complete range of synthetic colors, including FD&C dyes and lakes, blends, dispersions, liquid dyes, and powders, are manufactured to the highest standards to accommodate domestic and global markets. Because your brand’s success is ours, Sensient is constantly investing in resources to enhance customer experience and to further the industry as a whole. From building state-of-the-art, natural color facilities to facilitating educational opportunities through workshops and lectures across the globe, to providing the ACE Automated Color Expert (our proprietary online sample request system and product selection tool) we are dedicated to being an invaluable partner. Sensient Food Colors – The bold difference in your brand. Contact www.sensientfoodcolors.com.

News & Trends

NEWSLINE... YoCream, Danone Enter Merger Agreement YoCream International, Inc. and Danone have entered a definitive merger agreement under which a subsidiary of Danone will merge with YoCream. Danone, based in Paris, is a Fortune 500 company. Its U.S. subsidiary, The Dannon Co., ranks 24th on Dairy Foods’ Dairy 100 list of the country’s largest dairy processors, and YoCream ranks 98th, with sales of $50.7 million in 2009. In separate news, The Dannon Co. agreed in December to stop claiming that one daily serving of its Activia yogurt relieves irregularity, and that its DanActive dairy drink helps people avoid catching colds or the flu. The action was in response to a complaint by the Federal Trade Commission. John Hanna will remain chief executive officer and a director of YoCream following the closing of the transaction. The company’s senior management team will also remain intact. They, along with one former board member, will retain an ownership interest of approximately 5% in the company following the closing. In addition, the name of the company will remain YoCream International following the closing. YoCream’s business is manufacturing mixes for soft-serve frozen yogurt to foodservice operators. Its customers include Costco, quick-serve restaurants, convenience stores and independent yogurt shops. YoCream developed a smoothie product for the Jack In The Box restaurant chain. Besides making yogurt products, YoCream expanded into frozen carbonated beverages marketed under the Jolly Rancher and Jarritos brands. The company is known for its high-quality product. Yogurt has culture counts of 100 million per gram or higher (the National Yogurt Association requires only 10 million.) YoCream’s main yogurt line encompasses 40 flavors in non-fat, premium and nosugar-added varieties. YoCream Select features flavors inspired by Hershey candy brands, including Kisses, Reese’s and York Peppermint Patties. All of the company’s frozen yogurt contain high levels of beneficial live and active yogurt cultures, including S. thermophilius, L. bulgaricus, L. lactis and L. acidophilius. Other dairy offerings are frozen custard, ice cream and shake mixes. “The company has been exploring various opportunities for continued growth for some time,” Hanna says. “This transaction benefits our shareholders by providing them with the opportunity to receive a significant premium for their YoCream shares, and joining the Danone Group represents a natural progression in our corporate achievement to provide healthful live and active cultured frozen yogurt to consumers in the U.S. and abroad. We have continued our strong track record of innovation in this category and appreciate that Danone has recognized our leadership role for frozen yogurt in the foodservice industry.” YoCream expected the transaction to close before Dec. 28, 2010 (after this issue went to press). Should the closing not occur by the

 John Hanna, YoCream ceo end of the year, YoCream shareholders will receive an additional $0.97 per share if capital gains tax rates are higher on April 15, than they were on Dec. 31, 2010. The transaction is subject to the satisfaction of customary closing conditions, as well as the approval of YoCream’s shareholders. For more about YoCream, go to “Recession Proof ” in the June 2010 issue or online at www.dairyfoods.com.

Yoplait in Play A 50% stake in the Yoplait brand, owned by PAI Partners, a private equity fund, and Sodiaal, a French farmers’ cooperative, was put up for sale in late 2010. Yoplait is the world’s second-largest yogurt maker. Various news reports said potential buyers are General Mills, which owns the Yoplait franchise in North America, Bright Food of China and Switzerland’s Nestlé. PepsiCo, which bought the Russian dairy company Wimm-Bill-Dann in 2010, also has been mentioned as a potential buyer. Yoplait’s owners rejected a bid in November 2010 from Lactalis, France, for the entire company. The Financial Times reported that French government was willing to use a state-backed strategic investment fund to become a shareholder in Yoplait. Continued on page 26

24

Dairy Foods | January 2011

SUPPLIER CAPABILITIES SPOTLIGHT

Aseptomag Aseptomag is a Swiss-based engineering firm that designs and fabricates aseptic and hygienic process valves and flow components. We have over 30 years of experience in the field of aseptics and we utilize our knowledge to serve our clients around the world. Our aseptic valves are used in the areas of process engineering where the highest quality standards are required. Aseptomag is the market leader in this aseptic valve range and we are continually improving and expanding our product line. Our valves are known for their reliability, ease of maintenance, and a minimum amount of replaceable parts. Our goal is to provide the highest quality valves on the market while focusing on maintaining a low Total Cost of Ownership for our clients. We utilize modern fabrication techniques to pro-

duce our valves which can be integrated into compact modular skidded systems. At Aseptomag we are able to assist our clients from the design stage, through fabrication, and all the way to implementation and start-up. Our products are highly adaptable to a vast array of processes and applications. If you have a special application and require a specific solution please feel free to contact our

tic asep ‘000 ration 0 5 n tha ope More s in daily e v l a v

design department. We will work with you to develop a unique solution for your process.

"TFQUJD
Ÿ
4BGFUZ Aseptomag AG specializes in aseptic and hygienic process engineering. We work in cooperation with our clients to develop specific and innovative solutions for the food, beverage, pharmaceutical and cosmetic industries. Component Manufacture We develop, design and build high quality components for process engineering systems. Our products are recognized for their outstanding quality, functionality and easy servicing. Feedba Feedback Feed db ck dback Unit

Sampling Valve

Module Building We design and carefully integrate process technology into compact modular skidded systems. We utilize the most advanced means of production to meet the needs of our international clientele. We are your expert resource for all your needs:

s$ESIGN s%NGINEERING s-ANUFACTURING …and servicing.

Aseptic Shut-off Valve

Food Safety Mix-proof Valve

Aseptic Control Valve

For U.S. sales information contact: [email protected] Tel. 815 633 8411 www.aseptomag.us Aseptomag AG CH-3422 Kirchberg

Aseptic Double Chamber Valve

www.dairyfoods.com

25

WA S H I N G TO N WATC H

News & Trends

Senate Passes Food Safety Bill The U.S. Senate passed a food safety bill on Nov. 30, 2010 that gives the U.S. Food and Drug Administration more power to police food companies. The bill, supported by the White House, passed 73 to 25. The House of Representatives passed its own version last year. The Associated Press reported that the bill’s prospects are “unclear” because there is little time remaining for the House and Senate to reconcile different versions before the lame-duck session of Congress expires. AP reported that Sen. Tom Harkin (D-Iowa)

said he has agreement from some members in the House to pass the Senate bill, which would send the legislation straight to President Barack Obama’s desk. Harkin sponsored the legislation. The food industry, public health groups and consumer advocates backed provisions of the bill. The Grocery Manufacturers Association (GMA), in a statement by its president and CEO Pamela G. Bailey, said “We applaud the Senate for passing S. 510, The FDA Food Safety Modernization Act.” Bailey said the “landmark legislation provides

FDA with the resources and authorities the agency needs to help strengthen our nation’s food safety system by making prevention the focus of our food safety strategies. We urge the House of Representatives to swiftly follow suit so that the president can sign this important legislation as soon as possible.” The bill does not apply to meat, poultry or processed eggs, which are regulated by the Agriculture Department. Those foods are subject to more rigorous inspections and oversight than FDA-regulated foods.

USDEC’s 2011 Dairy Outlook: Are Higher Prices Sustainable? Strong global demand and some supply hiccups helped dairy markets recover in 2010, but panelists at USDEC’s fourth annual “Global Dairy Outlook” webinar Nov. 16, 2010 said the key questions for 2011 are whether demand can be sustained at higher price levels and how strongly milk production responds. At the event, which drew nearly 300 listeners from 17 countries, moderator Marc Beck, senior vice president of export marketing for the U.S. Dairy Export Council, Arlington, Va., suggested that benchmark commodity whole milk powder prices would trade in a band between $3,500 and $4,500 per ton next year, a price “that’s shown to be sustainable on the demand side and a price that is needed to sustain production growth and production profitability out of the market leader in Oceania.” While rising food inflation posed a risk to demand in the year ahead, Jon Hauser, editor/publisher of Xcheque.com, suggested that growing wealth in developing countries was enhancing buyers’ ability to pay. Historically, dairy prices in Asia have been depressed versus the Western world, largely due to export subsidies, says Hauser. With those subsidies removed, “the question is whether we are seeing food inflation or seeing the rest of world more able to afford dairy at prices that the Western world is used to paying.” Other panelists weren’t ready to concede the notion that a higher price threshold would prevail. “I tend to wonder if that’s really a sustainable price,” said Dalyn Dye, president and CEO of Hoogwegt U.S., Libertyville, Ill. “I wonder whether the amount of milk that might be produced when that kind of price translates back to farmers is really the amount of milk customers around the world can consume.” 26

Dairy Foods | January 2011

Added Phil Plourd, president of Blimling & Associates, based in Cottage Grove, Wis: “I am inherently skeptical of ‘paradigm shifts’ in any overarching sense. Price always matters. And it is easy to underestimate supply-side response. I am intrigued, however, at notions that the developing world is better able to absorb higher prices than the developed world. Countries such as China have cash. They need to keep the people fed. Still, bubbles are bubbles. We are not there yet, in my estimation. But I can see how we get there.” Continued buying from China would be key to how the 2011 markets unfold, speakers agreed. They’ll also be keeping their eyes on New Zealand weather and how quickly highfeed costs curtail milk production in the United States and Europe. Based on recent supply growth, panelists foresee softer conditions in early 2011 giving way to tighter markets later in the year. To view an archived version of the presentation, covering issues of price elasticity, global milk supply and currency exchange rates, go to www.usdec.org or www.webinars. dairyfoods.com. Continued on page 32

JUNE 8-10, 2011 MARRIOTT MINNEAPOLIS WEST ST. LOUIS PARK, MN

TECHNOLOGY SHORT COURSE

TECHNOLOGY SHORT COURSE

B RO UGHT TO YO U BY:

www.membranecourse.com B RO U GHT TO YO U BY:

Registration Now Open!

The Practical Membrane embrane Technology Short Course is back and better than ever. The 2011 Short Course will mark the 6th consecutive year that Dairy Foods Magazine and Filtration & Membrane World LLC have partnered to produce this one of a kind event.

This two-day short course will bring together plant engineers, scientists, chemists, and technicians with the first day of the program focusing on fundamentals of membrane technology and the second day focusing on new R EGI STR ATIO N FE ES membrane technologies and FULL 2-Day CONFERENCE REGISTRATION applications. An optional third day Early Bird – $795 (before March 31, 2010) to the program will include plant tours Standard – $895 (after March 31, 2010) where participants can visit local SINGLE DAY REGISTRATION membrane companies and system Early Bird – $495 (before March 31, 2010 manufacturers for an up close and Standard – $595 (after March 31, 2010) personal look at processes, DAY 3 TOURS technologies applications. giess and ap $75

ur o Y t Ge rship so n o p S y! a d o T TOM IMBORDINO Publisher/Midwest Regional Sales P: (773) 755-8990 [email protected]

Learn More at www.membranecourse.com Let our short course put you and your products face-to-face with new and existing industry decision makers.

Visit our website or contact your sales rep to learn more about sponsoring this event.

DR. SEFA KOSEOGLU Filtration and Membrane World LLC P: (979) 764-8360 [email protected]

WAYNE WIGGINS, JR. Western Regional Sales P: (415) 387-7784 [email protected]

AMY VODRASKA Eastern Regional Sales P: (973) 970-9000 [email protected]

CATHERINE WYNN Inside Sales P: (847) 405-4010 [email protected]

SUPPLIER CAPABILITIES SPOTLIGHT

MarketPlace THE FOOD MARKETING AGENCY, MarketPlace was formed in order to meet a growing need for a full-service marketing communications partner dedicated to the food and beverage industry. Simply put, we are a diverse group of experienced food and ingredient brand activists who are passionate about helping your company thrive. We are devoted to cultivating custom marketing solutions through an abundance of branding, technological, and creative tools, all based on a true understanding of your business. You can expect targeted, collaborative strategy first, followed closely by the appropriate, brandbolstering carry through. Our mission is to use our unrivaled industry wisdom, as well as our desire to rally around your company’s goals, to excite a positive, creative revolution in your market. Established by marketing and technology professionals who have an extensive history of success in the food and bever-

28

Dairy Foods | January 2011

(www.market-pl.com)

age industry, it is only natural that our focus followed suit. Our MarketPlace is your MarketPlace, and from a project’s inception to its finale, WE GET IT. Our customers are both consumer and business-to-business companies and, as a result, we benefit from having firsthand knowledge of a product’s entire lifecycle – from ingredient to finished application and from commercialization to consumer promotion. The combination of our food industry and agency experience allows us to fully understand marketing brands through highly developed strategies, all based on our expertise in marketing communications, technology, and dynamic design. Our core competency is our ability to think strategically, as well as deliver creatively and tactically. In essence, we become an extension of our customers’ internal resources in a collaborative effort to develop customized plans that grow your business. Once we fully grasp your goals, what

we deliver can take many forms, including inspired branding, engaging package design, sophisticated online tools, targeted campaigns and promotions, and strategic presentations and sales tools. Having been described as Brand Activists, the MarketPlace team is characterized by a relentless fixation on crafting complete marketing solutions that exceed your expectations and generate fresh, valuable opportunities in your market. Here you’ll find the business savvy to the intrepid designer; the marketing communications confidant to the technologically trained. We’re distinct because of the sheer breadth and depth of our relevant skills, and our forte is how we apply these skills, perfectly aligning your objectives with measurable results. So you see, we’re not just Brand Activists - we’re YOUR Brand Activists. Is yours a company that desires to define the food and beverage market in new and iconic ways? If your answer is yes, then we should talk. Go to www.market-pl.com to learn more and to visit our Facebook and Twitter pages, or call us at 314.647.9500.

SUPPLIER CAPABILITIES SPOTLIGHT

NAVBIA Photos courtesy of Hank Kaestner and Douglas Daugherty

Vanilla is the world’s most popular flavor. Most of the world’s supply of vanilla beans is produced by tens of thousands of small, mostly family-run farms.

In

fact, one of the world’s most impoverished countries, Madagascar, supplies the vast majority of the beans that are used throughout the world. It is no surprise then that the farming of vanilla beans is especially critical to the people of Madagascar and its economy. The North American Vanilla Bean Importers Association (NAVBIA) was formed out of necessity in 2010 by a group of concerned vanilla dealers and importers. Our primary mandate is to protect the authenticity and brand of the vanilla bean within the flavor and fragrance industry. Despite the Federal Regulations that are in place to do just that, misrepresentation and abuse of the vanilla brand and image are rampant within the industry today. As just one example, we estimate that over one billion pounds of ice cream sold in the US each year is mislabeled accord-

30

ing to the Federal Regulations currently

with natural substitutes. Many, such as

products has soared, we have actually seen a

in place. While the consumer is being

Natural Vanillins, are incorrectly being

drop in the consumption of vanilla beans at

duped, vanilla farmers in Madagascar,

perceived as acceptable simply because

the industrial level. How can this be?

Uganda and other origins are struggling

they are natural. Nevertheless, this is still

NAVBIA is a nonprofit organization and

to feed their families.

a direct violation of Federal Regulations.

our mandate continues to be defined as we

This despite the very clear Federal

Furthermore, it is a deception for the con-

evolve within the food industry. Stopping

Regulations stating that the characteriz-

sumer, who is bombarded with words like

further erosion of the usage of vanilla beans

ing flavor of Category 1 vanilla ice cream

“Pure” and “Natural” sometimes alongside

by making the industry aware of their regu-

must originate from the vanilla bean.

images of vanilla flowers and vanilla beans

latory obligations when sourcing their fla-

When it comes to Vanilla ice cream that is

by manufacturers vying for brand loyalty.

vor requirements is just one of our goals.

labeled “Pure Vanilla” or “Natural Vanilla”

The reality is that many of these advertised

Consumer awareness programs, product

ice cream there is no other alternative.

natural vanilla products are not flavored

testing and verifications, the promotion

Despite this clarity, many manufactur-

using the vanilla beans in accordance with

of the usage of vanilla beans and the pro-

ers have been tempted to replace natural

the Federal Regulations. Over the years, as

tection of the vanilla brand and image are

flavors originating from the vanilla bean

the popularity of naturally flavored vanilla

other key objectives.

Dairy Foods | January 2011

News & Trends

World Dairy Expo Seeks 2011 Award Nominations World Dairy Expo 2011 is in search of outstanding leaders from across the international dairy industry to fill four categories: Industry Person of the Year, Dairy Woman of the Year, Dairyman of the Year and International Person of the Year. The Industry Person of the Year award, for instance, recognizes excellence in research, development, education, marketing or other fields that are part of the dairy industry. The Dairyman and Dairy Woman of the Year awards are presented to individuals who are active dairy producers and whose primary source of income is derived from their dairy operation. His/her farming operation needs to demonstrate and excel in efficient production and breeding of quality animals, along with progressive management practices, involvement in community, government activities, breed organizations and other aspects of the dairy industry.

The International Person of the Year will be recognized for significantly contributing to international relations, business development, trade or cooperation in the dairy industry. Individuals will be honored at the Dinner with the Stars during World Dairy Expo, Oct. 4-8, in Madison, Wis. Nominations are due Feb. 15. Official applications are available online at www. worlddairyexpo.com, or by calling 608/224-6455 or via email at [email protected]. World Dairy Expo is an international dairy cattle and tradeshow that draws more than 65,000 visitors annually. Members of the dairy industry from more than 90 countries gathered in 2010 for the world’s largest dairy-focused tradeshow, international dairy cattle shows and sales, youth judging contests, virtual farm tours and educational programs.

Dairy Facts 2010 Now Available The latest edition of Dairy Facts, published by the International Dairy Foods Association and Dairy Foods, is now available in print and online versions. This 120-page book provides a comprehensive overview of 2009 sales, consumption and production data for the dairy

foods industry and is delivered in an easy-to-use format. Dairy Facts also offers information from government and private market research sources on the fluid milk, cultured dairy, cheese and ice cream and frozen desserts markets. To order a copy, go to www.idfa.org. Continued on page 36

An ERGONOMIC solution that safely & securely transfers product in single & multiple layers from one pallet to another. Applications include: Order fulfillment, specializing in bulk delivery. Creation of mixed pallets & pallet transfer. Conveyor feeding. Breakdown of damaged pallets. Breakdown of incoming product for receiving. Increase pick rates from 200 cases per hour manually to over 2,000 cases per hour with The TYGARD CLAW. An investment that provides a wide array of benefits, including major savings through reductions in manual labor, seasonal employment, overtime, warehouse injuries & overall insurance costs. The industry leader with over 15 years of proven results.

Products & Features Include: • The high performance Tygard Claw Side Mounted Systems. • The versatile quick disconnect Front Mounted Tygard Claw. • Tygard’s layer pick technology easily handles product no other attachment can. Including multiple sized pallets with ranges from 32”x37” to 40” x 48”.

32

Dairy Foods | January 2011

Phone: ( 7 2 4 ) 7 4 6 - 4 5 0 0 To l l F re e : 1 - 8 7 7 - 7 4 6 - 4 5 0 1 e m a i l : i n f o @ t y g a r d c l aw. c o m v i s i t : www.tygardclaw.com 300 Meadowlands Blvd • Washington, PA 15301

SUPPLIER CAPABILITIES SPOTLIGHT

Fogg Filler Fogg Filler, is continually focused on improving technology that better serves our customers and the environment. That is why Fogg is introducing the new Microb-Blaster® for bottles. It is an environmentally friendly and effective way to clean the atmosphere inside the bottles. The Microb-Blaster® for Bottles is a UV-HEPA Bottle Sanitizer. It has been designed to sanitize bottles with UV light and exchange the air inside the bottles with HEPA air filtration at the same time. It can achieve a .5 – 4 log reduction on the exposed surfaces of the bottles. This patent pending technology actively monitors the UV output to determine when the light source needs to be replaced. Because of the light source’s placement, density, and monitoring you can keep production running with confidence.

This unit can be integrated to a new Fogg Filling system or retro-fitted to nearly any line. By adding this machine to your line you greatly reduce the risk

of bringing bio-burden into the filling environment. This is one more level of product safety your customers will appreciate.

www.dairyfoods.com

33

SUPPLIER CAPABILITIES SPOTLIGHT

Norit Südmo More than ever, dairy and liquid food producers are seeking to combine sustainability and economic value by doing ‘more with less’. With Norit Südmo as your process partner, you can have a competitive product from a CAPEX standpoint with the benefit of the lowest total cost of ownership. Norit Südmo’s extensive range of sanitary and aseptic process valves combined with the expertise of our team offer hygienic and aseptic processors the ability to maximize their production time and operational flexibility. In addition, a strong focus on service provides for the optimum product life cycle. Innovative Products Norit Südmo’s proven products lead from a technology point of view. A few advantages of our mix proof valves include: • Robust body provides roundness to protect seal life • Clear protection of cross-contamina-

Norit’s Efficient Performance Technology

losses, chemical usage, and maintenance

continuously challenges us to seek solu-

materials and labor, Norit Südmo helps

tions that provide the optimal processes for

our customers meet their long-term

your dairy or liquid food plant.

financial sustainability goals. Norit Südmo’s past performance proves

tion with deflector technology Life Cycle Costs

the most cost-effective valve system option

Initial capital cost is, in most instances,

in the long run. Do not waste a day. Partner

a fraction of the whole life cost of a typi-

with Norit Südmo, the supplier who assures

Efficient Performance Technology

cal valve installation. Downtime with loss

that you will dramatically reduce your valve

Norit’s Efficient Performance Technology

of productivity and replacement of short

total cost of ownership and give you an

mark of excellence, for its top perform-

life expectancy consumable parts, such

advantage over your competitors.

ing products, incorporates one of the key

as seals, make up a large portion of the

Call us anytime at 815-639-0322, or go

principles of sustainability ‘do more with

total life cycle cost. Norit Südmo’s valves

to www.sudmona.com to view or down-

less’. This philosophy applies to prod-

provide more plant efficiency and lon-

load brochures and manuals. We look

uct innovations and solutions that offer

ger running times. By reducing product

forward to helping you ‘do more with less’.

• Most intelligent and robust control top technology

measurably higher performance and efficiency against competitive pricing. Our recently launched IntelliTop® 2.0 control unit carries this mark of excellence, and is a prime example of this principle put into action.

34

Dairy Foods | January 2011

We Know Innovation Matters Introducing the IntelliTop® 2.0

The best just got better

Building on our proven IntelliTop®, Norit Südmo’s IntelliTop® 2.0 is specifically designed to further increase plant efficiency by controlling, monitoring and reporting on all valve functions in the process plant. When you use the IntelliTop® 2.0 with our valve range, which includes the 365it PMO Mix Proof Valve, you have reliable, efficient and complete process control. No doubts. Norit. Just proof.

s Built-in micro-controller tracks maintenance information s Solenoid throttling controls opening and closing speed s IP 65/67/69K meets water tight needs in the process room All-around 360° visual display s s Low power consumption saves energy

Südmo North America Inc. TsF 815.639.1135 EINFO SUDMONACOMs I www.sudmona.com

News & Trends

GMA Launched New Website The Grocery Manufacturers Association (GMA), Washington, D.C., unveiled a new website and launched a blog dedicated to the issues, policies and news relating to the consumer packaged goods (CPG) sector. The new website, www.GMAOnline.org, is a redesigned digital platform that offers a wealth of resources, information and upto-the-minute news pertaining to GMA members and the organization’s strategic areas of focus, including health and nutrition, product safety, global commerce, customer collaboration and environmental sustainability. Other features include a rotating feature box on the homepage providing visitors with a direct link to the most relevant and timely issues and resources; a designated section for GMA members, allowing easy access to the latest research, industry model practices, events, public policy developments and more; and comprehensive public policy resources ensuring that the views and positions of the grocery manufacturers’ industry are readily available to all interested audiences. GMA’s new blog, Across the Aisle (www.GMAOnline.org/blog), will feature discussion and analysis of the CPG industry and policies affecting the industry, offered by GMA leaders and staff. Blog posts also will include interviews with heads of GMA member companies, regular commentary on media stories, observations on industry trends and public policy.

Additionally, GMA developed an active social media presence, with an industry- and policy-focused Facebook page (www. Facebook.com/GroceryManufacturersAssociation) and Twitter feed (@GroceryMakers). The association is using these social media tools to facilitate increased and easier interaction between the association and its members, policy makers, the media and other interested audiences.

Portland, Ore., Couple Endows Dairy Professorship A Portland, Ore., couple donated $860,000 to Oregon State University’s Paul G. and Sandra A. Arbuthnot Professorship Fund, to create the Arbuthnot Dairy Center within the College of Agricultural Sciences, support internships and endow a faculty member to develop and deliver state-of-

the-art education and outreach programs for OSU students and Oregon’s small dairy foods processors. The Arbuthnots’ gift qualifies for the OSU Provost’s Faculty Match Program, a new initiative to encourage donors’ investments by providing five years of additional support

for programs that receive endowed gifts for faculty positions that help advance priorities identified in the university’s strategic plan. Their gift is part of The Campaign for OSU, the university’s first comprehensive fundraising initiative. It has raised more than $630 million toward its goal of $850 million. Continued on page 42

36

Dairy Foods | January 2011

SUPPLIER CAPABILITIES SPOTLIGHT

Separators, Inc. Your “One Stop” Source… Great Service… Great Value

Service Separators, Inc is your full service centrifuge solutions provider. We offer “One Stop” shopping for your Alfa Laval, Tetra Pak, and Westfalia centrifuge needs and service many other brands. Our full array of service offerings are designed to get you started correctly and keep you running efficiently. Equipment Separators, Inc. specializes in fully remanufactured high speed disc and decanter centrifuges. Our robust remanufacturing process is done to O.E.M. specifications and is fully warranted. We source the best equipment and remanufacture to the highest standards delivering great value and availability. In addition the company offers a line of new Rotoseives designed for cheese fine and other small particle recovery.

Centrifuge Service, Equipment, and Parts

Separators, Inc. 5707 W. Minnesota St. Indianapolis, IN 46241 800-233-9022 [email protected] www.separatorsinc.com

Your One Stop Centrifuge Source

Service Equipment Parts

We specialize in the service, repair and remanufacturing of Alfa Laval, Tetra Pak and Westfalia centrifuges. Separators, Inc. keeps your equipment in production and running efficiently. 24/7 Parts & Service Bowl Repair/Balancing Centrifuge Controls Variable Frequency Drives

Parts In support of our customers we stock over 4,000 parts and offer 24/7 responsiveness. Stock items are frequently shipped the same day. Our knowledgeable parts staff makes finding the right parts for your equipment easy and credit card purchases are welcome. Key capabilities include: • Field Service – Preventative Maintenance and Repairs • Complete Remanufacturing and Repairs • Equipment Rental • Short Lead Time - Availability • Controls and Variable Frequency Drives • Installation and Start Up Support • Operator Training • Tailored JIT Part Kits • Centrifuge Consultation

(800) 233-9022

www.separatorsinc.com

www.dairyfoods.com

37

SUPPLIER CAPABILITIES SPOTLIGHT

DSM Nutritional Products A strong partner for a demanding market Dairy product marketers and manufacturers need strong partners to meet the growing expectations for today’s health-minded consumers. Increasingly, consumers continue to seek healthy alternatives to their favorite foods and beverages. They want fortified foods and beverages that deliver proven nutritional benefits, helping them look and feel their best. In the complex world of food and beverage fortification, only the strongest of partnerships can deliver a sustainable competitive edge. Choose the strongest partner to help deliver that advantage: DSM, a world leader in nutritional fortification for more than 70 years!

38

Broad product portfolio DSM Nutritional Products is the world’s premier nutritional ingredient manufacturer and solutions provider to producers of foods and beverages. Our extensive product portfolio includes user friendly formulations for all the fat and water soluble vitamins, carotenoids for coloration and fortification, highly refined ROPUFA® Omega-3 & Omega-6 Fatty Acids and novel nutraceuticals. Utilizing our extensive resources, we keep our customers ahead of the ever-changing marketplace, anticipating customer needs as nutritional trends develop and customer demands evolve.

Unique INNOVATION portfolio DSM’s extensive portfolio of healthful ingredients for dairy-based products includes: ALL-Q® coenzyme Q10 with exceptional bioavailability; Teavigo®, a high-purity EGCG from green tea; Fabuless®, a patented lipid system for weight management through satiety; resVida®, a high-potency, pure form of trans-resveratrol for healthy aging; ROPUFA® ‘15’ Omega-3 Food Emulsion, a fully suspended solution that allows higher levels of omega-3 fortification without influencing the taste or stability of any applicable dairy product.

Quali®-Blends just for you Quali®-Blends premixes provide dairy product manufacturers with the exact ingredients they need in homogeneous, customized blends, which enable them to reduce the costs of quality control, warehousing and processing while assuring them of high-quality products and services. Quali®-Blends premixes can include vitamins, carotenoids for nutrition and color, and an extensive range of nutraceutical ingredients, minerals, amino acids and natural extracts, which are formulated into customized dry and liquid premixes.

How can we health you? DSM can help you get to market faster with appealing health solutions that work. At the forefront of nutritional science, we can help you stay ahead of scientific and market developments with nutritional solutions ideally suited for dairy products. We identify consumer health interests and understand them as well as track market trends and translate this information into innovative nutritional solutions that are relevant to this growing market such as Bone, Cognitive and Heart Health, Weight Management and Kid’s Nutrition.

Dairy Foods | January 2011

Contact us To learn more about how DSM can support your dairy product fortification initiatives with appealing health solutions that work, contact us at 1-800-526-0189 or go to our website at www.unlimitednutrition-na.dsm.com.

SATISFY HER GOAL OF APPETITE CONTROL

Fabuless® is a unique, patented lipid system that promotes satiety and appetite control. It has an extensive body of scientific evidence that substantiates its effectiveness in both short and long-term weight management. Fabuless® is a natural and safe ingredient that works with the body’s own appetite control mechanism to offer a clinically proven weight management solution. Available in powder and liquid forms, Fabuless® has been used successfully in a broad range of foods, beverages and dietary supplements throughout the world. To find out more about how dairy products such as low-fat milk, yogurt and smoothies are ideal for the weight management and satiety benefits of Fabuless®, visit www.unlimitednutrition-na.dsm.com or call 1-800-526-0189.

© 2011 DSM Fabuless® is a registered trademark of DSM.

SUPPLIER CAPABILITIES SPOTLIGHT

California Custom Fruits and Flavors At California Custom Fruits and Flavors, we are always thinking of ways to excite the senses. A true custom ingredient innovator and manufacturer, nearly every product we make is specially crafted for each customer. Couple our customer-centric approach with a focus on flavor, ingredient and application development and the end result is consumer-preferred products. California Custom Fruits and Flavors has invested significant resources in the creation of our state-of-the-art flavor lab. Not only has this capability strengthened our application systems, but our flavors are featured in some of the largest brands within the dairy, beverage, bakery, confectionery, and foodservice industries. Diverse and enhanced capabilities in the development of ingredients and flavors across multiple product categories gives California Custom Fruits and Flavors a richer knowledge of what people want from a taste, texture, and product attribute perspective. We partner with our customers to develop custom flavors, flavor bases, fruit products, and variegates where texture, profile, and appearance drives the eating experience. Devising innovation using new ingredient or processing methodologies

40

Dairy Foods | January 2011

is enhanced by our diverse capabilities in application development. For example, we are developing texture enhanced variegates that become even more unique in the way in which they are introduced into ice cream during processing. Known as fruit sourcing and manufacturing experts, we offer premiere capabilities to our customers that allow us to deliver frozen dessert and cultured ingredients of all types, flavors and price points backed by solid supply and food safety programs. People are looking for ‘Superheroes’, or foods and beverages that offer bundled attributes, including great taste, texture, functionality, and convenience made with health-oriented ingredients that benefit the body. California Custom Fruits and Flavors’ dedication to health and wellness trends, like fruit incorporation, natural sweetener use, clean labeling and nutrition enhancement, are core to our capabilities. Achieving serving claims while maintaining consumer-preferred profiles involves as much art as science. By partnering with you, we provide solutions or

marketing opportunities to achieve… • Use of simple ingredients • Natural or organic claims • Functional benefits to the body • Lifestyle objectives • Ingredient addition • Ingredient reduction • Natural ‘goodness’ claims • ‘Free’ claims • Traceability and sustainability of ingredients • Food safety, stability and security Recent developments include products that net in a ½ to full serving of fruit and vegetables for dairy applications, and achievement of calorie reduction in dairy-based beverages by using Stevia as a natural sweetening agent. The purity of Stevia is an important consideration. We source only the purest form of Stevia, that way we achieve an optimal level of sweetness in which to apply masking flavors needed to deliver the perfect profile. We are California CUSTOM Fruits and Flavors. Custom means that we develop products with you, for you. Contact us as 877.588.0056 or visit us at www.ccff.com.

News & Trends

PEOPLE Xyience, Las Vegas John Lennon has been named new president, bringing 25 years of beverage industry leadership to the growing energy drink brand, including his most recent post as president and CEO of Pabst Brewing Co. DurLennon ing his tenure at Pabst, Lennon led the company to its first growth in organic sales volume in 20 years, resulting in improved profitability, while guiding the company through a sales transaction process. Prior to joining Pabst, Lennon was responsible for the 2006 launch of International Beverage USA (InterBev). Lennon has served as president and CEO of Pyramid Breweries and Beck’s North America, with responsibility for the United States, Canada and Caribbean. His background also includes a period as vice president and general manager of Guinness Caribbean and Latin America, where he served on the board of directors of several breweries and soft drink bottlers throughout the region. He also functioned in senior marketing and sales roles with the Nestlé Co., Mexico’s FEMSA Cerveza, Grand Metropolitan (now Diageo) and with Guinness in both the United States and Ireland. Sargento Foods Inc., Plymouth, Wis. Mike McEvoy has been promoted to president, replacing Mike Gordy who is retiring after 32 years with Sargento. McEvoy served as vice president of sales of the food ingredients division for the past 18 months. Prior to that, he was vice president of Portionables integration at Sargento, where he provided valuable insights into its manufacturing capabilities and customer interactions. McEvoy also served as general manager of Portionables, where he supervised operations, accounting and human resources. In his 12 years with Sargento, he also has held positions in operations, consumer product sales and marketing management. DCI Cheese Co., Richfield, Wis. T i n a D o z i e r was appointed help desk coordinator, responsible for installation and support of hardware, desktop software, operating systems and network connectivity. Jim Matelski was named IT infrastructure manager, responsible for ensuring the stable operation of DCI’s IT infrastructure. Joe Scheske was named senior portfolio supply planner, and will manage the supply chain for a major component of one of DCI’s key accounts. Rick Vitlip joins as quality analyst/auditor, responsible for providing guidance internally and within

the vendor base to promote vendor quality initiatives. Additionally, he will work to ensure that appropriate quality controls, risk mitigation mechanisms and continuous programs are in place. Chris Sandretti was promoted to general manager-Green Bay, responsible for managing the Green Bay conversion facility and supervising the supply chain team. Cathy King’s role has been expanded to now include training merchandisers and store personnel on DCI’s specialty cheeses. International Dairy Foods Association, Washington, D.C. Jonathan Gardner, a longtime food safety expert at the U.S. Food and Drug Administration, has been appointed to fill the position of vice president of regulatory affairs and Gardner international standards. In this role, Gardner will direct all aspects of IDFA’s Hazard Analysis and Critical Control Points (HACCP) Certification Program, and oversee product safety and quality control issues, as well as federal and state regulatory affairs. He also will participate in International Dairy Federation committees and the National Conference on Interstate Milk Shipments (NCIMS). While at FDA, Gardner served for eight years as a consumer safety officer on the Center for Food Safety and Applied Nutrition (CFSAN) Grade “A” Milk Safety Team. In this position, he focused on regulatory issues involving the Pasteurized Milk Ordinance (PMO) and served on several NCIMS committees, including the Third-Party Certification Pilot Program Committee, the Technical Review Committee and the Heating and Cooling Section Review Committee. Most recently, Gardner worked in FDA’s Division of Human Resource Development as the lead training officer for Grade “A” dairy and aseptic processing courses. He also led courses on environmental sampling, Good Manufacturing Practices (G M Ps) for food, food safety management at retail and veterinary medicine training. Before joining FDA, Gardner worked as an environmental health specialist for the Virginia Department of Health, where he served as the liaison between the department and other state and federal agencies involved in food and dairy regulation. He inspected Grade “A” dairy processing facilities and regularly validated the processing equipment for a variety of pasteurization systems. Comax Flavors, Melville, N.Y. Jake Cohen has been named sales associate, responsible for new business development, market research, account management and account service. Prior to joining Comax, Cohen was a digital media specialist for Context Web. Prior to that, he was the advertising sales director for PSP Sports. Continued on page 46

42

Dairy Foods | January 2011

Cost Savings and Higher Yields That You Can Take to the Bank

With the Westfalia Separator® hyvol® proplus ® system, dairies can expect significant reduction in milk losses as well as savings in both operating water and waste disposal costs. But that’s not all. Our patented process keeps more of the protein in the milk, allowing production of additional high value dairy products. And that’s even better news for your bottom line. Couple these advantages with low maintenance and energy expenditures and you get a separator that delivers improved profits from the very start. To learn more about our separators, call Chris Sandiford at 201-784-4334 or email him at [email protected].

Liquids to Value GEA Mechanical Equipment 100 Fairway Court · Northvale, NJ 07647 Phone: 201-767-3900 · Fax: 201-767-3416 Toll-Free: 800-722-6622 · 24-Hour Technical Help: 800-509-9299 www.wsus.com

1403

GEA Westfalia Separator, Inc.

FULL potential Are your dairy products reaching their FULL potential? Recent studies demonstrate that foods formulated with Fibersol®-2 digestion resistant maltodextrin can provide an increased feeling of satiety so consumers felt fuller for a longer period of time. Fibersol®-2 can also be used to replace calories from sugar and fat while increasing the fiber content to create ice cream and sorbet type products under the appropriate labeling standard Fibersol®-2…it’s the fiber you want for your dairy applications Archer Daniels Midland Company announced the formation of a joint venture between ADM, Matsutani Chemical Industry Co., Ltd., and Matsutani America, Inc. on May 1, 2006. This joint venture was formed to support the worldwide sales and marketing of the food ingredient Fibersol-2, a soluble dietary fiber.

without adding any taste, aroma or unwanted viscosity of it’s own. Fibersol®-2 digestion resistant maltodextrin is the fiber you want so your consumers and your dairy products can reach their FULL potential!

Fibersol-2 digestion resistant maltodextrin a soluble corn fiber that can be used in a variety of food and beverage applications as well as dietary supplements. Invented by Japan’s Matsutani Chemical Industry Co., Ltd., Fibersol-2 has been exclusively produced at ADM’s Clinton, Iowa, facility since 1999.

Only 1.6 Calories per gram!

The joint venture combines Matsutani’s strong technical and scientific expertise with ADM’s vast production facilities and transportation network, resulting in a quality food ingredient that is backed by highly consistent service and a readily available supply. Supports Digestive Health Fibersol-2, the premier slow fermentation soluble dietary fiber, has been shown in clinical studies to help support intestinal health. When formulating products for digestive health it is critical to meet consumers’ need for a great tasting product while using ingredients that are easy to use and well tolerated. Fibersol-2 is tasteless, improves body/texture and offers masking properties while it provides the benefits of a good fiber with superior digestive tolerance. It is also highly soluble, provides a clear and transparent solution, acid and heat stability, very low viscosity, promotes moisture retention and has very low hygroscopicity. Applications include: dairy products, beverages, processed foods, baked goods, dietetic foods and supplements.

SUPPLIER CAPABILITIES SPOTLIGHT

ADM/Matsutani LLC

satiety

Compatible with All Dairy Products Fibersol-2, a digestion resistant maltodextrin a soluble corn fiber (90+% water soluble dietary fiber), is compatible with all dairy product applications. This includes fluid, cultured, frozen, and fermented dairy foods such as: fortified milks, flavored milks, yogurt beverages, smoothies, coffee whiteners,whipped toppings, yogurts, pro-biotic products, sour cream, dips, dressings, cottage cheese, frozen desserts, no sugar added (NSA) frozen desserts, true sugar free frozen desserts, low/reduced fat ice creams, gelato, sorbet, water ices, full, low, no fat frozen yogurts, novelties, other frozen dairy confections and natural and processed cheeses. Fibersol-2 is stable under all processing and packaging conditions. Fibersol-2 adds no viscosity, color, or flavor to foods to which it is added.

lower calorie Improves Flavor, Mouthfeel and Sweetness in Dairy Products Fibersol-2 can significantly improve the flavor of dairy foods by influencing taste (i.e., mouthfeel). This includes dairy foods which may be sweetened with a variety of high intensity sweeteners, making these sweeteners truly more “sugarlike”. Fibersol-2 also improves the flavor of low solids dairy foods, classical acidic products and dairy foods to which other flavors may be added.

sugar-free digestive health

Check out the new www.fibersol2.com Whether you are developing a new dairy product or want to make an existing product healthier, go to the new www.fibersol2.com site and find out why Fibersol-2 is the fiberIFT youBooth want in #2737 your dairy products.

it’s the fiber you want soluble low glycemic response clean taste

ADM / Matsutani LLC

Go to www.fibersol2.com for details on our dairy prototypes and more information on all the benefits of formulating with Fibersol-2!

www.dairyfoods.com

45

News & Trends

PEOPLE Old Orchard Brands, Sparta, Mich. Doug Acree has been named regional business manager serving the greater New York metropolitan market. Acree maintains more than 25 years of grocery and consumer product sales experience, and brings a track record that includes a number of past national sales awards, as well as a skill set developed by holding top business development positions for international consumer products companies spanning across grocery and health and beauty categories, including American Italian Pasta Co. and L’Oreal Cosmetics. Royal DSM N.V., The Netherlands Chief executive officer Feike Sijbesma received the 2010 Humanitarian of the Year Award from the United Nations Association of New York for his outstanding commitment to corporate social responsibility and for DSM’s partnership with the United Nations World Food Programme (WFP). For some time, DSM has maintained a strategic partnership with the WFP to address the problems of malnutrition in the developing world. The partnership,

“Improving Nutrition- Improving Lives” is a program that has, to date, helped approximately two million people across Nepal, Kenya, Bangladesh, Afghanistan and other countries to enrich their lives through proper nutrition. The partnership aims to include micronutrients for at least 80% of WFP’s beneficiaries. Source One Packaging, LLC, Hauppauge, N.Y. Don Perillo has been promoted to national sales manager. This promotion follows 10 years of service, in which Perillo has displayed an exemplary sales record and has shown a steady commitment to client satisfaction.

Schneider

Wilbur Curtis Co., Montebello, Calif. Dan Schneider has been named vice president of national accounts. Schneider has been with the company for nine years as Midwest regional sales manager and more recently as vice president of sales for the Northern region.

Continued on page 50

46

Dairy Foods | January 2011

SUPPLIER CAPABILITIES SPOTLIGHT

ADI Systems Inc. ADI Systems Inc. specializes in industrial wastewater treatment, water reuse and wasteto-energy projects and can offer a number of solutions for the dairy products/processing industry, from treatment to water reuse to renewable energy from waste. We have a great deal of experience treating wastewater from dairy processing and cheese production plants, and we’ve installed hundreds of systems worldwide for dozens of different companies. With nearly thirty years of industrial wastewater experience and installations in over thirty countries, ADI Systems has the knowledge and technology to make every project a success. ADI offers a number of technologies that can provide different solutions for dairy plants: • High-strength wastewater treatment: First, we offer a variety of anaerobic technologies designed to easily treat the high-strength waste often generated during dairy processing, including high-rate systems, low-rate

systems, and anaerobic membrane bioreactors (MBRs). These systems are often used for pretreatment prior to discharge to a municipal treatment system. Renewable energy in the form of biogas is a by-product of this type of treatment and provides a further benefit to the dairy plant. • Treatment to Discharge Quality or Water Reuse/Recycle: Second, we offer a variety of aerobic technologies that can be used to polish the anaerobic effluent to a quality suitable for disposal or reuse, or can be used as standalone treatment. Our membrane bioreactor (MBR) system, the ADI-MBR, is based on the world’s leading MBR technology and can produce reuse-quality water within an easyto-operate, small-footprint package. The effluent is suitable for a variety of uses, from irrigation to cooling towers, as well as to provide ultra-high-quality feed water to a reverse osmosis (RO) system.

• Waste Solids Digestion: We also offer systems for the handling and digestion of waste solids, which incorporate energy recovery in the form of biogas. The energy recovered is, in many cases, a significant portion of the plant energy needs. • Energy Recovery: Finally, we can provide complete energy recovery systems that can reduce natural gas and electrical power consumption at dairy plants, including boilers and generators. This includes biogas collection, transmission, scrubbing, and utilization.

ADI Systems Inc. [email protected] 1-800-561-2831

ADI treatment solutions can tackle the toughest wastewaters from dairy processing plants, producing effluents for discharge or reuse. High-rate and low-rate anaerobic processes, aerobic systems, and membrane bioreactors (MBRs) are all available from ADI Systems Inc. ADI treatment systems can produce reuse-quality water within an easy-to-operate, small-footprint package and reduce energy consumption. Solution benefits: • Water reuse/reclamation • Waste-to-energy systems, biogas recovery and utilization • Eliminate surcharges and meet the most stringent effluent limits • Turnkey systems

ADI Systems Inc. – suppliers of world-class treatment technologies 1.800.561.2831 [email protected]

SUPPLIER CAPABILITIES SPOTLIGHT

Cognis® Nutrition & Health Cognis® Nutrition & Health…the leading global supplier of naturally sourced ingredients to promote healthy nutrition and well-being. Cognis provides complete solutions and marketing-oriented concepts to help customers meet consumer demands for innovative functional foods. Add value to your products with our marketable health claims and scientifically-proven ingredients. Experience, expertise and excellence… these are the cornerstones of our success. Cognis understands the consumer marketplace and will work with you to optimize your next new product. Whether formulation assistance, label claim support, or advertising co-promotion, Cognis’ customer-focused teams are experts in technical service, science, sales support, and marketing to ensure the success of your products Cognis Nutrition & Health is a business unit of the Cognis Group which employs over 6,000 people and operates production sites and service centers in 30 countries. Newtrition™…gives your product a healthy edge Newtrition™ from Cognis® Nutrition & Health provides the perfect balance of premium quality, naturally-sourced ingredients for your products to meet the hottest trends in the marketplace. Cognis Nutrition & Health is helping to transform ordinary dairy foods and beverages into new functional wellness foods. Newtrition™ ingredients can help you develop products and position your business for long term growth. Tonalin® CLA (conjugated linoleic acid), is a great example of the added value of Newtrition™. Tonalin® is the perfect balance for your fat fighting product. Tonalin® CLA helps reduce body fat by up to 10%, while maintaining lean body mass. CLA is a polyunsaturated fatty acid derived from natural safflower oil. CLA is a natural component of many dairy products such as cheese, milk, and

48

Dairy Foods | January 2011

ice cream. Now that healthy diets trend toward low-fat food choices, consumers do not get the CLA their body needs from food alone. To obtain the recommended 3.0 grams of dietary CLA required to achieve its body composition benefits, consumers would have to eat more than 4 gallons of ice cream, 7 pounds of beef or 4 gallons of milk every day. The Tonalin® range of conjugated linoleic acid products is available in multiple concentration forms to meet a wide range of formulation requirements. Approved dairy applications include: • Yogurt • Fermented Milk • Milk Based Drinks • Soy Milk • Fruit Based Drinks • Meal Replacements

Tonalin® CLA is #1 globally and the world’s most researched CLA, with 18 major studies proving its safety and effectiveness. The US Food & Drug Administration has recognized Tonalin® CLA as FDA GRAS. And, since Tonalin® CLA is sourced from natural safflowers, a renewable resource, it is an environmentally responsible choice. Global Leadership • #1 CLA brand • Superior quality • Broadest CLA portfolio Proven Science • Safe, effective and proven results, showing… ■ Reduces up to 10% of body fat ■ Prevents fat regain ■ Increases lean muscle mass • 18 clinical studies published in peer reviewed journals • FDA GRAS in multiple dairy applications

Technical & Application Excellence • Committed to ongoing R&D • Proprietary manufacturing process Customer Focused Support • Ranks #1 with consumers • Customized co-promotion programs • Powerful consumer marketing campaign and website (www.tonalin. com) With 40+ years of excellence in the food industry, Cognis is a world leader in naturally-sourced, science backed functional ingredients that meet the safety, performance and convenience expectations of both food processors and consumers.

Cognis 1.888.866.2546 www.cognis.com www.tonalin.com [email protected]

Newtrition -the perfect balance. TM

Tonalin® CLA’s fat-fighting and body shaping benefits can bring your body composition and well-being into balance.

t Reduces up to 10% body fat and prevents fat regain t Effectiveness and safety proven by 18 clinical studies t Multiple forms for easy addition to functional foods and beverages TM

Newtrition - Eat. Feel. Live.

For reducing body fat

Cognis Corporation Nutrition & Health Phone: 1.888.866.2546, Fax: 513.482.5516 Email: [email protected] © 2010 All Rights Reserved. TONALIN® conjugated linoleic acid (CLA) is an exclusively licensed product of Cognis Group.

www.cognis.com www.tonalin.com

News & Trends

SUPPLIER NEWS

Hixson, one of the leading design and engineering firms in North America, is proud to sponsor the Food Plant of the Future webinar series. This webinar series is intended to provide engineering and operations executives with insights and technology solutions to many of the critical issues facing food and beverage processors. The following webinars are now archived:

Bete Fog Nozzle Inc. expanded its sales representative network with the appointment of the Charles P. Crowley Co. (CPC) as its exclusive sales representative for the southern California and southern Nevada markets, thus expanding Bete’s coverage in these areas. The Charles P. Crowley Co. is an Irwindale, Calif.-based manufacturers’ representative and brings more than 75 years of professional sales representation experience in a variety of industries. Cognis strengthens its global presence by setting up new regional application centers for food ingredients. The first application center was opened in June 2010 in Kuala Lumpur, Malaysia to serve customers in the South/East-Asia region, while a second one will open up in Jacarei, Brazil, at the end of the first quarter of 2011. This facility will go hand in hand with the new production line that is due to commence operation, also at the end of the first quarter of 2011. There are also plans to open centers in China and the United States.

In honor of the 50th Anniversary of the Model 25 Series pilot-operated, pressurereducing valves, Spirax Sarco produced a movie demonstrating its principles of operations. This movie outlines the relationship between the spring compression, steam pressure, diaphragm chambers and pilot/main valve positions under various conditions. To view the 25 Series movie, go to www.spiraxsarco.com/us. Intelligrated collaborated with system integrator Automation Dynamics to achieve 300% distribution center productivity gains for KeHE Distributors, a U.S. distributor of natural and specialty food products to small and mass market retailers across the country. KeHE, which operates 13 distribution centers across the United States, initiated a centralization strategy that consolidated two of the company’s Northeastern centers into a new 312,000-square-foot one in Allentown, Pa., forming a single, high-efficiency operation. The Allentown installation, valued at $1.8 million, is a hybrid system of horizontal pick carousels, a pick- and putContinued on page 54

Surviving and Thriving with Automation Advancing Food Safety through Sanitary Design Building Realistic Sustainability into Food and Beverage Plants Access these and other archived webinars and learn about what’s coming next at www.foodplantofthefuture.com.

Connect with Dairy Foods, wherever you are! Now it's easier than ever to stay connected to the BEST source of the latest news and information. Find us on Twitter, LinkedIn and Facebook.

Follow Dairy Foods on Twitter >

www.twitter.com/dairyfoods

Find us on Twitter @dairyfoods. Get great article headlines, communicate with our staff and share your opinion with us. Join the Dairy Foods LinkedIn Group > www.dairyfoods.com/connect

Hixson 659 Van Meter Street Cincinnati, OH 45202 www.hixson-inc.com T: 513-241-1230 Email: [email protected]

Join quality and manufacturing professionals from all over the world at Dairy Foods Magazine Professional Network on LinkedIn. Read and participate in industry news, trends, educational opportunities, jobs and discussions. Become a Fan of Dairy Foods on Facebook > www.facebook.com/dairyfoods

Connect, share and interact with other individuals in your industry. We’ll share the latest information and events going on around you.

SUPPLIER CAPABILITIES SPOTLIGHT

EFCO Products Inc. EFCO Products Inc. is a global leader as an ingredient supplier for the food industry. With over 100 years of experience and a reputation of excellence, we have a proven history of providing our partners with a wide variety of high-quality, great-tasting ingredients. And now EFCO offers a new line of innovative Ice Cream Variegates and Bases to help you deliver the most delicious and desirable flavors to your ice-cream-loving customers! Two of our specialties are Superfruits and Super Flexibility. We have a long history of working with fruit fillings and toppings, and are on the cutting edge of the Superfruit flavor trends (such as acai-blueberry and pomegranate). Our Superfruit variegates are delicious and create tremendous customer appeal. Our flexible

approach to your needs is a super benefit. In addition, we offer standard variegates (such as caramel or fudge) and base formulations, as well as custom solutions. Need a prototype or sample formulations fast? No problem. EFCO is designed and equipped to respond quickly to your needs and to help propel you from new flavor idea to in-store success. We also

deliver a great range of packaging options, such as pails, pouches, totes, and drums, and we adhere to the strictest food safety and quality standards. Experience what EFCO variegate and base innovations can do for your products. Give us a call today or visit us online at www.efcoproducts.com—your customers will thank you!

When it comes to ice cream, we provide a Super twist. Introducing EFCO ice cream variegates and bases, featuring Superfruit flavors like pomegranate and acai-blueberry.

Over 100 years of experience... and still innovating.

800.284.3326 | efcoproducts.com

www.dairyfoods.com

51

SUPPLIER CAPABILITIES SPOTLIGHT

Neogen Corporation Neogen Corporation is a leader in developing and marketing diagnostic test kits that provide simple food safety solutions. Its products are unsurpassed in terms of ease of use, convenience and speed. In-house testing now available to dairy processors includes safety testing that was never known in the days when all testing was performed off-site. Current testing options include: • Sanitation monitoring, which allows for the almost instant verification of cleanliness of food contact surfaces prior to production; • Allergen testing kits, which allow HACCP verification of cleaning regimes with simple on-site tests that take only a few minutes; • Rapid microbial tests, which allow for the early detection of potential spoilage organisms, and allows evaluation and release of ingredients prior to their use in production. • Dairy antibiotic tests, which allow for detection of excess antibiotic residues in only minutes. Neogen’s products include: Rapid microbial testing Soleris® is a user-friendly, rapid optical testing system that accurately detects microbial contamination. The system measures microbial growth by monitoring pH and other biochemical reactions that generate a color change as microorganisms grow and metabolize. Using the Soleris system enables operators to easily identify, monitor, release products, and map problematic spots much faster than conventional methods. Food allergen testing Reveal® for Total Milk Allergen screens for milk residue at 5 parts per million 52

Dairy Foods | January 2011

speed and convenience of ATP testing in a lightweight, rugged instrument that fits in the palm of your hand. AccuPoint’s uniquely sturdy sampling devices consistently collect and detect potential contaminants from surfaces, liquids, and typically hard-to-access areas such as filler heads. AccuPoint’s intuitive software provides exceptional traceability and easy data analysis.

(ppm) in liquid products (e.g., juices and sorbet), clean-in-place rinses, and on environmental surfaces. Neogen also offers the Reveal 3-D line of food allergen tests – including for casein, soya and egg – which provides greater reliability with screening than ever before. The Reveal and Reveal 3-D rapid tests are especially useful in allowing multipurpose production lines to be tested quickly and reliably following the sanitation process, and provide results in as little as 5 minutes. Sanitation monitoring Neogen’s new AccuPoint® 2 ATP Sanitation Monitoring System puts the

Beta-lactam testing BetaStar® US is a receptor-based lateral flow assay for the detection of beta-lactam residuals in milk in only 5 minutes. This easy-to-use format has wide acceptance in the international dairy market.

Neogen Corporation 620 Lesher Place Lansing, MI 48912 800/234-5333 or 517/372-9200 [email protected] www.neogen.com

We Stand Behind Our Results Choose Neogen

Food Allergens Options include Reveal® for Total Milk Allergen, which screens for milk residue at 5 ppm in liquid products, CIP rinses, and on surfaces.

Neogen develops and offers an array of rapid and simple food safety tests for the dairy industry.

Microbial Contamination Soleris® is a user-friendly, rapid optical testing system that accurately detects microbial contamination, including coliforms and TVC.

Sanitation Monitoring AccuPoint® 2 ATP Sanitation Monitoring System puts the speed and convenience of ATP testing in the palm of your hand.

Beta-lactam Testing BetaStar® US is a receptor-based lateral flow assay for the detection of beta-lactam residuals in milk in only 5 minutes. For more information on these products, or all that Neogen offers, contact us today.

800/234-5333 or 517/372-9200 [email protected] s www.neogen.com

News & Trends

SUPPLIER NEWS to-light carton flow module and a conveyor system to route product through the various pick-and-pack zones. The system optimizes cubing and vertical space to achieve a dense pick, minimized footprint and increased picking accuracy while maximizing the efficiency of the existing labor pool. Innophos received first prize in the nutrition for the young and old category at the HiE Excellence Awards for its VersaCAL Clear, a highly soluble calcium phosphate for clear beverages. VersaCAL Clear’s effective combination of calcium and phosphorus helps promote healthy teeth and bones without compromising product taste and stability.

Sealed Air Corp. launched a new website that’s focused on establishing a closer relationship with customers, suppliers, investors and other stakeholders. Online users can read the latest information on Sealed Air’s businesses, view up-to-date news and events, access investor data and learn about the company’s sustainability initiatives. In addition to an updated look, the next generation of www.sealedair.com is designed to engage visitors with an improved brand experience and provide easier access to information on Sealed Air and its broad portfolio of packaging and specialty products and services, including the Cryovac brand of fresh food packaging technologies. The new

site also features updated navigation for customers to gain access to product information, brochures, resources and equipment videos. The RB Dwyer Group is printing shrink sleeve labels for the aerosol cans of Maple Grove Products’ Whipped Lightning, which is an alcohol-infused whipped cream. The full sleeve shrink labels made of heat shrinkable PVC were chosen specifically for this product since the nesting can curves up at the top, thus shrinking the labels to the curves of the aluminum can. The RB Dwyer Group prints six colorful labels, reflecting each flavor, on a 10-color press.

B R I E F LY … Cream Cheese Maker Named Business of the Year Franklin Foods, a leading manufacturer and marketer of cream cheese and cream cheese-based products received Vermont’s “Franklin County Business of the Year” for 2010. This award focuses on Franklin Foods’ community involvement, job retention, employee development and manufacturing investment. It was given by the Franklin County Industrial Development Corp. and accepted by John Ovitt, general manager of the Enosburg Falls, Vt., company. DFA Buys Castro Cheese Dairy Farmers of America acquired Castro Cheese Co., the owner of La Vaquita brand product line, which includes Queso Fresco, Panela, Queso Quesadilla and other artisanal cheeses commonly used in Hispanic dishes. Castro Cheese will become a wholly owned subsidiary of DFA and will operate as a separate business unit within the GDPG Consumer Brands Division. Likwise, DFA will retain its 72 employees, who will continue to be led by Alberto Bandera, the current operating executive. IFT Debuts Consumer Tips, Videos The Institute of Food Technologists launched www.iftfood facts.org, complete with consumer tips and videos. These oneto two-minute videos feature IFT food scientists who provide quick news-you-can-use tips for consumers. These videos also are paired with expanded online content. Foremost Farms to Offer Up to 10 Scholarships in 2011 Foremost Farms USA, Baraboo, Wis., will offer up to 10 scholarships worth $2,000 each to member-owners and the children of member-owners in 2011. The Agricultural Education

54

Dairy Foods | January 2011

Scholarships will be awarded to students who are pursuing a career in the agricultural field. The application deadline is Feb. 25, and scholarships will be awarded in the spring of 2011. The application is available for download from the “Member Benefits” section of Foremost Farms’ website at www.fore mostfarms.com or by calling 800/362-9196, ext. 8798. Velvet Ice Cream Receives Shining Star Award Velvet Ice Cream, Utica, Ohio, and its leadership team received the Shining Star Award from Ohio’s Department of Development. This award honors individuals who have been in business more than five years and whose business is owned by the daughter or granddaughter of the founder. Luconda Dager took over as president of Velvet Ice Cream in 2009, succeeding her father, Joseph Dager. Joanne Dager is vice president of Velvet’s foodservice division, and Andre Dager is the vice president of guest relations. Velvet also was recognized by the Conway Center for Family Business on the campus of Ohio Dominican University, Utica, for creating a succession plan that has placed the fourth generation of the Dager family at the controls of the nearly 100-year-old company. MooBella Secures Funding for Multi-patented Technology MooBella Inc., Taunton, Mass., secured $9 million in funding from Geneva, Wis.-based Inventages, life sciences-, nutritionand wellness-focused venture capital funds, with $1.5 billion under management. The MooBella Ice Creamery machine’s multipatented technology allows consumers to make their own fresh, hard-scoop ice cream in just 40 seconds. This funding will allow MooBella to continue to expand penetration within the core foodservice channels and advance its revolutionary technology.

SUPPLIER CAPABILITIES SPOTLIGHT

MasoSine MasoSine is a member of the WatsonMarlow Pumps Group, the world leader in low shear peristaltic and sine pump technology. Ideally suited to the food, beverage and dairy industry, our positive displacement sine pumps are the result of over 25 years of engineering innovation and product development. Through unique low-shear wavelike pumping action, MasoSine pumps gently transfer products like cheese curd, reducing fines and improving yield. Offering a powerful suction and low pulsation, MasoSine pumps are also the pump of choice for many dairy applications including curds and whey, yoghurt, cottage and cream cheese. With MasoSine, customers improve product quality while also overcoming

the costly maintenance limitations of conventional rotary lobe pumps. With only one rotor, one shaft and one seal, MasoSine pumps are quick and easy to maintain; there is no need for complex timing gears, multiple seals, or costly pump reconditioning. Fully CIPable and 3A certified, MasoSine pumps also offer superior cleanability and the reliability that dairy manufacturers need.

Sine pumps - gentle and reliable for dairy • Low shear pumping protects product integrity • No pulsation or meshing rotors • Fewer parts - lower maintenance and is fully CIPable • Improve cheese curd yield by lowering fines • Perfect for curds and whey, yogurt, cream and cottage cheese

Food and Beverage Division Watson-Marlow

MasoSine

Bredel

www.masosine.com 800-282-8823 www.dairyfoods.com

55

SUPPLIER CAPABILITIES SPOTLIGHT

Roquette America, Inc Roquette Offers Taste, Performance and Versatility Roquette is a premier supplier of advanced food ingredients for the healthy food market. Roquette’s extensive line of healthy food ingredients provides the latest in sugar and fat-replacement options for nosugar-added, low-fat ice cream, inclusions and variegates. SweetPearl™ Crystalline Maltitol and POLYSORB® FM Maltitol Syrup both provide the taste and texture of full-sugar, full-fat ice cream without the use of high-intensity sweeteners. The challenges faced by ice cream formulators to produce healthy products that offer the same indulgent eating experience as their traditional counterparts are significant. Excellent taste and texture - as the primary formulation hurdles - are at the top of the list of successful criteria, regardless of the claims that are made with sugar and fat replacement. POLYSORB® FM Sugar and Fat Replacement with Added Fiber POLYSORB® FM is a range of proprietary bulk sugar replacement ingredients, some of which have been tailored to meet the specific requirements of healthy ice cream. Available in both liquid and powder forms, POLYSORB® FM offers the taste and texture of full-fat, indulgent ice cream. This product delivers the performance of sugar and fat in a unique, single-product bulking system. In addition to outstanding taste and mouth-feel, POLYSORB® FM has been designed to give the same freezing and dipping qualities as traditional ice cream. POLYSORB® FM offers the additional benefit of providing enough soluble fiber for a fiber claim in no-sugar-added ice cream, if desired. SweetPearl™ Crystalline Maltitol for Direct Sucrose Replacement SweetPearl™ Crystalline Maltitol is another outstanding Roquette ingredient for the healthy ice cream formulator. Crystalline maltitol is the most sugar-like bulk sugar replacer available in the market today. SweetPearl™ can be used as a direct one-to-one replacement for sucrose in healthy no-sugar-added ice cream formulas. SweetPearl™ Crystalline Maltitol offers the highest purity and sweetness attainable in maltitol today. As with POLYSORB® FM, high intensity sweeteners are not required when formulating healthy ice cream with SweetPearl™ Crystalline Maltitol. This is the product of choice for direct replacement of sucrose in pure sucrose-sweetened ice cream formulations. Indulgent Healthy Variegates and Inclusions a Formulation Reality Roquette Specialty Sweeteners can be used in a variety of healthy variegates, sauces and inclusions. SweetPearl™ Crystalline Maltitol is the best choice for sugar-free chocolate inclusions and coatings available in the industry today. POLYSORB® FM is the maltitol syrup of choice for the highest quality no-sugar-added variegates, fudge sauces and fruit inclusions.

Roquette America, Inc www.sweetpearl.com and www.roquette.com

56

Dairy Foods | January 2011

Fiber

enrichment? Your success is in the recipe...

An Invisible Fiber - No Taste, No Sweetness! Excellent Digestive Tolerance Sugar Free Only 2.1 calories per gram

www.nutriose.com

om nature

Distributed by Roquette America and National Starch Food Innovation

SUPPLIER CAPABILITIES SPOTLIGHT

GEA Tuchenhagen North America Success By Design GEA Tuchenhagen is a global leader in the manufacturing of a wide range of sanitary flow components for the dairy, food, beverage, brewing and pharmaceutical industries. As the inventor of the mixproof valve, GEA Tuchenhagen has always focused on quality and innovation. From simple and smart design principals – like our metalto-metal sealing philosophy – to flexibility and space-saving options in installation, we’ve always listened to the needs of our customers to help improve efficiency and ROI. Whatever your flow component needs, GEA Tuchenhagan has the range of products and the service experience to get the job done. Revolutionizing the Dairy Industry In April 2007, in perhaps the greatest breakthrough in US dairy plant design in 25 years, GEA Tuchenhagen’s 24/7 PMO Valve (FDA memorandum M-b-353) became the first mixproof valve to be authorized by the US regulatory authorities to allow seat cleaning while product is present in the valve. This means that US dairy plants no longer have to shut down production for two to three hours per day and can now reap the financial benefits of full 24/7 production. Overnight this valve has changed the way US dairy plants are designed and operated. Most recently, the 24/7 PMO Tank Valve was added to the 24/7 PMO family of mixproof valves, becoming the first tank valve to hold an FDA Memorandum (M-b-359). Today, GEA Tuchenhagen manufactures and supplies a wide range of process valves, valve manifolds, in-line measurement and control equipment, cleaning devices, CIP manifolds and product recovery systems. Additional services offered include concept design engineering, manifold prefabrication, plant service and customer training.

58

Dairy Foods | January 2011

• Integrated balancer cleaning device allowing for ALL product-wetted parts of the valve, including the valve stem, to be cleaned as part of the seat lift procedure A full range of high-accuracy, highlysanitary control valves with: • Metal or soft seal • Pneumatic or electro pneumatic positioners • Available in shut-off or divert style housing configurations • Available in sizes up to 6” OD A product recovery system that allows plants to recover valuable finished product from process pipe lines (up to 99%) as well as use less chemicals and water to clean these lines afterwards. 3-A approved aseptic valves with PTFE and stainless steel bellows, which are especially suited for applications such as creamers and non-refrigerated products. Rounding out the wide range of sanitary components are GEA Tuchenhagen’s T.VIS® intelligent control modules for valve control and monitoring functions, pressure relief valves, inline sampling valves, instrumentation and cleaning devices. Products A full range of standard, longstroke and tangential single seat valves incorporating the standard GEA Tuchenhagen valve features such as: • Zero-maintenance and reversible actuators • Metal-to-metal sealing for longer life • Interchangeability of key parts for lower spare parts cost • Available in sizes up to 6” OD A full range of mixproof valves including the 24/7 PMO family of valves whose benefits include: • Complete safety against cross contamination – even with no or damaged gaskets

GEA Tuchenhagen North America 90 Evergreen Drive Portland, ME 04103 USA Tel: 866-531-5629 Fax: 207-878-7914 [email protected] www.tuchenhagen.us

Liquids to Value

Gentle Product Handling Means Higher Yields. That’s right. GEA Tuchenhagen’s 24/7 PMO Tank Valve™ for vats can render higher yields. Unlike standard cheese curd valves, this valve can be mounted DIRECTLY onto the vat, allowing gentle curd transfer, thereby reducing curd damage and increasing product yield. And that’s better for your bottom line. Call 866.531.5629 today to see how you can beneƂt.

GEA Mechanical Equipment

GEA Tuchenhagen North America 90 Evergreen Drive • Portland, ME 04103 • USA Tel 866.531.5629 (toll-free) • Fax 207.878.7914 [email protected] • www.tuchenhagen.us

®

New Products & Marketing

NEW PRODUCT REVIEW Northfield, Ill.-based Kraft Foods Inc., says its cheesemakers discovered a process to combine Philadelphia Cream Cheese with shredded natural cheese. When heated, cream cheese melts faster than natural cheese, so “A Touch of Philly,” the brand’s tagline, allows for a faster, smoother, more even melt with less oiling off.

Adding just a touch of cream cheese does not add a significant amount of calories or fat, meaning Nutrition Facts remain the same as like varieties of the company’s traditional Kraft Natural Shredded Cheeses. This innovative concept comes in five varieties: Italian Five Cheese, Mexican Style Four Cheese, Mozzarella, Three M Cheese and Triple C Cheddar. C

New CowRageous! All-Natural Snack Pudding comes in three varieties: chocolate, strawberry and vanilla. Manufactured by Kozy Shack Inc., Hicksville, N.Y., this nutrient-enriched, gluten-free refrigerated erated dairy-based pudding targeted to o kids comes in six-packs of 4-ounce cups. ups. A single serving is a good source of vita-

Hershey’s Ice Cream, H Harrisburg, Pa., H introduces Candy in Bar Overload Cone. Ba Each 6-ounce cone Ea contains specially co developed premium dev chocolate nougat ice cho cream swirled with cre caramel and loaded cara with chocolate-covered peanuts. The eye-catching, red foil eyepackaging is designed pack with a perforated-edge sleeve that hugs the cone, making it convenient to co open and to keep hands clean. ope ““It’s the ultimate novelty treat that combines popular trea candy bar flavors in one cone,” cand says Tom Holder, vice president of sales and marketing.

NOTEWORTHY I NTROD UCTION S Launch Frozen Innovations Inc., Kitchener, Ontario, Canada, “launches” Launch Omega frozen dessert bars based on w whey protein concentrate (WPC) a and canola oil. Each 2.75-ounce bar contains 9 grams of prottein from the WPC and 540 milligrams from the canola oil, as well as 102 calories.

60

Dairy Foods | January 2011

The simple theme is strong in product innoovations. New Marzetti Simply Dressed salad d dressings from T. Marzetti Co., Columbus,, Ohio, contain a minimal number of all-natural ingredients. For example, the blue cheese variety contains its namesake cheese, along with a base of buttermilk, mayonnaise and a few seasonings.

New Products & Marketing

I N T E R N AT I O N A L m milk from our own cows, and add fruit, cane sugar and a cocktail of cultures.” The product is distributed in select markets u throughout Texas. Seale t plans to expand outside the p state in 2011, at the same s time the company rolls out t other new dairy products. o

mins A and D, calcium and dietary fiber, with no artificial colors, preservatives or high-fructose corn syrup. The Laughing Cow brand adds half-thefat flavors to its popular cheese wedge product line. Bel Brands USA, Elk Grove Village, Ill., a subsidiary of Fromageries Bel, a family-owned cheesemaker headquartered in Paris, introduces Light Blue Cheese; Light Mozzarella, SunDried Tomato & Basil; and Light Queso Fresco & Chipotle. Sold in round boxes of eight 0.75-ounce wedges, a serving contains 35 calories. The Three Happy Cows brand of drinkable yogurts from County Line Farms, Dallas, a new, small dairy with its own herd of grass-fed, pasture-raised cows, comes in four flavors: blueberry, mango, piña colada and strawberry. Sold in 8-ounce plastic bottles, each serving contains 200 calories. “The recipe is simple,” says Don Seale, president. “We start with reduced-fat

Subscribe to Dairy Product Innovations (www. dairyfoods.com/dpi), an e-newsletter focused on new dairy products and new products and services from dairy industry suppliers. Subscribers receive Dairy Product Innovations monthly with the occasional special installation or themed issue focusing on specific niches such as artisan cheese or organic and natural foods. To subscribe, visit www. dairyfoods.com.

Many cultured products currently feature separate compartments with candy, granola or other sweet ingredients as toppings. That same concept now can be experienced with frozen products. Unilever’s Hertog brand in The Netherlands recently debuted Party Ice Cream with Popping Chocolate & Colored Sprinkles. This product includes a tub of regular vanilla ice cream, plus two individual packets of sundae toppings. Dairy-based Da sports drinks — for before, during d and after exercise — are more widely w available in Europe than in the Unitited States. For exammple, p Norway’s Tine SA rolled rol out YT, a drinking ng yogurt yo positioned as a pre-fitness drink formulated to provide long-lasting energy throughout a workout. Tine developed the product with the Norwegian Olympic team. Japan’s Chichiyasu Dairy Inc., introduces a yogurt designed for fo women’s health, specifically s to prevent anemia. m New Iron Yogurt with Folic Acid contains ta 200 micrograms of folic acid to aid in red re blood cell formation, and 4 milligrams of o iron, which is claimed to be equal to eating i 50 prunes.

Contributed by Krista Faron, director of iinnovation and insights, Mintel Research Consultancy, Global New Products C Database (GNPD). For more information D ccall 312/932-0400 or visit www.gnpd.com.

www.dairyfoods.com

61

New Products & Marketing

NEW PRODUCT REVIEW: FOCUS ON YOGURT Spoonable yogurt sales had yet another tremendous quarter in terms of retail sales volume growth during the third quarter of 2010 (up p 8.1%), compared to quarterly year-ago go levels, reports the International Dairy ry Foods Association, Washington, D.C., C., in its Cultured Dairy Products Report. ort. This is despite experiencing a 3.1% 1% increase in its average retail sales price. e. Much of this growth is due to consumumers’ increased attention to wellness and yogurt’s healthful halo. It is also helpful that marketers continue to roll out flavorful new varieties and innovative better-for-you formulations. For example, The Dannon Co., White Plains, N.Y., expanded its Activia product line to include Activia Parfait Crunch. Made with the brand’s famous “Bifidus Regularis” probiotic culture, legally known as Bifidobacterium lactis DN 173-010, the new parfaits are a 6-ounce container of flavored low-fat yogurt topped with a dome of low-fat granola. All varieties contain 220 calories, 3 grams fat and 6 grams protein. The fruit flavors — mixed berry, peach and strawberry — provide 2 grams fiber, while the vanilla provides 1 gram fiber. Activia Parfait Crunch begins shipping this month. Pine Plains, N.Y.-based Coach Farm is expanding its line of goat milk dairy products with the launch of a farmstead Goat’s Milk Probiotic Yogurt available in four all-natural flavors: honey, plain, strawberry and vanilla. “Traditional Greek Yogurt is made from goat’s milk, and we thought with the increased popularity of premium yogurt over the last few years, there was no better time than the present to t introduce a spoonable in goat’s milk probiotic yogurt,” says Steven Margarites, president. M “Our drinkable product, Yo-Goat, Yo-Go has been a popular product produc for many years among consumers who are lactose consum intolerant. intolera We hope to see that popularity translated to our populari spoonable product as well.” spoonab line is produced in small The lin only the Grade batches using u A milk fr from Coach Farm’s own dairy goats. goats The four flavors are 62

Dairy Foods | January 2011

available nationally tionally to retailers in 6-ounce containers and the plain flavor is distributed nationally to restaurant and foodservice establishments in 3-pound bulk containers. Parmalat Canada, headquartered in Toronto, rolled out Astro BioBest Plant Sterols Yogourt to the Canadian marketplace. The yogurts are sold in 8-packs of 100-gram cups. Each 100gram serving is enriched with 50% of the daily amount of plant sterols recommended to help lower cholesterol, according to Canadian regulations. “Whether it’s preventing the onset or finding ways to lower it, managing cholesterol is no easy feat,” says Nash Lakha, president and CEO. “Our goal at Parmalat Canada is to be able to provide consumers with a simple, everyday food that’s easily incorporated into theirr diet with the added bonus of a functional ingredient that at specifically lowers cholesterol, which is a significant factor in heart disease. “Clinical studies on sterols, such as those used in our yogurt, have been conducted, proving that sterols significantly lower choles-terol levels,” says Lakha. a. “It’s exciting to have the ability to harness active tive ingredients found naturally urally in vegetables and fruits and into d incorporate them h other foods so that consumers can benefit in ways that weren’t possible before.” Astro BioBest Plant Sterols Yogurt comes in four flavors: blueberry, raspberry, strawberry and vanilla. 

Enter the MilkPEP Awards online and win great prizes.

The MilkPEP Awards have moved online! Now it’s easier than ever to share your success stories and win an iPad ®, Flip ® Camera and more. Plus, you can enter as often as you like for great monthly prizes. You’ll even have a chance at the grand prize of starring in your own Milk Mustache “got milk?” ad. Kim Peter used innovative ways to promote ‘Refuel with Chocolate Milk’ and grew sales for Anderson Erickson Dairy. Want to see your smiling face in an ad like this? Just tell us your success story. Go to milkpep.org today and enter to win your MilkPEP Award.

MilkPEP. You own it. Now use it. © 2011 America’s Milk Processors. got milk?® is a registered trademark of the California Milk Processor Board.

SUPPLIER CAPABILITIES SPOTLIGHT

Danisco USA Inc. Enhancing health with Danisco Creating the most successful Health & Wellness (H&W) solutions is a matter of balancing health benefits with the way consumers experience a product. At Danisco, we understand that good flavor and good health should never be mutually exclusive. Our expertise in the effective, synergistic interplay of both active and functional ingredients helps deliver dairy products that promote good health and taste great. The combination of that expertise with a broad product portfolio is what makes Danisco special as an ingredient supplier. By pairing health-promoting ingredients with our functional ingredients—stabilizers, emulsifiers, enzymes and cultures—we can help you achieve the optimum combination of taste, texture and nutritional benefits. Sugar, fat, salt and calories can be reduced while maintaining desirable sensory characteristics. Our health and nutrition portfolio includes ingredients that support: Digestive health Immune health Bone health Weight management Heart health Sustainability is also an important part of our H&W solutions. Consumers who fall into the LOHAS (lifestyle of health and sustainability) segment are interested in naturally healthy foods, the environment and a simple, sustainable way of life. Danisco offers ingredient solutions that respond to the needs and desires of this important and growing market segment, delivering a “clean label,” organic offerings and natural food protection through sustainable business practices.

64

Dairy Foods | January 2011

Danisco can help you take advantage of opportunities to increase health benefits in a wide variety of dairy applications: Milk Dairy-based beverages Yogurt Smoothies Kefir Cheese Cottage cheese Sour cream Coffee creamers Ice cream/frozen desserts Petit Suisse Desserts Whipping cream At Danisco…first you add knowledge When you choose to formulate with ingredients from Danisco, you’re benefiting from decades of scientific research, discovery and development by some of the brightest minds in the world of food science. You’re also getting the support of a global supplier with an impressive reputation that offers the technical, market and regulatory expertise you need. Through knowledge-based innovation, our health-promoting, functional ingredients bring health to everyday life. To let us help you take your dairy products to the next level, call Janelle Crawford at 1-800-255-6837 x 3421.

Danisco USA Inc. Four New Century Parkway New Century, KS 66031 Tel: 800.255.6837 Email: Janelle.Crawford@ danisco.com Web: www.danisco.com

Œ(ERMWGS97%-RG

'LIIVW

8SKSSHLIEPXL ˆ(MKIWXMZI,IEPXLˆ-QQYRI,IEPXLˆ*EX 6IHYGXMSRˆ7YKEV 'EPSVMI6IHYGXMSR

ˆ7SHMYQ6IHYGXMSRˆ*MFIV%HHMXMSRˆ0EGXSWI6IHYGXMSRˆ2EXYVEP*SSH4VSXIGXMSR

+MZI]SYVHEMV]ETTPMGEXMSRWERIHKI[MXL(ERMWGSLIEPXLERH[IPPRIWWMRKVIHMIRXW =SYVGYWXSQIVWEVISRXLIPSSOSYXJSVMRRSZEXMSRWXLEXXEOIXLILIEPXLERH[IPPRIWWFIRI½XWSJXLIMVJEZSVMXI HEMV]TVSHYGXWXSXLIRI\XPIZIP8SKIXLIV(ERMWGS´WLIEPXLTVSQSXMRKMRKVIHMIRXWERHJYRGXMSREPMRKVIHMIRXW° WXEFMPM^IVW IQYPWM½IVW IR^]QIW ERH GYPXYVIW°QEOI MX LETTIR IRWYVMRK XLI STXMQYQ GSQFMREXMSR SJ XEWXI XI\XYVIERHRYXVMXMSREPFIRI½XW 0IEVRLS[SYVLIEPXLTVSQSXMRKERHJYRGXMSREPMRKVIHMIRXWGERKMZI]SYVHEMV] TVSHYGXWERIHKI'SRXEGX(ERMWGSXSHE] 'SRXEGXYWEX)\X [[[HERMWGSGSQ

SUPPLIER CAPABILITIES SPOTLIGHT

Autocrat Coffee & Extracts

ence with regular and organic coffee

Make the most of the recent “Coffee Craze” by capturing your share of the $59 Billion coffee market.

extracts, iced cappuccino bases, coffee syrups, espresso pieces, and instant and freeze-dried coffee. We can provide you with a wide variety of packaging options and offer products that are Kosher and

By 2014, the United States Coffee and Ready-To-Drink Coffee Market is expected to increase 23% from $48 Billion to $59 Billion.

Organic certified. Autocrat was started in 1895 in Rhode Island where it remains a fourth-generation family-operated business today. A major key to our continued ability to compete is our willingness to work

Autocrat, a leading producer of coffee ingredients, is uniquely positioned to help

harder, be more proactive, and be person-

you benefit from this trend. Our capabili-

ally attentive to the needs of our custom-

ties make us the ideal partner for meeting your coffee extract needs. Coffee and coffee products are all that we do. We focus on coffee 100 percent! We are coffee specialists, not flavor generalists, and pride ourselves on knowing coffee and coffee extracts better than anyone else. To understand consumer values, attitudes and behaviors related to coffee and coffee-based products, we have conducted consumer marketing research concerning the latest coffee taste trends. Our full staff of research and development experts has created custom coffee extract formulations for many dairy applications

66

Dairy Foods | January 2011

including milk, smoothies, ice cream, yogurt, ready-to-drink beverages, and iced cappuccino drinks. Autocrat uses only an all natural

ers. Our aspiration is to be perceived as being “a pleasure to do business with” and assisting you in making the most of the recent “Coffee Craze.”

extraction method of obtaining coffee extract from roasted coffee beans. In recent years we have invested millions of dollars and thousands of personnel hours working with equipment companies to

Autocrat, Inc. 10 Blackstone Valley Place Lincoln, RI 02865 800.288.6272 [email protected] www.autocrat.com

perfect the operation of this process. Our method is unique and patently superior

C

O FFEE

allowing our shelf-stable coffee extract to maintain flavor and vital essences. As an approved FDA low-acid food plant, we have capabilities and experi-

E

XT

RA C T

S

Find out why Autocrat is uniquely positioned to meet your needs for Coffee Extracts

With over 100 years of tradition, Autocrat offers regular and organic coffee extracts that are used to flavor ice cream, iced cappuccino drinks, soy beverages, and other dairy products.

Scan this code with any mobile device QR code reader to get more information about Autocrat.

For samples and more information call 1.800.288.6272 ext. 129 www.autocrat.com/ceTopReasons

Autocrat, Inc. Lincoln, RI • 1.800.288.6272 • www.autocrat.com

New Products & Marketing

DAIRY MARKET TRENDS

Coming Out of Hibernation  Marina Mayer

Executive Editor

t’s no surprise that ice cream doesn’t make the grocery shopping list in the wintertime. Aside from curbing the various strains of illness (ice cream soothes strep throat), consumers are warming their kitchens with other not-as-cold items. Let’s face it, the market for ice cream has seen some warmer days. That’s because sales of ice cream are strongest from April through September. According to Chicago-based SymphonyIRI, ice cream sales totaled $3.95 billion for the 52 weeks ending Oct. 3, 2010, a 4.1% decline from the previous period. Unit sales of 1.2 billion were down 1.4%. Private label ice cream products led the category with sales of $991.6 million, down 4.7% from a year ago, SymphonyIRI data outlines. Branded products also showed declines. Breyers, Dreyer’s Edy’s Slow Churned, Häagen-Dazs, Ben & Jerry’s, Turkey Hill and Dreyer’s Edy’s Grand experienced a dollar sales drop, with Dreyer’s Edy’s Grand taking the biggest hit. Its sales declined 23.8%, according to SymphonyIRI data. However, when stacked up against previous quarters, ice cream sales will begin to rise in the New Year, allowing some ice cream brands to incur an uptick in sales despite Jack Frost nipping at consumers’ noses. Some of the top 10 brands did grow. Dreyer’s Edy’s Fun Flavors, for instance, saw a 40.4% uptick in dollar sales and 44.6% in units since last year thanks in part to its “buy one, get one free” promotions that extended into the winter months. Wells’ Blue Bunny also saw a 5.5% leap in dollar sales and a 14.7% in unit sales since last year thanks to its introduction of all-natural, no-sugar-added and premium ice cream options. Blue Bell dollar sales also increased 3.1% in dollar sales and 1.75% in unit sales SymphonyIRI numbers show.

I

Sales of frozen yogurt, sherbet The frozen yogurt segment also is showing signs of warming up, while the sherbet/sorbet/ice category is frozen in place. Frozen yogurt sales rose 1.2% to $198.5 million in sales, with units up 3.5%. Sherbet/sorbet/ices dropped 3% in dollar sales and 1.1% in units, according to SymphonyIRI. For its part, Turkey Hill saw a 410.1% jump in dollar sales since last year thanks to an assortment of new flavors and packaging initiatives. The company redesigned its frozen yogurt packages with a new color band and a front-of-pack strip that outlines healthy ingredients, such as number of calories, calcium, vitamin D, omegas and more. Wells’ Blue Bunny saw a 173.2% jump in dollar sales and a 214.8% leap in unit sales for its Durango line of low-fat frozen yogurt, as well as, its all-natural frozen yogurt offerings. The cold weather may be causing a damper in sales of ice cream and sherbets, but processors can rest assured. If the New Year is similar to years past, sales of frozen dairy treats will come out of hibernation in the spring and join the ice cream social.  68

Dairy Foods | January 2011

Quarterly Sales of Ice Cream Reporting Period 13 weeks ended

Dollar Sales (millions)

% change vs. yago

Unit Sales (millions)

% change vs. yago

9/26/10

$1,101.2

-3.0

345.5

-1.5

6/27/10

$1,041.9

-5.9

322.0

-4.4

3/28/10

$909.7

-4.9

277.2

-0.8

12/27/09

$906.3

-2.9

277.3

+1.8

9/27/09

$1,135.2

-1.5

350.8

+3.0

6/28/09

$1,107.6

-0.2

337.0

+3.8

For the latest 52 weeks ending Oct. 3, 2010 Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Wal-Mart)

Top 10 Brands of Ice Cream 1. Private Label $991.6M in Sales -4.7% 25.1 Dollar Share 2. Breyers $435.1M in Sales -2.6% 11.0 Dollar Share 3. Blue Bell $297.1M in Sales +3.1% 7.5 Dollar Share

4. Dreyer’s Edy’s Slow Churned $295.5M in Sales -7.4% 7.5 Dollar Share

7. Dreyer’s Edy’s Grand $145.0M in Sales -23.8% 3.7 Dollar Share

5. Häagen-Dazs $247.6M in Sales -2.8% 6.3 Dollar Share

8. Dreyer’s Edy’s Fun Flavors $138.3M in Sales +40.4% 3.5 Dollar Share

6. Ben & Jerry’s $218.9M in Sales -0.3% 5.5 Dollar Share 10.

9.

9. Wells’ Blue Bunny $133.5M in Sales +5.5% 3.4 Dollar Share

8. 7.

1.

6.

10. Turkey Hill $118.4M in Sales -7.0% 3.0 Dollar Share

5. 4.

2. 3.

T t l category Total t $3,957.3M $3 9573M in i Sales S l (-4.1%), ( 4 1%) $1,221.1M $1 221 1M Units U it (-1.5%) ( 1 5%) For the latest 52 weeks ending Oct. 3, 2010 Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Wal-Mart)

From sourcing cocoa beans in various origins, to processing and manufacturing chocolate, to delivering top-quality Ambrosia® chocolate to you, ADM Cocoa monitors each step of the process. To work with a supplier that understands the complete chocolate cycle, call ADM Cocoa at 800-558-9958.

®

The Chocolate Resource

COCOA

CANDY & CONFECTIONERY

BAKING & CEREALS

BEVERAGES

DAIRY

SNACK FOODS

For customers around the world, ADM draws on its resources — its people, products, and market perspective — to help them meet today’s consumer demands and envision tomorrow’s needs. www.adm.com © Archer Daniels Midland Company

800-558-9958

SUPPLIER CAPABILITIES SPOTLIGHT

Gertrude Hawk Gertrude Hawk Chocolates has been dedicated to creating the most delicious gourmet chocolates since 1936. Gertrude Hawk Ingredients, a division of Gertrude Hawk Chocolates, is the industry leader in supplying the dessert industry with miniature shell moulded pieces, chips & bits, and panned items. They have invigorated ice cream flavors with a full range of off-the-shelf items and the capability to customize the flavor and shape of any inclusion to bring excitement to any ice cream line-up. Through technology and expertise, Gertrude Hawk brings major breakthroughs and innovations to the marketplace. Their ability to conch and refine many of their own chocolate and coating blends give them the capability to make milk, dark and white varieties. This flexibility also gives them and ability to make industry specific products like lo-melt, hi-melt and shelf stable confections as well as savory, chocolate of origin, All Natural, GMO Free, Trans-Fat Free, PKO Free, Fair Trade and Organic. Gertrude Hawk is also an SQF Certified supplier and facility. Gertrude Hawk’s most recent innovation for the ice cream / dessert industry are Lo-Melt Cut Peanut Butter Cups. The product is made with lo-melt technology which is engineered exclusively for ice cream giving you the slow, indulgent melt you would expect from chocolate. They are not augured, crushed or pulverized like the standard peanut butter cups that have been used in the ice cream industry for years. Instead, Gertrude Hawk has invested significantly in technology to make this product a success and change the way cut peanut butter cups are utilized in the marketplace. In the end, they make shakes & desserts cleaner and more visually appealing which makes for a happier customer. They are available in

70

Dairy Foods | January 2011

multiple cut sizes depending on the customer’s requirements. Gertrude Hawk’s shell moulded gourmet confections are available in a nearly unlimited variety of shapes and sizes with an assortment of creamy, savory or fruit filled centers such as peanut butter, caramel, raspberry, mint, coffee, cherry and many more. The Research and Development Team is also closely tuned to culinary trends to determine which dessert segments may match their profiles and capabilities. Recent innovations to match culinary dessert trends include

our Caramel Sea Salt Truffles, Espresso Chips and Caramel Baking Chips. Lastly, Gertrude Hawk can pan almost any particulate in their state-of-the-art panner including Coarse Ground Sugar, Coconut, Salt, Graham, Pretzels, Waffle Cones, Cookies, Cookie Dough, Malt Balls, and of course Nuts – Almonds, Pecans, Peanuts, etc. Gertrude Hawk continues to be a leader and innovator in the world of ingredients and inclusions. Visit their website at www.gertrudehawkchocolates.com for more information.

Ingredient Technology Photo courtesy of Hydrosol

Formulating with Fiber: Know Your Options

Fiber food ingredients contribute functionality and nutrition to all types of dairy foods.

 Donna Berry Product Development Editor

he science of fiber food ingredients continues to evolve, with more benefits being discovered and additional sources identified. As a result, the fiber-enriched food and beverage market is booming, and dairy foods have been identified as an ideal carrier for fiber food ingredients. In the 1990s, there were likely less than 20 suppliers of fiber food ingredients, and most of them were marketing conventional, insoluble-type fibers, according to the report Fiber Food Ingredients in the U.S. from Packaged Facts, Rockville, Md. Today, there are more than 50 companies supplying fiber food ingredients to U.S. food formulators. Dairy Foods talked with 19 of these suppliers to learn about the solutions they offer product developers. Here’s what they shared.

T

Dairy Foods: What are some key characteristics of your fiber ingredient(s)? Black: Tate & Lyle manufactures natural prebiotic fibers from corn. There are currently two options, depending upon application and formulation goal. The original is a 70% fiber ingredient that contains 20% sugar. This low-viscous fiber can be labeled as soluble corn fiber, corn syrup or corn syrup solids on ingredient legends, making it extremely consumer friendly. The newest offering contains 85% fiber and less than 5% sugar. It is ideal for use in no-sugar-added and low-sugar products. It can be labeled as soluble corn fiber or maltodextrin. Tate & Lyle also manufactures polydextrose, a low-calorie fiber offering that provides body and texture in reduced-calorie, no-sugar-added and high-fiber foods. Cammarata: Microcrystalline cellulose (MCC) is derived from naturally occurring cellulose in tree pulp. FMC customizes MCC to be used in a variety of different food applications. The products are standardized to meet specific viscosity, gelling, suspension and stabilizing properties. MCC is a good source of insoluble dietary fiber, yet contributes no, or very little calories in food systems. It is virtually inert and will not interfere or interact with other nutrients added to foods for fortification, such as vitamins and minerals. FMC also markets carrageenan and alginates, both natural sources of soluble fiber. Carrageenan is sourced from red seaweed, 72

Dairy Foods | January 2011

while alginates are extracted from brown seaweed. They both can be customized for specific thickening, stabilizing, gelling and film-forming properties. Chaudhari: Fortitech creates custom nutrient premixes for foods and beverages and can source many types of fiber for dairy applications. Very few ingredients offer the versatility that fiber does

Dairy Foods talked to: Pashen Black, marketing communications manager, Tate & Lyle Mike Cammarata, application scientist, FMC BioPolymer Ram Chaudhari, senior executive vice president, chief scientific officer, Fortitech Hans-Ulrich Cordts, technical sales-dairy industry, Hydrosol Bill Driessen, technical sales manager (Americas), Taiyo International Inc. Angelica Horst, director-regional business BioActives, Danisco Rodger Jonas, director of national sales, PL Thomas Ramakanth Jonnala, research and development scientist, International Fiber Corp. Kati Ledbetter, product development scientist, Archer Daniels Midland Co. Christina Munteanu, senior technical services specialist, Corn Products International Lorraine Niba, business development manager-nutrition, National Starch LLC Mar Nieto, senior principal scientist, TIC Gums Joseph O’Neill, executive vice president of sales and marketing, Beneo Inc. Vince Patti, marketing, Fiberstar Inc. David Peters, sales and marketing director, Biovelop AB Cathy Peterson, group vice president-applications and technical services, SunOpta Ingredients Group David Romeo, managing director, Nutraceuticals International Scott Turowski, technical sales, Sensus America Inc. Neelesh Varde, business development coordinator, Roquette America

Ingredient Technology

in the role that it can play in a variety of health conditions. The impact it can have on cardiovascular health as well as digestive health is something manufacturers should take into consideration when formulating products that address these conditions.

Photo courtesy of FMC BioPolymer

Cordts: After extensive research, Hydrosol’s applications technologists have developed a special system of dietary fibers that greatly intensifies the mouthfeel of low-fat milk drinks. The new functional system consists of vegetable fibers that have been combined in such a way that the microparticles produce soft microgels with a diameter of about 100 μm. These microgels are experienced as a creamy mouthfeel. The natural fat replacement system is suitable for all dairy products that are homogenized at pressures greater than 50 bar. By this method, the fat content of the end product can be reduced by up to 50%. The ingredient is both easy to use and economical. Driessen: Partially hydrolyzed guar gum (PHGG) is a source of soluble dietary fiber. It is not guar gum, as PHGG is partially hydrolyzed, and after the hydrolysis process, the physical properties are completely different. PHGG dissolves completely clear in water and does not affect viscosity at normal dosage levels. It is a prebiotic fiber because it produces high amounts of butyrates in the digestive system. Of all the short-chain fatty acids (SCFAs), the butyrates are the best indicators of a true prebiotic fiber because butyrates remain inside the colon and act as an energy source for intestinal villi. The other SCFAs (acetates and propionates) are also beneficial, but they are carried in the blood to be metabolized in the liver or in muscle tissue. It is important to note that SCFAs are produced via a fermentation process in the digestive system. If that process happens rapidly, it can result in uncomfortable bloating, gassiness and excessive flatulence. This is important for product formulators to understand because consumers will learn to avoid products that cause them discomfort or embarrassment in social situations. The fermentation of PHGG is extremely slow, compared to other dietary fibers. It produces high levels of the beneficial butyrates, yet without discomfort. Horst: Danisco offers a soluble fiber called polydextrose, which can be characterized as a digestion resistant starch, specifically DP 3+. Polydextrose is a glucose polymer with a complex three-dimensional configuration. It is made from sorbitol and dextrose, both naturally occurring ingredients derived from corn and citric acid and is 80% fiber. The remaining sugars range from 0.25% to 4.0%. Jonas: PL Thomas markets defatted chia flour, which provides 47% fiber in a soluble and insoluble blend. This product also provides a side benefit of having 3% omega oil, which is embedded in the flour to allow for a long shelf life. This bland, grain-based ingredient is normally incorporated up to 3% on a weight basis. Jonnala: International Fiber offers a number of insoluble fibers that have application in dairy foods, in particular yogurt and other cultured dairy products. This includes cellulose, oat fiber, white wheat fiber, bamboo fiber and sugar cane fiber. Not only do they contribute fiber to the application, the right combination of ingredients can increase the apparent viscosity, contributing to stability and product consistency. Insoluble fibers also have application in frozen desserts, where they affect viscosity and shear-thinning behavior, as well as ice crystal formation for improved stability. Insoluble fibers are usually heat stable and do not break down or

 Select fiber-containing ingredients assist with stabilizing aerated dairy desserts.

change under acidic conditions, pasteurization or other heat treatments encountered during dairy foods manufacturing. Ledbetter: ADM offers digestion-resistant maltodextrin, which is a soluble corn fiber that is 90% soluble dietary fiber and contains 1.6 calories per gram. In dairy and beverage applications, the soluble corn fiber maintains the functionality of a standard maltodextrin with minimal formulation development or formulation adjustments. Soluble corn fiber was developed to offer product developers a versatile and convenient way to add soluble dietary fiber to a range of food products, including dairy foods and beverage applications. Munteanu: Corn Products offers a range of fiber ingredients suitable for dairy products, including short-chain fructooligosaccharide (scFOS). This prebiotic soluble fiber is derived from sucrose and has a caloric contribution of 1.5 calories per gram. It allows for a wide range of claims at levels as low as 1.1 grams per serving. Another offering is galactooligosaccharide (GOS), a soluble prebiotic fiber that delivers 1.85 calories per gram. GOS is manufactured from lactose via an enzymatic process. Clinical research supports the immune health benefits of GOS, allowing manufacturers to formulate products supporting immune health. Our third offering is agave inulin, which is a novel natural soluble fiber made from the agave plant. Inulin from agave contributes 1.23 calories per gram and has a purity of 90% on a dry basis. Niba: National Starch supplies two prebiotic soluble fibers that have been shown to have great functionality in dairy product applications: soluble corn fiber and soluble wheat fiber. These dextrinbased fibers, manufactured by Roquette, are only 2.1 calories per gram. Human studies also show that there is a reduction in glycemic response with soluble corn fiber. Clinical research demonstrates that they are fermented by various beneficial colonic bacteria to produce physiologically beneficial SCFAs, and positively impact Continued on page 74 www.dairyfoods.com

73

Ingredient Technology

Photo courtesy of FMC BioPolymer

 Yogurt beverages can be easily formulated to be “high in” or an “excellent source of” fiber, meaning a serving delivers 5 grams or more. digestive health. Most important of all, these fibers are extremely well tolerated and do not cause digestive discomfort. Short- and long-term studies show that up to 45 grams per day of soluble corn fiber or soluble wheat fiber can be consumed without causing digestive discomfort. A prebiotic claim can be made with 2.5 grams per serving of these fibers. Nieto: TIC Gums carries both soluble and insoluble fiber food ingredients. Our soluble fibers include viscous polysaccharides such as alginates; carboxymethylcellulose; guar, konjac, locust bean, tara and xanthan gums; and pectin, and non-viscous fibers such as gum Arabic and inulin. The insoluble fibers we market include bamboo fiber, cellulose powder and MCC. These ingredients are available individually or as specialty fiber blends, depending on the customer’s specific requirements. O’Neill: The chicory root is a rich source of inulin. The inulin component may be enzymatically hydrolyzed to form shorter chain oligofructose. Beneo offers both of these low-calorie ingredients (1.5 calories per gram). Inulin is a white, soluble powder with a neutral to slightly sweet taste and no aftertaste. Available in liquid or powder form, oligofructose is more soluble than sucrose with a moderately sweet taste. These non-digestible oligosaccharides are fermented in the colon, leading to the selective stimulation and promotion of healthful bifidobacteria (the prebiotic effect), helping to improve digestive health and function. As ingredients, inulin and oligofructose improve taste and mouthfeel, enable fat and sugar reduction, and impart all the benefits associated with dietary fiber, such as moderation of blood sugar levels after eating and speeding up the transit time of food through the gastrointestinal tract. Uniquely, inulin and oligofructose can also help promote long-term bone health by improving the absorption of dietary calcium. A patented form of oligofructose-enriched inulin has also been shown to increase bone mineral density and lower body mass index.

Patti: Fiberstar’s citrus pulp fiber is being used by dairy and beverage processors in a variety of ways to improve the quality, nutrition and label declaration of their products, often while reducing ingredient costs. The all-natural fiber derived from a by-product of orange juice processing is different than traditional fibers because of the unique combination of its chemical composition and physical characteristics. The citrus fiber product is composed of one-third soluble fiber and one-third insoluble fiber and also contains 8% protein. This chemical composition gives the fiber the ability to tightly bind fats and oils in addition to water. The patented mechanical process used in its manufacture opens the fiber matrix to create an amorphous molecule with high internal surface area, allowing the fiber to hold oil and water more tightly through processing, cooking, baking and storage than other ingredients. In dairy products, citrus fiber can replace higher-priced synthetic emulsifiers and stabilizers, partially replace fats and oils, and control viscosity and texture. In beverages, citrus pulp fiber can stabilize other ingredients, control viscosity and texture and impart a pulpy mouthfeel. Peters: Biovelop’s fiber ingredient is oat beta glucan, the soluble fiber from oats. Our patented, chemical-free technology enables us to produce a natural, highly versatile, clean-label ingredient, which bestows the well-recognized health benefits of oats on a wide variety of dairy products but without the oat taste or color. Our oat beta glucan enables products to provide or contribute to consumers’ recommended daily intake of 3 grams of beta glucan, therefore allowing access to FDA and EFSA health claims for the maintenance of healthy blood cholesterol levels. Our oat beta glucan can also help to lower blood pressure, regulate blood sugar, promote satiety and act as a prebiotic for improved gut health. Peterson: SunOpta offers a variety of individual dietary fibers such as oat, soy, pea and barley, as well as blends of soluble and insoluble fibers. These are versatile ingredients that can enhance food and beverage products by adding both nutritional and functional benefits. Oat fiber, in particular, is an ideal choice for increasing fiber content, reducing calorie content and enhancing texture. Consumer perception of oat fiber on an ingredient statement is very positive, as both “oat” and “fiber” solicit an impression of health, nutrition and well-being. Insoluble oat, soy and pea fibers are virtually calorie free while barley soluble fiber provides 3.4 calories per gram. Romeo: Nutraceuticals International markets one of the newest fiber food ingredients to enter the natural products scene. It comes from the fruit of the baobab tree, which grows wild in South Africa and India. Known around the world as a superfruit, the fruit contains an extraordinary blend of vitamins, minerals and other nutrients and is 70% fiber. We have partnered with a direct manufacturer of a standardized baobab fruit powder extract, which is low in calories, sugar, fat and carbohydrates. It is soluble in hot and cold water and can be used as a sugar or fat substitute. Turowski: Sensus manufactures a range of soluble fiber ingredients sourced from chicory root. Also known as inulin, chicory root fiber can deliver a variety of nutritional and functional benefits to most dairy applications. Nutritionally, there are several clinical studies that demonstrate the prebiotic properties of these ingredients, thus supporting claims related to digestive health. Continued on page 76

74

Dairy Foods | January 2011

There’s something special about our sea salt. For one thing, it comes from a sea.

© 2009 Cargill, Incorporated

Cargill is the leading national supplier of domestic sea salt that comes from a living sea. We always give you

www.cargillsalt.com

the most consistent taste and texture. No wonder the food tastes so good. See what else we bring to the table. Call 1-888-385-SALT to get our Sea Salt Marketing Guide and visit www.cargillsalt.com to learn about consumer and marketing insights that can help you grow your business using our innovative salt solutions. collaborate

>

create

>

succeed™

Ingredient Technology

In addition to a caloric value of 1.5 calories per gram, there is emerging research demonstrating the ability of chicory root fiber to support weight management. Perhaps the most unique aspect of these ingredients is the wide range of functional benefits they can deliver, particularly in dairy applications. These ingredients can improve texture and replace fat. Specific products can also serve as low-calorie, all-natural sweeteners. These forms of chicory root fiber can provide as much as 65% the sweetness of sugar and perform very similar to high-fructose corn syrup in regards to functionality. Varde: Roquette America has a line of soluble fibers derived from both corn and wheat. They are classified as resistant dextrins. They are derived from non-genetically modified corn and wheat starch, have excellent dispersability and dissolution, and have a high dietary tolerance. Nutritionally, these resistant dextrins are prebiotic fibers and they have been clinically proven to increase satiety and aid in weight management. At 85% fiber, these resistant dextrins offer a high-purity source of fiber that can be easily used to make a fiber claim. Dairy Foods: How does a product developer formulate with your fiber ingredient(s)? Black: Our product developers have worked with manufacturers to create high-fiber ice cream and sour cream using our soluble corn fibers. Recent fiber-rich prototypes include Greek-style yogurt, a chocolate exercise recovery drink, savory yogurt spreads and sweet fruit dips.

Cammarata: MCC has many uses in dairy-based products. For example, in dairy beverages, addition of 0.2% to 0.5% MCC contributes to mouthfeel and texture while also imparting excellent suspension of insoluble particles such as calcium or cocoa. Since it is completely heat stable, MCC functions even under ultra-high temperatures. It can also be used to impart body and mouthfeel for fat replacement in frozen desserts. Typical usage levels for a full-fat ice cream would be 0.25% to 0.35% and 0.30% to 0.45% for a low-fat or nonfat product. Cordts: With flavored milk drinks, our unique vegetable fiber system is stirred into milk in the cold state. After a short swelling time, the milk can be mixed with the other ingredients in the usual way, then homogenized, heated and filled. It is the high-pressure homogenization that forms the microgels. It is much the same with drinkable yogurt. You put the functional system into the milk first, homogenize the mixture under pressure and then add the cultures. Once ready, containers are filled. For a low-fat drinking yogurt, 0.1% to 0.2% of the fiber system is enough to maintain the accustomed mouthfeel. In addition, it is possible to reduce the cost of the formulation. Driessen: Because PHGG is easily dissolved in water and has low viscosity, it has a wide range of suitable applications. Further, it has good stability at low pH (3.5) and heat during processing. With no unpleasant taste and no strange mouthfeel, it is easy to use PHGG to develop foods and beverages that deliver high levels of fiber without adversely affecting the product quality. And, possibly more important, PHGG does not cause uncomfortable bloating or gas.

Sign Up To Receive Your Free DIGITAL Edition of Dairy Foods Today! Innovative Ideas for Dairy Processors No special reader software to download! Use your standard browser to view the Dairy Foods Digital Edition. Get the Digital Advantage NOW at www.dairyfoods.com/digital.

Customer Service (847) 763-9534. 76

Dairy Foods | January12011 DFDigitalAd-Horizontal.indd

10/26/10 9:22 AM

Ingredient Technology

Horst: While our polydextrose has many of the properties of sugar, it has low sweetness and virtually no taste. It is used in sugar-free, reduced-sugar, low-fat and fiber-enriched dairy products such as drinking yogurt and liquid cultured milk, ice cream, growing-up milk formulas (for 1- to 4-year-olds), creams, fresh cheese and processed cheese. It has high solubility and low viscosity, which offers the possibility of high-fiber dosages. In dairy products, it has a clean mouthfeel, increases the mouthfeel in low-sugar products and enhances creaminess. For processed cheese, specifically, polydextrose allows good structure, no gumminess and good humectant properties while still allowing the cheese slice to melt. Special grades of ultra-refined polydextrose prevent browning. Addition levels are 3% to 15%, depending on the application. Ledbetter: Our soluble corn fiber is unique in that it is colorless, odorless and tasteless; adds minimal viscosity; contains minimal sugars and is soluble in water up to a 70% solution. It is suitable for sugar-, fat- and calorie-modified applications, as it only contains 1.6 calories per gram and contains very few simple sugars for consideration of a no-sugar-added or sugar-free claim and can be used up to 10 grams (dry basis) in any food application while providing only 0.2 grams of sugars. Besides being GRAS as maltodextrin, it can be labeled as a maltodextrin, digestion resistant maltodextrin or soluble corn fiber. Munteanu: Our scFOS has a short-chain structure, making it a non-viscous, highly soluble ingredient. Functional benefits such as mouthfeel and flavor enhancement are also associated with scFOS. Additionally, scFOS is stable through processing and throughout

the shelf life of enhanced dairy products. Inclusion levels range between 1.1 grams and 3.22 grams per serving, depending on the desired label claim. Suggested labeling declarations include fructan and fructooligosaccharides(FOS). GOS is highly soluble and shows superior stability during severe processing conditions such as low pH and high heat. GOS has a clean taste and will not have a negative impact on the sensory profile of food products. Suggested inclusion levels are 3 grams per serving and label declarations include galactan, oligosaccharides or simply GOS. Agave inulin features a branched structure that contributes to a smooth mouthfeel in low-fat dairy applications. The soluble nature of the material allows for easy incorporation, while its clean, pleasant taste helps maintain a good sensory profile. Suggested inclusion levels are at 3 grams per serving for a “good” source of fiber claim and label declarations are agave fiber, agave inulin and inulin. Niba: Soluble corn fiber and soluble wheat fiber are multi-functional and can be used in a range of dairy-based applications. They are stable to processing and storage conditions such as low pH, high acid, pasteurization and freezing. Nieto: Intermediate moisture and semi-dry products such as grain-based foods can be easily fortified with fiber. However, beverages and liquid products, especially milk-containing ones, are not as easy due to viscosity issues, as well as possible incompatibility with milk proteins. Many gums can destabilize the structure of milk protein and only a few of these gum fibers will work in dairy systems. In non-acidified dairy systems such as milk and frozen desserts, the best fiber system is one that contains inulin as the Continued on page 78

ACCELERATE YOUR

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

www.dairyfoods.com

77

Ingredient Technology

main fiber source, as inulin will not impart viscosity. Carrageenan complements inulin and functions as a stabilizer. O’Neill: Inulin stabilizes water into a creamy structure with the same mouthfeel as fat, enabling the reduction of fat while maintaining a creamy texture, roundness and a better balanced flavor. It stabilizes emulsions and dispersions, and improves the stability of aerated dairy desserts such as chocolate, yogurt and fruit mousses. Usage levels of 3% to 5% will typically impart a fat mimetic effect. Oligofructose is a natural sugar replacer and is suitable for diabetics. It can help eliminate the artificial aftertaste of high-intensity sweeteners. Certain fruit flavors are also more pronounced when used in combination with oligofructose. Patti: When used in dairy products and beverages, our unique functional fiber is labeled as citrus fiber or citrus flour. When used for emulsification, thickening or as a stabilizer, it is generally added at 0.25% to 1.5% of formula weight. In reduced-fat formulations, one part of the citrus pulp fiber is added with six to 12 parts extra formula water to replace up to 50% of formula oil or milkfat. Because citrus fiber and water cost less than the oil or milkfat they replace, manufacturers save on ingredients. Peters: Our oat beta glucan soluble fiber has been used to create prototypes of fermented low-pH milk drinks, buttermilk, low-fat cream cheeses and crème fraiche-type products. In dairy products, it can be used as a fat replacer, emulsifier, stabilizer and viscosity modifier. With usage levels of just 1% to 3%, oat beta glucan provides dairy products with an indulgent, creamy mouthfeel, previously only found in full-fat products.  Small amounts of fiber-containing ingredients have long been used in frozen desserts to assist with emulsification and stability. Today, novel ingredients are being added to boost fiber contents on the Nutrition Facts.

Kids’ Foods Get Fiber Boost Digestive health is a growing category, particularly for children’s products. According to consumer market research from Tate & Lyle, Decatur, Ill., 67% of U.S. parents believe fiber is an important component of their children’s health and 35% believe the benefits of consuming products with fiber help their children with digestion. Companies such as Beech-Nut h-Nut Nutrition Corp., Latham, N.Y., Y., recognize parents’ desire for fiber in n foods formulated for kids’ nutritional needs and recently introduced DHA Plus lus Yogurt Blends with Juice. Each 6-ounce -ounce shelf-stable plastic bottle contains ntains yogurt (heat-treated after culturing) turing) blended with fruit purée and fruitit juice (maximum 40% juice). This toddler oddler beverage is enriched with all the he vita vitamins and minerals that growing babies  Added inulin allows need, including calcium, vitamin D, B for a prebiotic claim. vitamins, iron and zinc. It is enhanced with prebiotic fiber in the form of inulin and the omega-3 fatty acid docosahexaenoic acid (DHA). The fruit and pectin stabilizer also contributes fiber, with the final product delivering 1 gram of soluble fiber and 1 gram of insoluble fiber. 

Peterson: The addition of 1.0% to 1.5% barley soluble fiber concentrate to a low-fat yogurt or beverage will deliver the 0.75 grams of beta glucan required for the heart-health claim, as well as provide an indulgent mouthfeel, mimicking a full-fat system and reducing the reliance on other texture enhancers. It is important to remember that insoluble fibers can also play a role in fortification of dairy products such as beverages, smoothies and yogurts, as insoluble fibers can provide a reduction in formula cost compared to soluble fibers. A “good” source of fiber claim is achievable in a beverage, for example, with approximately 1% oat fiber. For fiber levels beyond that level, SunOpta offers a blend of soluble and insoluble fibers that was specifically designed for dairy applications. Turowski: We created a low-fat chocolate milk that contains 3 grams of fiber per 8-ounce serving (as compared to no fiber in traditional chocolate milk). Using our inulin, calories are also reduced by 11% (from 180 to 160) and total sugars by 22% (from 27 grams to 21 grams). Varde: A major interest from our dairy customers is the ability of our resistant dextrins to withstand pasteurization, sterilization, fermentation and thermal processing. In yogurt smoothies or kefir products, resistant dextrins are used both nutritionally and functionally. Because of their organoleptic properties, resistant dextrins have been shown to add some mouthfeel to dairy beverages, as well as diminish some off-notes, for example, those that consumers may perceive from high-intensity sweeteners. 

Photo courtesy of FMC BioPolymer

78

Dairy Foods | January 2011

Want to read more about fiber? Suppliers provide commentary on the future of fortifying dairy foods with fiber food ingredients. Visit www.dairyfoods.com.

EVERYTHING YOU NEED IN ONE SHOW INGREDIENTS TRENDS PACKAGING PROCESSING TECHNOLOGY SUSTAINABILITY

TO REGISTER OR EXHIBIT VISIT WWW.DAIRYSHOW.COM. ATLANTA, GA • SEPTEMBER 19–21, 2011 Use this code when filling out your registration form: A1DF11

Ingredient Technology

DAIRY DETECTIVE

The Greeks Bear Gifts — Thick, Creamy Yogurts ver the past 10 years, refrigerated yogurt has had a remarkable combined annual growth rate averaging around 30% and nearly 40 million new users. And poised to push yogurt sales even higher in the next decade is a new category of higher-protein yogurts, commonly called “Greek” yogurt. Thick, protein-rich yogurts were rare just a few years ago, but have emerged as an important new category. The first Fage (pronounced “fa-yeh”) Greek yogurt was introduced in the United States in 2002. Since 2005, about a dozen Greek brands have emerged, with major marketers such as Yoplait, Dannon and Kraft introducing Greek varieties in 2010. And while most popular brands are labeled as Greek or strained yogurt, there are also Icelandic and American versions. The Greek-style yogurt segment is adding volume to the total yogurt category, with Greek yogurt sales more than doubling every year for the last five years — to more than 100 million pounds in 2010 (annualized estimate), according to data from SymphonyIRI Group, Mintel and DataMonitor. Advantages of these new yogurts include rich, creamy texture, higher protein content and fewer stabilizers, resulting in a more natural product. “There has been an increased awareness of the value of protein in the diet, which may explain some of the popularity of higher-protein yogurts,” notes Mary Higgins, vice president of trade service, U.S. Manufacturing and Ingredient Marketing, U.S. Dairy Export Council, Arlington, Va.

O

The ingredients in Greek yogurt Most companies can make Greek yogurt, but they may have to modify their process. “One method is to use a separator to strain the liquid whey after the yogurt is set. Another method is to start with fluid milk fortified with milk protein concentrate (MPC) or functional blends of MPC and whey protein concentrate (WPC). Still another method is to add ultra-filtrated (UF) 80

Dairy Foods | January 2011

milk,” notes Dr. Mirjana Curic-Bawden, senior scientist at Chr. Hansen, Milwaukee. Choice of a yogurt culture depends on the production method, formulation and desired taste and flavor profile. “If yogurt is made by separation, the processing may take longer, and use of a very mild flavor and low post-acidifying culture is recommended. For protein-fortified yogurts, the cultures with low-to-medium yogurt flavor work better, as they bring freshness notes. High-viscosity yogurt cultures are recommended for low-fat and non-fat versions,” Curic-Bawden adds. Proper selection, testing and processing of dried protein concentrate ingredients is essential to yield a product with clean flavor and no graininess. Source of whey powder or WPC is important as it may bring some undesired notes. For instance, whey powders from cheeses produced with microbial rennet may have residual enzymatic activity and show some bitterness in the end notes. “Certain blends of milk proteins and whey proteins will allow for better flavor and textural properties. Glanbia offers a range of dairy proteins under the brand name OptiSol, designed to work in conjunction with native milk proteins, as well as added milk proteins, to create a very clean dairy flavor and limited graininess seen with standard milk solid addition,” explains Tim Harried, business development manager, functional ingredients for Glanbia Nutritionals, Fitchburg, Wis. While most high-protein yogurts have increased levels of milk protein, Tula Foods, Evanston, Ill., has chosen to fortify its Better Whey of Life yogurt with whey protein. “Whey protein is among the highestquality proteins and provides superior health benefits,” notes Daphne Mazarakis, Tula Food’s founder and president. In the development of its yogurt, Tula Foods collaborated with the Wisconsin Center for Dairy Research for ingredient selection. Skyr (pronounced “skeer”) is the traditional concentrated (strained) non-fat yogurt of Iceland, and may be very tart.

Sharon Gerdes

However, with the right flavor, such as orange/ginger or blueberry, this can be a pleasant product. In Europe, Greek yogurt is a synonym for high protein and high fat, but in the United States, most are fat-free. One exception is Fage, whose Classic contains 20 grams of fat per 7-ounce serving. These higher-protein yogurts are significantly less sweet than traditional yogurt, and typically are all natural and do not contain high-intensity sweeteners. Most traditional yogurts contain 3-5% protein and 10-16% sugar by weight. In contrast, Greek yogurts contain 8-10% protein and about 4% sugar, with slightly higher sugar levels in those varieties sweetened with fruit. How to use the product There are many uses for Greek yogurt. It can be used as a lower-fat and natural alternative to sour cream. Regular sour cream has 18% fat, compared to 10% fat in classic Greek yogurt. Non-fat Greek yogurt is an excellent alternative to fat-free sour cream. “It is worth mentioning that 0% fat Greek yogurts are now filling a position that is in Canada, Mexico and most of European countries taken by quark and fromage frais (fresh cheese). Namely, some U.S. Greek yogurts are so mild they are very similar to quark. Quark and fromage frais are actually made by the same technologies used for Greek yogurt, by separation or protein fortification, but using mesophilic, and is similar to a fresh cheese,” Curic-Bawden adds. Labne (also spelled labaneh and lebnah) is a Middle Eastern thick yogurt, used extensively in cooking, salads and salad dressing. For more details on Greek yogurt, e-mail [email protected].  Sharon Gerdes is a food industry consultant who works with the U.S. Manufacturing & Ingredient Marketing program at the U.S. Dairy Export Council to promote the use of dairy ingredients in food and beverage formulations.

SUPPLIER CAPABILITIES SPOTLIGHT

Curwood Bemis’s Acquisition of Alcan Food Americas Strengthens Curwood’s Single-Source Solutions in Cheese Packaging Enhancements include expanded cheese packaging technologies, two week service program. OSHKOSH, Wis. – Bemis Co., Inc., a worldwide supplier of flexible packaging materials, completed the acquisition of Alcan Food Americas on March 1 of 2010, strengthening the company’s ability to serve the cheese marketplace. Bemis’s Curwood division, a leading supplier of cheese packaging since its founding in 1958, has merged the majority of Alcan’s technologies and services into its market offering. Assets now under the Curwood umbrella that manufacture cheese packaging include the Boscobel, Wis., quickturnaround plant; the Neenah, Wis., natural cheese plus wax-coated and IWS processed cheese packaging operation; the Russellville, Ark., stock preformed CPET tray operation; and the Des Moines, Iowa film production facility. “These assets have dramatically strengthened our cheese product offering,” says John Hackinson, Vice President of Marketing for Curwood. “Our expanded capabilities allow us to deliver the most comprehensive, technologically advanced, cost-efficient cheese packaging portfolio in the Americas. We have clearly emerged as the leader in cheese packaging, and we intend to earn that position with customers each and every day.” Oshkosh, Wis.-based Curwood got its start in New London, Wis., when businessmen Howard Curler and Bob Woods left American National Can (later to become Alcan) to launch their own flexible packaging business. Their vision was to develop polymer extrusion technology to make the finest flexible packaging possible for the meat and cheese industries.

82

Dairy Foods | January 2011

In a small, rented garage, their plans began to take shape with a single machine and their first product—polyethylene packaging films. In 1962, the new company added vacuum-packaging equipment to their offering. Bemis purchased Curwood just seven years after its founding, providing resources to invest in new technologies to meet the emerging needs of its meat and dairy customers. Throughout the years, Curwood engineered packaging advances that improved the way cheese—and many other products—went to market. Examples include Curpolene films for chunk cheese; the first slider zipper package created for Sargento; and reclosable tray & lid packaging for sliced cheese. “We are continually working to provide total packaging solutions to improve every aspect of cheese packaging, including machinability, shelf life, retail appeal, consumer convenience and sustainability,” says Don Schnabel, Curwood’s Director of Marketing for Cheese. “We also focus on cheese makers’ needs for

reduced lead-times, shorter runs, reduced obsolescence and reduced inventory.” The acquisition allows all Curwood facilities to turn flexible packaging around in just two weeks. Also new in Curwood’s portfolio is processed cheese packaging, including individual wrapped slice (IWS) technology and wax- and foil-coated materials. “Now cheese makers can single-source their full cheese packaging needs with us,” says Schnabel Curwood maintains strategic manufacturing and service centers throughout North America, South America and Europe. Bemis employs over 20,000 individuals in 84 manufacturing facilities in 13 countries around the world. Founded in 1858, Bemis is included in the S&P 500 index of stocks and reported pro forma 2009 net sales, giving effect to the Food Americas acquisition, of $4.8 billion.

THE PACKAGE MAKES IT POSSIBLE!

SM

Sharper Response. (Only at Curwood.) Choose the Packaging Supplier with the Cheese Industry’s Only 2-Week Turnaround Get chunk, sliced and shredded cheese packaging in just two weeks, with Curwood’s Cellular Service Model. You’ll experience world-leading response, plus the broadest portfolio of cheese packaging technologies available. All, backed with comprehensive development and scale-up; 24/7 technical y. support; and unmatched manufacturing reliability. ating Want the ability to move quickly and lower operating 4672 costs? Think fast! Call Curwood at 1-800-544-4672. "!$'%2!6%.5%s0/"/8s/3(+/3( 7) s  s#(%%3%0+' "%-)3#/-s777#527//$#/©2010 Curwood, Inc. 12.10

SUPPLIER CAPABILITIES SPOTLIGHT

TIC Gums Creating Product Success Stories for More than a Century For over 100 years, TIC Gums has been the trusted global source for stabilizers, texturizers, and advanced gum formulations. By providing food and beverage manufacturers with creative solutions backed by unparalleled customer support, we have given our clients a distinctive advantage over the competition. Whatever the need, TIC Gums has the know-how to create product success stories. As the leader in advanced texture and stabilization solutions for the food industry, we offer a stable supply of texturizers, rigorous quality control programs, and unwavering focus on food safety and supply chain security. Our Dairyblend stabilizers are costeffective solutions to the specific challenges of dairy applications. Depending on the application and stabilizer selection, Dairyblend systems can be used to improve body and mouthfeel, control ice crystal formation, or replace ingredients like MSNF, sugar, or fat. Two remarkable products in the TIC Gums portfolio serve to underscore our commitment to innovation and cuttingedge technology in the area of dairy foods. The first is TICorganic® Agar 150-C FCC/NF, the latest addition to our comprehensive line of certified organic gums. This newest TICorganic gum is a high gel strength fine mesh extract from the Gelidium species of red seaweed with various applications, including improving the gelling properties of yogurt. Third-party organic certification means the entire line of TICorganic gums

84

Dairy Foods | January 2011

meets the stringent standards established by the U.S. Department of Agriculture (USDA). As a result, any yogurt or dairy company producing organic products does not have to rely on non-organic ingredients that could jeopardize organic claims. Both TICorganic Agar RS-100 and TICorganic Agar 150-C FCC/NF is also high in fiber, another plus for health-conscious consumers. Another high performing TIC Gums product is Dairyblend SC-NAT, a costeffective, natural alternative to gelatins or starches. Sour cream products using Dairyblend SC-NAT withstand freezing and thawing without cracking, and enjoy

improved body and mouth feel, and controlled ice crystal formation. Dairyblend SC-NAT can be used in traditional cultured sour cream as well as acid set, and in both standard (18% butterfat) and reduced fat (9%) sour creams. Lower usage levels deliver a thick, pourable product, while higher usage delivers a heavy bodied traditional sour cream. Companies not only trust these products and the entire range of TIC Gums products and technologies, they also rely on the most knowledgeable food scientists in the business. Known as the Gum Gurus®, our team stands ready to help create or improve a product, sometimes at a moment’s notice. Our scientists are at the vanguard of food science and the emerging focus on texture – the least understood, yet most promising frontier for food and beverage makers. Customer service, cutting-edge technologies, and an eye to future trends, combined with its commitment to excellence, have made TIC Gums synonymous with quality for more than a century.

A DELICIOUS MILKSHAKE... ...THAT BYPASSED TEXTURE DESIGN DURING THE DEVELOPMENT PHASE. Dairy products are at the mercy of texture, a food property that can even alter the perception of flavor—for better or worse. Texture is a functional attribute that demands attention at the first stage of product development. The Gum Gurus® at TIC Gums are world-class food scientists in the development of textures that can increase likeability and shake up your competitors.

Contact the Gum Gurus at (800) 899-3953 or ticgums.com/chat

Ingredient Technology

WELLNESS WATCH

Donna Berry

 Donna Berry Product Development Editor oods for weight management continue to evolve with advancements in nutritional and physiological sciences. The industry is shifting from “minus” foods (i.e., diet and low and light foods) towards “plus” foods, with such functional weight management products providing consumers with differentiation and added value. Such “active” formulations are reflected in the fact that the terms “diet” and “weight loss” have been replaced by “weight management.”

F

A booming marketplace According to U.K.-based Leatherhead Food Research, the worldwide weight-management market of foods and beverages was worth an estimated $7.3 billion in 2009, and is set to grow at a rate of 6-8% annually for the next five years. Leatherhead explains that successful weight-management foods are both convenient and offer a benefit that can be felt quickly, if not immediately. Marketers must clearly convey this benefit to consumers, otherwise consumers will become skeptical. The product must also deliver on taste and texture, as today’s consumers are not willing to sacrifice sensory satisfaction for the sake of losing a few pounds, especially when there are so many options in the marketplace. Growth so far has been largely due to innovations within the bakery/cereals and beverage markets, which have respective shares of 33.5% and 28.4% of the weight-management market. This is

86

Dairy Foods | January 2011

largely due to the ability of these products to carry ingredients associated with weight management, such as fiber and protein, as well as the fact that they are generally perceived by consumers as both convenient and healthy. Ready meals and snacks come in third place with a 21.6% share; while dairy comes in fourth with an 8.2% share, according to Leatherhead. All other foods make up the remaining share. Dairy has the potential to increase share of the weight-management food and beverage market, as not only are dairy foods an inherent source of high-quality protein, many dairy applications are ideal carriers of fiber and additional protein, including both soy and whey. For these reasons plus others, Weight Watchers International Inc., New York, the global leader in weight management programs, recognizes nonfat dairy foods as “power foods” in its new PointsPlus program.

“We are retiring the popular Points weight loss system, which was implemented 13 years ago in the States and at the time represented the best science,” says Stephanie Rost, corporate program development director and a registered dietician. “The new PointsPlus program reflects the latest scientific research that has been discovered since the original program rolled out. “PointsPlus goes far beyond traditional calorie counting to give people the edge they need to lose weight and keep it off in a fundamentally healthier way,” she says. The PointsPlus program takes into account the energy contained in each source of calories — carbohydrates, fat, fiber and protein — and it also factors in how hard the body works to process them, and even more importantly, accounts for how these nutrients affect feelings of hunger and fullness.

Dairy Product Introductions Making a Satiety or Weight-Control Claim (product line launches) 2006

2007

2008

2009

2010*

2006-2010

United States

8

12

19

5

6

50

Global (including U.S.)

41

104

103

76

74

398

* Jan. 1 to Nov. 30

Source: Mintel

 The number of new dairy products making a satiety or weight-control claim was highest before the recession hit. The improving economy, coupled with advancements in weightmanagement research, should result in increased activity in this area during the next five years.

Ingredient Technology

Study Says HFCS Does Not Uniquely Promote Obesity For the past five years, high-fructose corn syrup (HFCS) has been implicated as a prime suspect in the obesity epidemic. However, new research presented Oct. 9, 2010 at the Obesity Society’s 28th Annual Scientific Meeting shows no statistical differences between people given HFCS and those given sucrose (sugar). Results from the double-blind study revealed that fructose-containing sweeteners do not uniquely contribute to obesity when consumed as part of a healthy, weight-maintenance diet. In the study, overweight or obese adults were placed on a 10-week eucaloric diet — a diet that supplies the body with just the right number of calories necessary to maintain current body weight. The eucaloric

 Nutrient-dense dairy foods satisfy, w which is one of the reasons why the W Weight Watchers brand can be found o on so many.

“The end result iss that consumers are re guided towards healthy althy and satisfying foods, s, without having to think too much about it,” she says. “In addition to the new formula, foods that are low in energy density and therefore, more highly satisfying, are emphasized within the program. Specifically, all fresh fruits and most vegetables now have zero PointsPlus values. We realized that sometimes members were skipping fruits and vegetables because they said they didn’t want to ‘waste’ their points. Now, they’re picking them more, because they are a more enticing choice.” Powerful dairy foods Weight Watchers is also introducing the concept of Power Foods to its new PointsPlus program. “This element of the program provides an easy way to identify the best food choices among similar foods, for example, those foods with higher eating satisfaction, lower sugar, lower sodium, healthier fat and more fiber,” says Rost. “Many nonfat dairy foods are identified as Power Foods.” Rost explains that Weight Watchers has always promoted and encouraged the consumption of dairy foods throughout the day. “Weight Watchers recognizes that dairy foods are so

diet incorporated either HFCS or sucrose-sweetened low-fat milk. Participants’ consumption of low-fat milk accounted for 10-20% of their daily allotted calories, which represents typical levels of sweetener consumption. Study participants did not experience a change in body weight, percent of body fat, fat mass or percent of abdominal body fat. Sucrose and HFCS each contain the same number of calories. These results are meaningful for the food and beverage industry because they provide further scientific evidence that products containing HFCS do not promote weight gain more than products containing sugar. 

much more than just a source of calcium,” she says. “Most dairy foods are nutrient dense and can be very satiating. In fact, we refer to milk as an ‘exception’ beverage, as it does more than thirst quench. This is not just because of the high-quality protein found in milk, but the fact that milk contains a higher percent of solids than many other beverages.” David Kirchhoff, president and CEO of Weight Watchers, says, “We are changing the way Americans view calories and select their food. Our new PointsPlus program will not only deliver weight loss success, it will help transform America’s eating habits and the way we make our food choices.” Weight Watchers licenses its brand to food companies manufacturing products that comply with the company’s standards. This includes LaLa Foods Inc., Dallas, which makes Weight Watchers yogurt; Schreiber Foods Inc., Green Bay, Wis., which makes Weight Watchers natural and process cheeses; and Wells’ Dairy Inc., Le Mars, Iowa, which produces Weight Watchers frozen desserts. “All the Weight Watchers branded dairy products can be used by both those following the Weight Watchers program and weight-conscious consumers who are looking for a betterfor-you alternative that doesn’t sacrifice on taste,” says Hugh Dever, director of licensing. “Weight Watchers has provided licensees with information about the new PointsPlus program for use on both the front and back of the packaging. This packaging should be reaching shelves in January, consistent with the time of year when many people are making a resolution to lose weight and make healthier food choices.” This will be an exciting year for the weight-management market. Make sure to promote your dairy products for the power they possess.  Donna Berry is the product development editor of Dairy Foods. She can be reached at 312/656-6453 or [email protected]. www.dairyfoods.com

87

SUPPLIER CAPABILITIES SPOTLIGHT

Fruitcrown Products The Fruit Specialists in the Dairy Industry For over 70 years, Fruitcrown has been a custom formulator and manufacturer of fruits and flavoring systems for the Dairy Industry. Fruitcrown offers a wide range of fruit preparations and creative flavor systems for cultured yogurt, frozen desserts and other fruit containing products in the Dairy, Beverage and Baking Industries. When you think of Fruitcrown, think of us as the Fruit Specialists offering solutions for the following products: • Yogurt • Ice Cream • Cottage Cheese • Cream Cheese • Flavored Milk • Flavored Beverage & Smoothie Bases • Bakery Toppings & Fillings Fruitcrown has many existing fruit and flavor products or we can custom formulate a flavor ingredient system to meet your specific requirements. Our products are formulated to consider all technical characteristics for your product such as choice of flavor, sweetener, sweetness level, usage rate, color, fruit content/integrity and stabilization. Our customers have come to rely on our experienced product development team and creative applications lab to meet their ever demanding new product development needs. The Fruitcrown motto is “Praestantia Valet” which means “Quality Prevails.” Our efforts, under the full control of our internal field supervisors, begin in the fields where the fruit is grown and harvested, continuing through to the packing facilities, field canneries and freezing plants. When the fruit arrives in our processing facilities, our QC Department takes charge, monitoring the hand inspection of every pound of fruit going into our products in addition to obsessive scrutinizing of all phases of processing. Fruitcrown Products meets all food safety and regulatory guidelines. We are inspected by Siliker and the American Institute of Baking (A.I.B.) yearly and

88

Dairy Foods | January 2011

are certified as an Organic and Kosher osher facility by NSF/QAI and KOF-K F-K Kosher Supervisory Services. Our state-of-the-art cool fill (85°F) aseptic processing systems are specifically designed to provide high quality, pathogen free product with phenomenal fruit show and integrity, including soft textured fruits such as strawberries, peaches, blueberries and raspberries. Our ur systems are engineered specifically ally for Fruitcrown and therefore are unique in their design and their ability to o protect fruit integrity while meeting the increas increasing quality and sanitary demandss of our customers. With processing facilities cilities in Wisconsin and New York, we are well positioned to meet the needs ds of our national customer base in n a diverse industry. We also have multiple packaging options to give our customers flexibility in their plant. These include: • 1 gallon plastic jug (4 per case) • 5 gallon aseptic Bag in a Box • 50 gallon aseptic Bag in a Drum m (top unloading) • 50 gallon aseptic Bag in a MINITOTE™ (bottom unloading) g) • 220 gallon aseptic Bag in a Tote (bottom unloading) With all these resources available lable to service our customers we look forward rward to becoming your partner in the Dairy Industry!

Fruitcrown Products 250 Adams Blvd. Farmingdale, NY 11735 800-441-3210 [email protected] www.fruitcrown.com

FRUITCROWN Products Corporation Specialists in phenomenal fruit show such as strawberry, peach and other delicately textured fruit Fruitcrown Products Corporation is dedicated to providing the finest product available in the industry. Our quality control and production staff maintain the highest standard possible in the manufacture of our aseptic fruit bases, flavors and specialties. This superior quality, coupled with price and service, yields outstanding value. Our research and development capabilities are strong and creative. Rapid sample submission with follow-up adjustments, if necessary, is our policy. Our applications laboratories are equally impressive, offering time and cost savings opportunities to our customers.

FRUITCROWN Products Corporation 250 Adams Boulevard | Farmingdale, NY 11735 800-441-3210 | Fx. 631-694-6467

www.Fruitcrown.com

SUPPLIER CAPABILITIES SPOTLIGHT

Union Pacific Union Pacific Delivers Door-to-Door Logistics Expertise Every day, customers in every industry take advantage of Union Pacific’s logistics expertise. Union Pacific coordinates the efficiency of America’s rail network with the flexibility of trucks and the reach of ocean carriers to provide door-to-door freight transportation solutions. No matter what customers ship, or where they need to ship, Union Pacific gets it there. With logistics expertise and coordination that come with managing a fleet of more than 8,000 locomotives and 200,000 rail cars, Union Pacific makes it easy for customers to navigate complex logistics processes. Through on-time freight transport from a variety of locations -whether near rail or not -- Union Pacific helps customers manage tighter inventories to meet growing business demands.

No Rail, No Problem Through its Union Pacific Distribution Services subsidiary, Union Pacific logistics experts have experience in practically every industry including automobiles, chemicals, energy, agriculture, met-

als, minerals, forest products, consumer goods and more. Union Pacific’s new-customer onboarding team helps customers determine which services best meet their transportation needs. The company offers

Moving millions of pounds of dairy products efficiently from the West Coast to the East and everywhere in between is no small task. It takes the largest fleet of refrigerated rail cars in America, moving in expedited lanes across a synchronized, multi-modal transportation network. It takes Union Pacific. Find out more at UnionPacific.com or call (800) 877– 0513.

• Union Pacific can move one ton of freight 480 miles per gallon of fuel. That’s like your car getting more than 250 miles to the gallon. • Rail is almost four times more fuel efficient than truck, according to the U.S. EPA. • Freight trains generate a carbon footprint that is an average of 75 percent less than trucks. • Union Pacific owns America’s cleanest Class I locomotive fleet.

new customers a unique “white glove” service for the first 90 days to ensure a seamless transition of their business to Union Pacific. From initial introduction through the first shipment, the onboarding team acts as a single point of contact, easing the process of becoming a Union Pacific customer -- from credit application, to shipment,

invoicing and every¬thing in between. In essence, the onboarding team represents a new-customer welcoming committee. Fuel-Efficient and Environmentally Responsible Freight Transportation Shipping by rail is the most fuel efficient and environmentally responsible mode of ground freight transportation.

Wherever you find business, you’ll find us.

Union Pacific 800-877-0513 www.unionpacific.com

Ready to try the latest in Mixing Technology? ✔ Vacuum suction delivers powder up to 400 lbs/min ✔ Drastically reduce batch times ✔ Wet out and instantly disperse with no fish-eyes or agglomerates ✔ Eliminate bridging at any viscosity range ✔ Floor level powder/liquid addition reduces operator injuries ✔ Induct liquids from drums with optional wand

?

ASK US ABOUT OUR TRIAL PROGRAM

See the

✔ Field proven on dairy powders, NFDM, whey, starches, gelatin, flavorings, sugars, sweeteners, gums & hydrocolloids

in action! Visit our website www.admix.com/fastfeed.htm

Contact Admix today at 800-466-2369 and ask how the Fastfeed can improve your process.

sneak peek a look inside…

Better Foods, Safer Foods

REPORTS

-ray machines and metal detectors keep foods safe. Checkweighers assure foods are made to consistent sizes. Dairy processors and equipment vendors share tips.

X

Page 126

Keeping It All Together quipment for casing, stacking and palletizing keeps dairy products safe, neat and protected from damage on the loading dock, in transit and at their destination.

E

Page 136

Columnists • Allen Sayler on safety, Page 120 • Clay Detlefsen on sustainability, Page 124 Photo by Nestlé USA

Equipment Showcase N

ew equipment for cheesemaking.

Page 144

A Toast To Flavored Milk Thanks to robust sales of Nesquik flavored milks, innovations in the Juicy Juice brand and a new partnership with Jamba Juice, Nestlé USA is far from a milquetoast in grocery and convenience store channels.  Jim Carper Chief Editor

Reiser

fast forward what’s coming in February…  Perry’s Ice Cream  Greener Logistics  Sustainable Packaging

or a brand that uses a rabbit as a mascot, Nesquik wasn’t too mobile. Nestlé USA’s popular flavored-milk brand had been pretty much tied to grocery stores and other retail outlets with refrigerated cases. But since the Nestlé Beverage Division created shelf-stable products that do not require refrigeration, new

F

channels of distribution opened up, including mom-and-pop convenience stores, amusement parks, minor league baseball parks, campgrounds, bowling alleys and movie theaters. Nestlé’s shelfstable milk is making inroads into those outlets with limited refrigerated storage space or display space. The Glendale, Calif.-based dairy and Continued on page 94 www.dairyfoods.com

93

Corporate Profile Shoppers Lap Up Nesquik; Juicy Juice Gets Squeezed Sales data from supermarkets, drugstores and mass merchandise outlets, excluding Wal-Mart, for the 52-week period ended Oct. 31, 2010. Source: SymphonyIRI Group, Chicago. Product

Dollar Sales

Change

Dollar Share

Unit Sales

Change

Average Price

Juicy Juice Aseptic Juices

$80,466,670

-6.8%

$34.85

31,800,910

-6.8%

$2.53

Nesquik Ready-To-Drink Milk

$29,662,140

246.8%

$15.10

11,305,950

394.2%

$2.62

 In the category, the average price of ready-to-drink milk was $2.22 but Nestlé was selling Nesquik at a premium ($2.62) and gained market share. Juicy Juice told the opposite story. Nestlé charged a nickel more than the category average and lost unit sales and market share.

food processor believes so strongly in the growth potential of shelfstable milks that it built its own $670 million plant in Anderson, Ind. (see “Nestlé LEEDs the Way,” page 104.) Nestlé had been using co-packing arrangements with other dairy processors. “Our biggest challenge is producing high-quality dairy-based beverages within a highly regulated industry that dictates clear standards for processing and labeling,” says Kim Peddle-Rguem, director of marketing, immediate consumption beverages. “Our investment in Nestlé Anderson and our state-of-the-art aseptic technology have opened up a route to market that will enable us to make our ready-to-drink dairy-based beverages available

 Juicy Juice is the No. 1 juice drink brand for children, Nestlé says. whenever and wherever consumers want them, vastly increasing our ability to influence consumption outside of the home.” The company sees “a tremendous opportunity for growth” in impulse (or “point of thirst”) channels, especially when it comes to getting its brands recognized, Peddle-Rguem says. In response to the production of shelf-stable Nesquik at the Anderson plant, Nestlé reshaped its chilled-beverage sales force to focus on direct-store-distribution (DSD) accounts. The expanded sales force has taken the lead and broadened distribution into new accounts, says Joe Melone, sales director for Nestlé’s DSD beverage sales force. “It all goes back to having our products available wherever and whenever the consumer desires them,” Melone says. “We really just scratched the surface, and we’ve had a lot of successes, but I think there’s so many more venues out there that we haven’t got to.” The strategy seems to be paying off. Unit sales of Nesquik shot up 394% in the 52-week period ending Oct. 31, 2010, according to SymphonyIRI Group, a Chicago-based research firm. In addition, the DSD partnerships have led to new innovations, not just for the brands produced in Anderson, but across Nestlé’s entire beverage portfolio, the company says. Nestlé has seen increasing popularity for its 8-ounce bottles of Nesquik flavored milk and 8-ounce 100 Calorie Nesquik flavored milk. In June 2010, the company introduced Juicy Juice Sparkling in apple, berry and orange varieties. The juice and the 100-calorie chocolate milk address consumers’ desires for lower-fat and lower-calorie options. Juicy Juice Sparkling, which comes in 8.4-ounce slim cans, contains 70% real fruit juice, 30% sparkling water and no artificial flavors, colors or added sugars. One can (90 calories) is considered a full serving of fruit. The expansion of the sales force has helped Nestlé’s recent beverage launches, including a 10-ounce Juicy Juice PET bottle and Juicy Juice Sparkling. The juice products, Nesquik milks and Coffee-mate non-dairy creamers have become popular options for foodservice, education, hospitality and hospital accounts, Melone  Nestlé positions Juicy Juice as a better-for-you beverage to appeal to shopper moms, an important demographic target. Continued on page 96

94

Dairy Foods | January 2011

Corporate Profile

HISTORY Headquartered in Vevey, Switzerland, Nestlé S.A. was founded in 1866 by Henri Nestlé. It calls itself “the world’s leading nutrition, health and wellness company.” The company employs about 280,000 worldwide, and has factories and operations around the globe. Nestlé’s United States headquarters is in Glendale, Calif. Its dairy brands include Carnation Milks, Edy’s, Nesquik, Häagen-Dazs and The Skinny Cow. Other packaged food brands include Baby Ruth, Buitoni, Nescafe, Raisinets and Stouffer’s. Nestlé S.A. reported 2009 sales of $99 billion, with Nestlé USA accounting for $10.4 billion.

 From left: Kim Peddle-Rguem, marketing director, immediate consumption beverages; Chuck Dries, vice president, manufacturing; Rob Case, president, Nestlé beverage division; and Brian Degnan, divisional vice president, customer development.

says. In the foodservice industry, Wendy’s restaurants, a division of Wendy’s/Arby’s Group, sells 8-ounce fortified low-fat white milk and chocolate milk. Within convenience and drug store accounts, the DSD partnerships increased placement of point-of-sale items, Melone says. A marked improvement in the placement of static clings, pricing stickers and additional point-of-sale items has been seen in retail accounts, he says. The new route-to-market also opens more opportunities for sampling and interaction with local accounts, including in-market appearances by the Nesquik bunny. The partnerships also have yielded product expansion in existing outlets, Melone says.

“Our DSD distributors and partners control a lot of the shelf space not only in the dairy door, but in the tea door and the water door, and everywhere else, so they look at the whole beverage set, rather than just the dairy set,” he says. “We also have the opportunity for secondary placements, too, both with Nesquik, with the Juicy Juice brands, and so on. They’ve done a really nice job with secondary placements on kids’ shelves.” But it is adults, not children, who drink the most Nesquik. Adults age 25 years and more account for 70% of Nesquik consumption, Peddle-Rguem says. The portion-control and better-for-you positionings of the milks and juices appeals to shopper moms, an important demographic segment. Nestlé markets Nesquik and Juicy to graph address emerging consumer trends. addr “From our perspective, consumers are looking for bet“F ter-for-you products that are natural and deliver great tertaste,” says Peddle-Rguem. “Additionally, we are seeing tas an increase in on-the-go beverage consumption. Nestlé is ccommitted to continuous product innovation.” One such innovation is a new energy drink, O although the company decided it was better to link alth arms with an existing player than to develop its own arm product from the ground up. Nestlé has a licenspro ing partnership with Jamba Juice Co. to develop a in new line of ready-to-drink energy beverages. They n will be available for retail sale in the northeastern w United States in early 2011. The goal is to take the U product nationwide in 2012. p Nestlé Jamba All-Natural Energy Drinks will feature real fruit juice boosted with natural caffeine. “The line of energy drinks will provide a meaniingful point of difference to consumers within the $$8.5 billion energy drink category,” says PeddleRguem. The Jamba energy drinks will be available in R fflavors such as pomegranate blueberry, strawberry banana and crisp apple flavors. b  Nestlé goes after the coffee-house drinker with flavored nondairy creamers. Continued on page 98

96

Dairy Foods | January 2011

SUPPLIER CAPABILITIES SPOTLIGHT

Federal Mfg. Co. Federal Mfg. Co.’s reputation for building reliable and robust sanitary bottle filling machinery is known worldwide. For over 65 years, Federal has developed equipment to meet the rapidly evolving requirements of processors and packagers. The pace of that evolution has never been quicker. To meet today’s packaging requirements, Federal invests significantly in Engineering to develop custom solutions that improve production efficiency, enhance machinery cleanability, extend product shelf life, and insure quality. Designed and built with the same sanitary principles as the fillers trusted to fill sensitive products around the world, Federal Mfg. introduces a line of monobloc, large format fillers. These fillers are constructed modularly

with the filling carrousel separate but attached to the drive base. This allows sanitary fillers of unprecedented size and speed to be developed. Models with 60-valves can attain filling speeds on one-gallon milk bottles to 220 per minute. Eighty-four (84) valve half-gallon

models provide production speeds up to 380 per minute. Smaller bottles can be filled at the highest rate on machines with 120 valves. This series of fillers has been engineered with large diameter starwheels to provide the gentlest transfer of filled containers from the filling table to the capper. They are manufactured to the specifications set forth by 3-A® Sanitary Standard for Fillers and certified by third-party inspection. High-accuracy Net-Weight filling models are also available.

Federal Mfg. Co. (414) 384-3200 [email protected] www.FederalMfg.com

Modular monobloc design brings the ultimate in highspeed filling and capping. • • • •

60-valve one-gallon models 84-valve half-gallon models 120-valve small bottle models Available in both sanitary level and net-weight designs • 3-A (Third-Party Certified) • ESL features optional Federal Mfg. Co. Milwaukee, WI (414) 384-3200 [email protected] www.FederalMfg.com

df01114Federal.indd 1

www.dairyfoods.com 12/14/10 8:53 AM

97

Corporate Profile Meanwhile, Coffee-mate continues to succeed. Dollar sales of its refrigerated coffee creamers rose 2% and unit sales were up 4.6%, in a 52-week-period ending October 2010, according to Symphony IRI Group. The new Café Collections line, going after the coffee-house consumer, consists of three flavors: Caramel Macchiato, White Chocolate Caramel Latte and Café Latte. The company reports its seasonal flavors continue to perform “extremely well.” Nestlé introduced three flavors in 2010: Sugar and Spice, Eggnog Latte and Gingerbread Latte. Despite the success of Nesquik in 2010, Chicago-based market research firm Mintel pointed out a weakness in Nestlé. “With its Nesquik brand its lone entry in [refrigerated flavored milk], Nestlé lacks the product diversification of other manufacturers. This puts the company’s fortunes on the performance of a single brand, where others have multiple brands to pick up the slack if one should falter.” Mintel’s analysis came in the wake of a drop in share of 2.7 points in early 2010. In looking at Nestlé’s juice sales, Mintel blamed the decline in sales on the recession. “The company had kept the brand invigorated by rebranding it from Libby’s to Nestlé and introducing Harvest Surprise—a vegetable and juice blend targeted at kids. However, Harvest Surprise, a premium-priced juice, declined considerably as recession-torn consumers stayed with staple (cheaper) flavors such as apple and lemonade, as these are the favorite of kids—the main consumer of Nestlé’s fruitt juice products,” according to a Mintel analysis. Peddle-Rguem concedes that timing wass an issue. One of the shopper insights Nestlé gained ined from Harvest Surprise is that moms struggle le to deliver vegetable nutrition to their children. ren. Harvest Surprise was seen as a solution n because it “disguised vegetables,” PeddleRguem says, venturing that the brand was “before its time.” Nestlé uses a broad mix of marketing strategies, all emphasizing to consumers the benefits of its products. Its Juicy Juice brand has participated in Box Tops For Education for three years. This is a way to reach a key demographic: mothers of school-age children. Box Tops has been “enormously successful. It drives brand loyalty and shows we’re moms’ allies in raising happy, healthy kids,” says Joanne Crawford-Dunér, director, integrated marketing communications. In 2010, Nestlé once again used the Copita Juicy Juice program to appeal to the Hispanicc market. The program tied into the World Cup  Adults age 25 and older consumer 70% of Nesquik flavored milks. Gingerbread Latte is a seasonal flavor in the Coffee-mate line. Blueberry pomegranate is one of three energydrink flavors Nestlé is producing under the Jamba Juice brand. Rollout is in the Northeast this year.

98

Dairy Foods | January 2011

with events in Chicago, New York and Los Angeles in which 1,600 children in 104 youth soccer teams participated. Bilingual spokesperson Claudia Gonzalez, a registered dietitian and author, led nutrition workshops for parents and children, while past World Cup soccer players participated in soccer clinics with the kids. “The program generated positive media coverage in Hispanic outlets such as El Clasificado, Entre Familia and MegaTV,” Crawford-Dunér says. On the web, Nestlé developed an interactive, “augmented reality game” for the Nesquik brand. A webcam (required to play) puts the player in the factory and players score points by filling milk bottles in a set amount of time. With the No. 1 flavored milk brand in Nesquik and the No. 1 juice brand for children in Juicy Juice, Peddle-Rguem says Nestlé will continue to “provide consumers with product choices that meet their needs in the locations where they are shopping. We continue to evolve our brands to address the changing preferences of consumers who are looking for products positioned around health and wellness, value and on-the-go consumption.” “We want to delight consumers with our beverage brands every day and wherever they enjoy beverages. That means continued innovation/renovation to drive to new and unique beverages and a robust route-to-market that makes our brands available whenever and wherever consumers want to consume,” Peddle-Rguem says. DFR Jennifer Z Zegler, managing editor of Beverage Industry, contributed to this article. The interview with Joe Melone first appeared in the August 2010 appea issue of Beverage Industry (like Dairy Foods, a BNP Media publication). Me

SUPPLIER CAPABILITIES SPOTLIGHT

T.D. Sawvel Co. Inc. Have you checked out T.D. Sawvel lately? You’ll find that our new models are the best way to move your business forward. The fully-automatic Model 80 is one of our most versatile machines, providing a highly flexible platform for makers of ice cream and other frozen desserts. Designed for container sizes from 3-64 oz., tooling is now available for filling square-round shapes. Another highlight is our Model 135-MPD “two-up” high speed cup filler, which is designed for filling frozen desserts at speeds up to 120 cpm in sizes from 3-32 oz. Whether you are dosing 1 ounce or 6 gallons at a time, T.D. Sawvel Co., Inc. provides effective automated solutions for denesting, filling, sealing, and capping a wide range of packaging shapes. Founded in 1976 with an early focus on automation for the ice cream industry, T.D. Sawvel’s dedication to supplying high quality solutions has led us to continually expand across many types of food products plus limited industrial applications. We look forward to filling your needs.

T.D. Sawvel Co. Inc. Toll Free: 877-488-1816 Phone: 763-479-4322 Fax: 763-479-3517 www.tdsawvel.com

www.dairyfoods.com

99

SUPPLIER CAPABILITIES SPOTLIGHT

S&D Food Innovation & Ingredients (A Division of S&D Coffee, Inc.) S&D Coffee’s Food Innovation & Ingredients Division creates customized extracts and flavors supported by turnkey, personal service. We are vertically integrated from the source to your door, which means uninterrupted access to the broadest selection of raw materials while ensuring price stability. We understand the demands of the Food, Beverage and Dairy industries and offer unique products and services like Cold Brewing (The Toddy® Process), Custom Product Development and Modern, State-of-theArt facilities. We uphold the standards of ISO 9001:2008 and SQF and our products reflect our commitment to quality. Products Extracts (Hot or Cold Extraction) • Coffee Extracts • Tea Extracts (All Varieties) • Botanical Extracts Flavor Ingredients • Concentrates • Flavor Bases • Variegates • Toppings / Drizzles • Syrups Approach S&D Coffee has been supplying high quality roast coffee since our founding in 1927. With over 80 years of coffee sourcing and roasting experience, ver-

tical integration has evolved into a core competency. We have used the same practices to develop our tea blending and processing capabilities to become the largest iced tea supplier to the U.S. Food Service industry. Capabilities Our coffee roasting and tea blending expertise has been extended to the development of a modern extraction plant allowing us to produce coffee, tea and botanical liquid extracts. We market the extracts as unique product lines as well as utilizing the concentrates to create and blend customer specific flavor ingredients such as flavor bases, syrups and variegates. Due to the unique markets served with liquid extracts, the Food Innovation and Ingredients division was created to focus on our customer’s needs with industry specific capabilities such as: • ISO 9001:2008 Certification • SQF Certification • Toddy® Process for “cold” extraction • Traditional Hot Brew extraction capabilities • Packaging Flexibility from pails to tankers • Product Customization of extracts and flavor ingredients • Internal Logistics resources • Highest levels of quality assurance maintained throughout process

The Toddy® Process While Quality Assurance is a science, the art of our quality process is the delicate extraction methods developed to deliver optimal flavor and aroma for our customers. Using the proprietary Toddy® extraction process, S&D produces a consistent, smooth, cold brewed liquid extract for any flavor and aroma application. We also employ a hot brew process for applications requiring bolder flavor notes in which the subtle flavor and aroma from the Toddy® process are enhanced. Contact Us S&D Food Innovation and Ingredients can design a custom flavor system for any Dairy, Food, Beverage or Sweet Good application. Please contact us:

S&D Food Innovation & Ingredients 300 Concord Parkway South Concord, North Carolina 28027 Phone: 800 933-2210 Email: [email protected] www.sndflavors.com 100

Dairy Foods | January 2011

SUPPLIER CAPABILITIES SPOTLIGHT

Rocket® Products, Inc. Rocket® Products, Inc. has been producing quality beverage concentrates for over 57 years. Our dedication to our customers has allowed us to offer the highest level of quality, consistency, and service to the dairy industry. At Rocket® Products we use only the finest ingredients for our one-of-a-kind concentrates so the best tasting drinks are created. The owner and creator, Charles E. Lazier, comes from a family owned company spanning three generations beginning in the soft drink business. The first

102

Dairy Foods | January 2011

incorporation occurred in 1903, giving this family 100 years of valuable experience. Many of the ideas that have been instrumental in the success of Rocket® Products, Inc. today has come from a long line of family influence and knowledge. Since all of our products are naturally flavored with Lemon Juice, our lemonades have that fresh squeezed lemonade flavor with a smooth taste. Our Orange concentrates have a refreshing new delicious orange flavor, and our Fruit Punch concentrates contain that fusion of fruity

flavors which make them unique. Request your samples today and experience the great taste that our products can provide for you and your customers. As we say at Rocket®, “Have you had your Lemonade today”?

Rocket® Products, Inc. 1740 Chase Drive Fenton, MO 63026 (800) 325-9567 Fax: (636)-343-9115 www.rocketproducts.com

Some Things Never Go Out of Style. That’s why old fashioned lemonade is more popular than ever.

100% Natural Lemonade Sweet, Fresh Lemon Flavor Costs Pennies Per Serving

Everyone is getting back to basics but that’s just where Rocket® Products has always been. For more than 57 years, we’ve been producing the highest quality lemonades that are natural, which eliminate any metallic aftertaste, and give you that refreshingly sweet taste of lemons. As far as we’re concerned, the good old days are still here. We offer a wide variety of lemonade products available in various dilutions and yields, as well as orange and fruit punch concentrates. For complete information about our family of products, visit www.rocketproducts.com.

Rocket lemonade...it’s like drinking a little slice of sunshine!

1740 Chase Drive s Fenton, MO 63026 s 800-325-9567 Fax: 636-343-9115 s www.rocketproducts.com

Plant P lant C Close-up lose-up

Photos by Nestlé USA

Nestlé LEEDs the Way The company bottles Nesquik and Coffee-mate in a new facility that received Leadership in Energy and Environmental Design certification.  Jennifer Zegler Contributing Editor estlé USA leveraged its global expertise when designing its Nestlé production facility in the United States. The company’s expertise included incorporating elements of sustainability into the design of the plant in Anderson, Ind. The plant, located on 190 acres, received Leadership in Energy and Environmental Design (LEED) certification from the U.S. Green Building Council, Washington, D.C. The green elements on the campus include a wastewater recovery system for reuse in cooling towers, low-emission natural gas boilers and skylights for natural light in the production area. Sustainability also was considered when Nestlé selected Anderson, 20 minutes north of Indianapolis. Indiana was chosen for its central location and proximity to major highways, says Pamela Krebs, the former manager of division and brand affairs for the beverage division of Nestlé USA.

N 104

Dairy Foods | January 2011

The 880,000 square feet of production and distribution space opened in March 2009. The plant has the space for raw material receiving and storage, PET bottle production, mixing and aseptic bottling of Coffee-mate liquid non-dairy creamers and ready-to-drink Nesquik flavored milk and warehousing of the finished products. The company spent $500 million on the facility, and then built a $170 million, 220,000-square-foot expansion to open this year. Nestlé initially projected it would employ 300 to 350 people; it currently employs more than 550. The new space accommodates one new production line and provides additional storage room for raw materials. The plant includes machine rooms, truck and rail docks for shipping, a battery-charging room, wastewater treatment facility, administrative offices and cold-storage areas with computerized warehousing. The plant maintains a 24-hour, seven-day-a-week production schedule to keep up with national demand for its products.

Plant Close-up

 Opposite: Pre-formed bottles feed into the unscrambler just before going to the blow molder. Above: Bottles travel en masse from the filler to the labeler. Right: A finished pallet of Nesquik goes through the stretch-wrapper.

Production is determined through weekly schedules based on sales forecasts and supply chain data, says site manager Michael Strong. The four bottling lines can run a range of package sizes from 8-ounce Nesquik to 32-ounce Coffee-mate. The Anderson site manufactures its own pre-forms and blowmolds from raw PET resin, which is received by rail. The plant is the first facility in the nation to receive approval from the U.S. Food and Drug Administration for PET aseptic production, which allows longer product shelf life; the company calls this “a major technological achievement.” Manufacturing its own bottles gives the company added flexibility in its production schedules and is more environmentally friendly because it saves on shipping costs for pre-forms and bottles, the company says. “With our ability to now offer a variety of shelf-stable products, Nestlé has been able to tap into new distribution channels, giving us a greater competitive advantage and expanded sales opportunities,” a company spokeswoman said.

Continued on page 106 www.dairyfoods.com

105

Plant Close-up

 At the liquid loading station, milk is received and transferred from tankers to raw milk silos.

AT A GLANCE Nestlé USA Location: Anderson, Ind. Year Opened: March 2009 Size: 880,000 square feet of production and distribution space on 190 acres Employees: 550 Products made: Ready-to-drink Nesquik flavored milk, Coffeemate liquid non-dairy creamers in PET bottles Processing capacity: Four bottling lines running a range of package sizes, from 8-ounce Nesquik to 32-ounce Coffee-mate. The plant maintains a 24-hour, seven-day-a-week production schedule. Packaging: The plant manufactures its own pre-forms and blowmolds from raw PET resin, which is received by rail.

From raw materials to packaged beverages Sugar is received by rail and stored in silos, Strong says. The plant also has indoor loading docks to receive dry and liquid ingredients. Production begins with ingredient processing in which the dry ingredients are blended together in individual batches. Once the ingredients are blended, the liquid is sterilized through highly automated ultra-high temperature processing. The sterilization creates an aseptic product, which is held under sterile conditions until it is bottled. “Our aseptic filling operation really is the point of differentiation when you look at us and a normal beverage facility,” Strong says. “It’s really that filling operation combined with our processing that gives us the aseptic product, which you see really transforming the industry.” After filling, the products flow onto the bottling lines where shrink sleeves are applied and the products are packed into cases. The cases are palletized and transferred to the adjacent warehouse, which runs on an automatic storage and retrieval system. Pallets are stored in the warehouse until they are picked by the AS/RS for manual loading onto a truck. The ambient products do not require refrigeration in the warehouse. The shelf-stable nature of the products also saves on refrigeration in distribution by not requiring refrigerated trucks. Nor do customers need to chill the product until it’s on the shelf. In addition, the aseptic nature of the products provides production flexibility because the products can be produced in advance and stored. Asceptic products maintain a long shelf life for customers. Continued on page 108

106

Dairy Foods | January 2011

FREE

Webinar

Sponsored by

Renovation Mythbusters Thursday, March 10 | 2:00 - 3:00 p.m. EST Major food and beverage expansion projects often start with the preconception that a Greenfield plant is needed to achieve desired performance goals. This preconception is based on some pervasive myths: • MYTH #1: Too many compromises have to be made with renovations/expansions or Brownfield conversions. • MYTH #2: Renovations are too risky, costly and take too long. • MYTH #3: Few suitable Brownfield properties can be renovated for food and beverage production. Featuring real-world examples, the latest Food Plant of the Future webinar from Hixson, one of the leading design and engineering firms in North America, dispels some of these common misconceptions. Join us as we discuss the benefits and drawbacks of renovating/expanding and Brownfield development to help you determine which option best fits your plant expansion needs.

Live Q&A with attendee-submitted questions will follow.

Don’t miss this exciting opportunity! Register for FREE at

webinar.dair yfoods.com Can’t attend live? Register and watch on-demand.

Plant Close-up

 Nesquik bottles move from the labeler to the case packer. Aseptic advantages The plant’s aseptic production has transformed Nestlé’s beverage business. The company says aseptic filling retains more nutrients, uses less sugar and is more energy efficient. The shelf-stable products also have created new opportunities for distribution, says Joe Melone, sales director for Nestlé’s direct-store-distribution beverage sales force. “Prior to Anderson and having shelf-stable capability, we were pretty much confined to a refrigerated distribution channel from manufacturing to getting product on the shelf,” Melone says. “Now with shelf-stable products, that opens the door considerably to a whole new go-to-market strategy with a whole new set of distributors.” The Anderson plant produces only Nesquik and Coffee-mate, but the beverage sales force handles Nestlé’s entire beverage portfolio, including Juicy Juice. In 2007, the sales force transformed from a 20-person staff focused on chilled beverages to an expanded nationwide network of DSD beverage salespeople. The benefits of shelf-stable products also are fueling the growth of the Anderson plant, the company says. Nestlé has been able 108

Dairy Foods | January 2011

to secure placement on children’s menus in many foodservice accounts, Disneyland theme park and at colleges and universities across the country, which has increased the production demand, Krebs says. “In a very positive way, it’s a never-ending cycle – you make a product that’s more versatile, you’ll have more customers,” she says. “You make more customers, you need more product, and so on.” Flexibility of Anderson’s lines allows for the opportunity for production of new products in the future, she says. Products in Nestlé’s pipeline also will take advantage of the DSD beverage sales force and expanded distribution network, Krebs says. “As [new beverage] products are launched and introduced, this will be a great way to really get the expansion out there and increase the availability so as consumers are able to enjoy them, they are able to find them wherever they are looking for them,” she says. DFR Jennifer Zegler is managing editor of Beverage Industry, a BNP Media publication. This article has been adapted from “Plant Focus: New Nestlé facility creates greater opportunities,” August 2010.

SUPPLIER CAPABILITIES SPOTLIGHT

Donaldson Company, Inc. Donaldson’s innovative filter designs meet your purity requirements with a focus on energy-efficient operation and reliable performance to minimize operating expenses and reduce downtime. • Providing filtration solutions from pre-filtration to final, and from low to high capacity. • Stocking service items and replacement filter elements for many brands of filter housings for shipment within 24 hours.

Donaldson Company, Inc. Compressed Air and Process Filtration Tel: 800.543.3634 Fax: 952.885.4791 processfi[email protected] www.donaldson.com

think think DONALDSON *OEVTUSJBM
"JS

t 4UFSJMF
"JS

t $VMJOBSZ
4UFBN

t 5BOL
7FOUJOH

t Process Liquids

donaldson.com

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

Member of

Registered

Member of

ageme an

ality M Qu

Tel 800.543.3634 Fax 952.885.4791 processfi[email protected]

System nt

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

9001:2008

ISO

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

www.dairyfoods.com

109

SUPPLIER CAPABILITIES SPOTLIGHT

FOSS North America At FOSS North America, we are proud to provide analytical solutions for quality and process control to the Food and Agriculture industries. FOSS offers instrument solutions for online, at-line, and laboratory analysis of raw ingredients, in-process, and final product verification. FOSS has partnered with dairy and milk testing laboratories around the world for more than 30 years, and were the first to introduce many new technologies to the dairy industry, such as the MilkoTester. Over the years, we have invested heavily on creating and improving technology to help optimize dairy production. Our focus is on controlling the quality assurance areas at all stages along the value chain. FOSS has solutions for dairy herd improvement, to payment of raw milk, to the production line, where standardization is vital for product control and profitability, and finally, verification of end-product quality. We offer a complete range of dedicated solutions, which determine the hygienic and chemical quality of raw milk and dairy products

MilkoScan™ FT2: for analysis of milk, cream, yogurt, whey, ice cream and other dairy products

ProFoss™: for in-line analysis of powders, butter, mozzarella and liquid whey

Profitable dairy processing At the dairy, the frequency of analysis and accuracy of the methods, often determines how close a production may be to target, hence profitability. Platform, at-line and lab analysis FOSS offers a number of user-friendly, rapid analyzers which can be applied in-line, at-line, or in the lab for analysis of composition in raw materials, intermediate products, as well as finished products. Our brand names include: MilkoScan™, FoodScan™, InfraXact™, ProcesScan™ FT, and ProFoss™ just to name a few. We have calibrations for determining the primary constituents in complex liquids, fermented products, cheese, yogurt, butter, ice cream, powders, and more. Constituents include protein, total solids, moisture, lactose, fat, and ash, as well as specific sugars, lactic acid, urea, free fatty acids, etc., in some products.

110

Dairy Foods | January 2011

FoodScan™: for butter, cheese and yogurt analysis

Don’t sweat it. We’ve got you covered.

Instruments: MilkoscanTM ProcesScanTM InfraXactTM FossomaticTM ProFossTM MosaicTM Herd Navigator

FOSS is your partner throughout the milk value chain. No matter what kind of dairy products you’re making, our analytical instruments give you the ability to sustain your business into the future with raw material optimization and product consistency.

ŒEnsure incoming milk quality ŒOptimize cost and yield while ensuring consistency ŒVerify quality of final products Visit www.foss.us/value or call 1.800.547.6275 to see how to sustain your business into the future.

SUPPLIER CAPABILITIES SPOTLIGHT

Tetra Pak Inc. Tetra Pak Processing provides solutions and services to enable our customers in the dairy, cheese-making, beverage, icecream, prepared food and cosmetic industries to achieve safe, cost-effective, continuous processing of quality products. Processing Equipment We offer a wide range of unique sanitary equipment covering all the needs of the liquid food industry applications: pumps, valves, heat exchangers, homogenizers, high speed centrifugal separation, ice cream freezers, variegate dosing, filtration, blending, mixing. Our offer goes from simple components to complete turn-key projects. Full System Supplier We supply complete integrated processing, packaging and distribution lines, and stand-alone equipment, carefully tested to make sure they give you optimal performance. Plant Engineering Tetra Pak’s strength in plant engineering and project management is reflected by 50 years of experience in designing food processing and packaging plants, by thousands of plants in operation worldwide, and by a presence in more than 120

112

Dairy Foods | January 2011

countries. At every stage of project management, from initial evaluation to plant handover, Tetra Pak can take complete responsibility. From factory revamping to design and installation of complete new production lines, our capabilities range from food process engineering, controls, automation, project management, installation, start-up and training. Genuine Spare Parts As part of our product support, Tetra Pak offers a complete line of genuine spare parts for ensured reliability, including pumps, valves, and integration components. Using genuine spare parts ensures that you will have fewer unplanned stoppages, minimum downtimes, easier ordering cycles, and less inventory to stock. Maintenance Solutions Our maintenance solutions help you maximize the performance of your plant. We’ll time the delivery of your spare parts to coincide with service so that you can save on inventory costs and downtime. Tetra Pak can also dispatch maintenance experts to be a part of an annual shutdown to perform maintenance activities without interrupting day-to-day operations.

Upgrade Solutions As a total solution provider and longterm partner, Tetra Pak offers a wide range of customized and pre-built upgrade solutions for our complete systems, aseptic modules, and processing components including Tetra Alex homogenizers, Tetra Centri separators and the Tetra Alfast Milk Standardization module. We address competitive market demands, food safety concerns, government regulations, and the challenges of swift technological advancement.

Tetra Alex® 400 Homogenizer

Pioneering design for sound performance • Turnable wear parts for lower service costs • Serial piston cooling to reduce cooling water consumption • Easy and safe access for maintenance with hygienic design • Safe 80 dB sound levels when running under pressure • Reliable design with a 5-year pump block warranty as standard

Complete Processing. Innovative Solutions. Visit us at www.tetrapakprocessing.com or directly; [email protected] 800-806-9675 Tetra Pak, , PROTECTS WHAT’S GOOD and Tetra Alex are trademarks belonging to the Tetra Pak Group.

Plant Close-up

Behind the Scenes A photo gallery of Nestlé’s aseptic plant in Anderson, Ind. Photos by Nestlé USA

 Left: Super Sacks hold dry ingredients for Nesquik and Coffee-mate liquid products. Below: PET pre-formed bottles coming from the injection molder.

PLUS For more behind-the-scenes photos, visit www.dairyfoods.com/dfr.

114

Dairy Foods | January 2011

Plant Close-up

 Clockwise from left: Nesquik bottles are coming out of filler and on their way to the labeler. The Nesquik rabbit welcomes visitors to the Nestlé facility in Anderson, Ind. Bottles travel en masse from the filler to the labeler.

www.dairyfoods.com

115

SUPPLIER CAPABILITIES SPOTLIGHT

H.S. Crocker Co. It’s no accident H.S. Crocker Co., has been successfully operating since 1856. H.S. Crocker is 100% Employee owned with participation at all levels through team driven production. All our employees work together in our plant locations: Huntley, IL and Exton, PA, all locations adhere to strict standards of quality as prescribed by the Crosby Quality College and now advancing to be SQF Certified. The Huntley facility, well known for Lidding structures, also produces: Push thru Foil for Blister Paks. Roll Stock for Blister Packing with special Heat Seal Coatings and various Specialty Printed Lid Solutions for a wide range of applications. Printing on 9 and 10 color Flexographic presses from 13” - 45” with front and back print capabilities. Regular USFDA, IL FDA and Pharmaceutical audits keep the Huntley facility on the cutting edge of traceability, which identifies every step in the production process. The Huntley plant is compliant with CGMP and HACCP guidelines. H.S. Crocker Co. has developed several new non-foil lidding structures to seal various portions size containers and polymers. For years, customers have asked for a pre die-cut lid other than foil. Metal Detection, Microwaveable, Tear and Puncture Resistance are just a few of the advantages associated with these new materials. CUP LINE: H.S. Crocker offers portion cups (thermoformed) in a wide variety of sizes and designs. You can develop your new cup at a very competitive cost. NEW PRODUCT LINE: H.S. Crocker has both foil and non-foil lidding available in roll and die cut. Both Cups and Lids can be ordered to your specifications. H.S. Crocker has positioned themselves as the LEADER in PRINTED LID SOLUTIONS

116

Dairy Foods | January 2011

by applying their 150 years of experience towards today’s markets. Through the addition of new product lines and redeveloping old lines. The continued efforts of our company is evident by the continual purchases of new and efficient equipment. A constant updating of equipment allows us to offer the best possible cost savings to our prospects and customer. We consider the environment to be very important and this is why we have chosen to

sue water based inks and adhesives for over 20 years. We recycle the vast majority of what we produce in our plants in a concerted effort to be GREEN. HS Crocker Co., Inc. 12100 Smith Dr. Huntley, IL 60142 Ph: 847/669-3600 Fax: 847/669-1170 www.hscrocker.com

SQF Level 2 Certified

SUPPLIER CAPABILITIES SPOTLIGHT

Reiser For more than 50 years, Reiser has been a leading supplier of processing and packaging equipment to the cheese industry. During that time, the company has gained recognition for its high-quality equipment, innovative technology and outstanding service and support. Vemag Cheese Block Former Reiser and Vemag have designed a variety of Cheese Block Forming Systems for all types of applications and production requirements. This solution combines a Vemag Stuffer with a Reiser-engineered Cheese Horn – a cheese block forming and extruding attachment. The Vemag Cheese Block Former extrudes exactweight cheese blocks with consistent dimensions and clean, uniform edges. This innovative solution eliminates waste by repurposing cheese trim, ends, scraps and other pieces to produce cheese blocks. A common application for this system is the production of cheddar cheese blocks for retail.

At the heart of the system lies the Vemag Stuffer. The Vemag features a powerful, positive displacement doublescrew pump that provides the highest 118

Dairy Foods | January 2011

levels of portioning accuracy while transporting the product extremely gently. The Vemag is available in various models and hopper capacities to meet any production requirement. The Cheese Horn is an attachment to the Vemag. The Cheese Horn extrudes a shaped cheese block with consistent thickness and width. The Horn is equipped with a cutoff device to control the length of the product and ensure exact-weight portions with clean, even edges. Changeover from one shape to another is easily achieved by simply swapping out the Cheese Horn’s die insert. The cheese block can be virtually any shape – square, rectangular, circular and even wedge-shaped. Supervac Vacuum Chamber Cheese Packaging Supervac automatic belt vacuum chamber packaging machines feature a double biactive high-pressure sealing system to produce the best package seals in the industry. Heat and pressure are applied from above and below the packaging

material to produce not just one seal, but two superior seals. A Supervac can easily handle all types of bags and packaging materials, including foil packaging. The sealing system virtually eliminates leakers, rework and returns.

Reiser 725 Dedham Street Canton, MA 02021 Phone (781) 821-1290 Fax (781) 821- 1316 [email protected] www.reiser.com

S U C C E S S

S T O R I E S

HOW A VEMAG CHEESE

FORMER

E LI M I NATE D WASTE and increased YI E LD S A T RU E S T O RY: A few years ago, we met a cheese maker who lamented how much waste he had from the off-cuts of his cheese block slicing and cutting processes. Some of this cheese could be shredded, but that solution did not work for all of his varieties. He came to Reiser with the request to reform the cheese scrap so that he could eliminate waste and increase yields. Reiser put its engineers to work and after extensive testing they developed the Vemag Cheese Block Former. The Vemag was able to take the cheese pieces and reform them into usable cheese blocks. The USDA Dairy Accepted Vemag features a powerful double-screw pump which compacts and transports the cheese extremely gently and without smearing. An Extruder attachment gives the reformed block its shape, and a cut-off device controls the length of the block while ensuring exact-weight portions and clean, even edges. Our solution helped the cheese maker repurpose his cheese scrap, eliminate his waste, and increase his profitability.

THE VEMAG PRODUCES PERFECTLY FORMED CHEESE BLOCKS Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com

Leading the food industry in processing and packaging solutions.

Sayler on Safety

A 7-Point Checklist for Evaluating Suppliers n my April 2010 column, “Who is the Weakest Link in the Food Chain?,” I made the point that suppliers could unintentionally defeat all the food safety and quality programs put in place by dairy plants. A review of the first (and so far only) report from the Food and Drug Administration’s Reportable Food Registry showed that of the 1,844 entries (contaminated food events) for all food categories, 125 were “primary reports” while 1,638 were “subsequent reports” triggered by the primary event. This is detailed in the report, “A New Approach to Targeting Inspection Resources and Identifying Patterns of Adulteration: The Reportable Food Registry (RFR) - First Reporting Period: September 2009 – March 2010.” While the dairy portion of the RFR report accounts for only 18% of the total, overall RFR numbers for all food sectors are likely similar for dairy products. The message hidden in these overall numbers is that the “subsequent reports” could mean a supplier has caused additional reporting by downstream food processors, distributors or retail companies after the primary report. Subsequent reports versus primary reports results in a factor of 13:1, which can be interpreted that a supplier’s failure drove 13 product withdrawal or recall notices by other downstream food companies.  FDA is promising new numbers for the rest of 2010 soon, but this 13:1 factor is not expected to change and may even grow. What can be done to lower this 13:1 factor and ensure your suppliers make the grade and your plant does not become an RFR statistic? The answer is dependent upon, “What criteria do you use to qualify and select a supplier?” The level of due diligence for supplier selection should be based on some of the following criteria: • Supplier certification by one of the Global Foods Safety Initiative HACCP-based schemes such as SQF, BRC, IFS or FSSC22000. NonGFSI-based supplier certification systems may also be acceptable.

I

Allen Sayler

• Supplier product qualification by recognized non-profit or governmental organizations, (in other words, a “Good Housekeeping Seal of Approval”). A good example for dairy plants is the purchase of processing equipment that is authorized to carry the 3-A Sanitary Standards Inc. (3-A SSI) symbol or purchasing equipment listed by USDA’s Dairy Program. • Reliable history of product delivery based on testimonials from sister plants or professional colleagues working in the same food sector. • Current, acceptable inspection or audit scores from properly trained FDA, state or local regulatory agencies. This is dependent upon the government auditor having food safety training and technical knowledge. • A potential supplier’s product should not be listed in FDA’s recall database during the past three years. (This benchmark should not be used by itself, as sometimes supplier’s products listed in this database result from a supplier’s own internal food safety programs identifying a problem, which is a positive indicator.) • Suppliers participating in dairy industry tradeshows like the International Dairy Show generally have a strong reputation. • Annually sponsor a supplier training/evaluation workshop that communicates your expectations, provides opportunities for training of suppliers and creates an opportunity to evaluate potential new suppliers. Ensure your suppliers make the grade by establishing effective supplier criteria. Convince senior management that there is a positive return on investment for dedicating resources to supplier evaluation, ongoing monitoring and periodic benchmarking. (Read my August 2010 column, “Reorganizing Food Safety & Quality Accounting - Key to Minimizing ‘Explosions’” for ideas.) DFR Allen R. Sayler is vice president, food safety, technology and regulatory solutions of Randolph Associates Inc. He can be reached at [email protected].

1,844 RFR Entries by Report Type* Primary (industry and regulatory) reports

125

Subsequent reports (upstream, downstream)

1,638 81

Amended reports 0

200

400

600

800

1000 1200

1400 1600

 The 125 primary (industry and regulatory) report RFR entries encompassed seven categories of food safety hazards (E. coli O157:H7, Foreign Object, Listeria monocytogenes, Salmonella, Undeclared Allergens/Intolerances, Uneviscerated Fish, and Other) distributed across 25 commodities for the reporting period from Sept. 8, 2009 to March 31, 2010. Source: U.S. Food and Drug Administration

120

Dairy Foods | January 2011

SUPPLIER CAPABILITIES SPOTLIGHT

Eriez ERIEZ’ X-Ray Inspection Systems Eriez’ E-Z Tec XR Series is a line of automatic X-Ray Inspection Systems delivering the highest level of product and packaging integrity. E-Z Tec Inspection Systems: • Identify contaminants • Control product and package mass • Scan for missing or damaged product • Detect packing voids • Recipe and fat analysis • Confirm fill levels Superior Sensitivity Eriez’ automated X-Ray inspection systems employ advanced linear array technology for superior sensitivity, speed and sophistication for both loose product flow and packaged inspection. The

E-Z Tec Inspection Systems provide real time analysis of process and packaged foods, pharmaceuticals and other goods requiring the highest levels of product integrity. Systems monitor product and package attributes such as count, weight, fill level, broken or damaged product, as well as detecting unwanted metals, stone, glass, bone and some plastics.

Eriez 1-888-300-(ERIEZ) 3743 Or visit us at: www.Eriez.com

Metal Detectors & X-Ray Inspection

Eriez’ New Vibratory Inspection Conveyors Our new Dual Inspection Vibratory Conveyors offer precise product control and uniform coverage giving hand inspectors easy visual recognition of imperfect product or foreign objects.

Features include: • Vibratory action rotates and flips product • Easy visual inspection • Precise product control • Reduced noise • Safe operation with no rotating parts or lubrication • Sanitary wash down • “Green” low energy consumption

Vibratory Screeners

Magnetic Separators

FREE!

Vibratory Selection Guide & How-to-Use Brochures

Visit eriez.com Call 888-300-3743 www.dairyfoods.com

121

SUPPLIER CAPABILITIES SPOTLIGHT

GEA Niro Soavi About Us GEA Niro Soavi is the global technology and market leader for high pressure pumps and homogenizers. Established in 1947 and part of the GEA Group – one of the leading engineering companies worldwide –GEA Niro Soavi maintains its leadership position through product innovation, reliability and local presence in order to satisfy customer expectations. Our international sales and service network allows GEA Niro Soavi to be close to customers regardless of where they are, with local, competent and professional support. Products The GEA Niro Soavi homogenizer product line provides leading technology with the widest range of machines that cover all possible application needs for the dairy industry. From pilot to large-scale fully automated units, in either sanitary or aseptic execution, our homogenizers

gram that matches your exact needs

properties through the paces. This pro-

are also in compliance with 3-A stan-

ensuring less downtime, better perfor-

gram also gives you maximum flexibil-

dards and USDA guidelines.

mance and improved quality - wherever

ity in test scheduling, product formula

you need it, whenever you need it.

variations, and confidential development

The use of high efficiency homogeniz-

The GEA Niro Soavi preventive main-

guarantees the most effective homogeni-

tenance program is conducted on site

We provide you with a full range of

zation at the lowest pressure, not only on

by our technical experts. Preventive

test equipment that meets your specific

milk, but also on high fat content, high

maintenance can reduce your downtime

needs. All of our rental machines come

viscosity, recombined and high total sol-

and allow your plant to operate more

with the option to buy.

ids products, providing customers with

efficiently. Often we try to schedule the

Our technical support staff is avail-

low operating costs.

preventive maintenance to coincide with

able to answer questions and provide tech

GEA Niro Soavi operates in accordance

your annual shutdown in order to per-

support when needed.

with the ISO 9001:2000 certified Quality

form major maintenance activities with-

System, which represents the philosophy

out interrupting your normal operations.

of the company in sales, after sales, engineering and production processes.

Homogenizer Rental Program The GEA Niro Soavi Rental Program

122

work.

ing valves, like the patented NanoValve™,

After Sales Service

enables you to rent our equipment so you

With GEA Niro Soavi as your service

may test your product at your plant. This

partner your life becomes much easier

allows you to operate the homogenizer/

and enjoyable. We shape a service pro-

microsizer while putting your product’s

Dairy Foods | January 2011

GEA Niro Soavi N.A. 10 Commerce Park North, Unit 7 Bedford, NH 03110 Tel. 603-606-4060 Website: www.nirosoavi.com Information: [email protected]

Liquids to Value

High Capacity. Smart Choice.

Improve product quality and productivity, with the GEA Niro Soavi NS5355 – setting the standard for dairy homogenizers. This ƃexible, high-capacity homogenizer can be precisely conƂgured for your application needs, delivering superior performance to keep you ahead of the competition. The NS5355 features: • ƃow rates up to 15,000 GPH • super efƂcient NanoValve reduces operating costs • less water consumption, less noise • reduced maintenance, low cost of ownership GEA Niro Soavi NS5355 the smart choice for your bottom-line.

GEA Mechanical Equipment

GEA Niro Soavi N.A. 10 Commerce Park North, Unit 7 • Bedford, NH 03110 • USA Tel (603) 606.4060 • Fax (603) 606.4065 [email protected] • www.nirosoavi.com

Spotlight on Sustainability

Best Practices in Waste-Heat Recovery he U.S. Environmental Protection Agency (EPA) estimates that manufacturers in the United States spend about $100 billion a year on energy costs. At individual plants, energy is often the highest operating cost after raw materials and labor. That’s why EPA has expanded its Energy Star program, which encourages energy efficiency, to include industrial facilities. With global energy consumption continuing to rise — EPA expects U.S. demand to increase by 31% within 25 years — dairy processors and manufacturers are implementing energy-management programs to improve energy performance, save on operating costs and reduce greenhouse-gas emissions. As part of an industry-wide sustainability effort, dairy processors and manufacturers recognize that an effective energymanagement program starts with a top-down commitment from individual businesses, but is successful in large part due to the identification and sharing of best practices across the entire industry. Sharing best practices based on each other’s experience helps processors identify the energy-efficient practices and technologies that may work best in their plants and for their business model. A few of these best practices fall under the category of energy recovery and recycling, which are highly cost-effective means for producing energy, and can be implemented on a broad scale to both new and existing facilities. I’d like to share some best practices and experiences from the dairy industry.

T

By capturing thermal units that were literally flushed down the drain, Oakhurst Dairy saves at least 2,500 gallons of heating oil a year. Waste-heat recovery Dairy manufacturers recover waste heat from processing equipment by capturing the energy — typically steam or hot water — thereby utilizing the thermal energy. Oakhurst Dairy in Portland, Maine, captures solar energy through roof panels to preheat water to temperatures as hot as 110°F. By reducing the energy required to heat water for case washing (150°F to 160°F), the system reduces the company’s heating oil consumption by more than 5,000 gallons annually. An extension of the project includes a hot-water-recovery system attached to the case wash. Hot water from the case wash is routed through a heat exchanger, recovering waste heat and recycling it back into the solar panels. By capturing thermal units (from the hot water) that were literally flushed down the drain, Oakhurst saves an additional 2,500 gallons of heating oil per year at a minimum. 124

Dairy Foods | January 2011

Clay Detlefsen

Another successful waste-heat-recovery implementation was in the boiler system of a Wisconsin dairy. After an energy audit, the dairy identified multiple issues that caused inefficiencies in the facility’s boiler system. Among other upgrades, the dairy installed a blowdown heat-recovery system to capture heat from the boiler blowdown stream. This reduced both energy consumption and the city water required at the blowdown drain discharge point. All upgrades to the boiler system combined reduced the plant’s natural gas consumption by 10,500 MMBtu per year, for a cost savings of $39,400 annually. The plant will realize a return on its investment in 1.6 years, which is right in the middle of the one- to two-year payback period most dairies typically require for capital investments. Combined heat and power (CHP) CHP is two to three times as efficient as traditional power generation because it recycles excess heat generated rather than throwing it away. Recycled Energy Development (RED), based in Westmont, Ill., works with industrial consumers and other large users of power to capture energy that is normally wasted and turn it into clean electricity and heat for operations. RED develops the concept, provides financing, technology selection, engineering, environmental permitting and construction, and then manages the operation. Studies indicate that 20% of total U.S. generating capacity could come from CHP by 2030. United Dairymen of Arizona, a cooperative of 70 dairy farmers, for example, is planning to replace electricity with natural gas at its processing facility in Tempe, Ariz., through a CHP gas turbine generator. The estimated implementation cost is $7.6 million, with a potential annual savings of $3.1 million. That’s a simple payback of 2.5 years. According to RED, onsite cogeneration can provide a manufacturing plant with all of its thermal and electric needs, and excess power can be sold back to the electric grid. Success in energy management As dairy processors strive to be more efficient, reduce cost and save our global resources, it is helpful to review EPA’s seven steps for energy management, which are based on the successful practices of many Energy Star partners. They are: 1. Make a commitment, 2. Assess performance, 3. Set goals, 4. Create an action plan, 5. Implement action plan, 6. Evaluate progress and 7. Recognize achievements. Taking advantage of industry best practices and following these guidelines for energy management can help a dairy facility improve its energy and financial performance while distinguishing it as an environmental leader. More information on the Energy Star guidelines can be found at the Buildings and Plant tab on the www.energystar.gov website. DFR Clay Detlefsen is vice president for regulatory affairs for the International Dairy Foods Association, Washington, D.C. This is his first column for Dairy Foods.

SUPPLIER CAPABILITIES SPOTLIGHT

CEM Corporation For over 30 years, the dairy industry has relied on CEM Corporation for accurate, dependable compositional testing systems. We design and develop innovative laboratory instruments that meet the requirements of officially recognized methods, yet are fast and easy to use. Our award-winning systems can be found in major companies, prestigious universities, and government testing and research facilities around the world. Our chemists and engineers have not only been essential to the development of our innovative instruments, they’ve also helped develop official methods, spoken at numerous scientific conferences and had articles, books and book chapters published. CEM invented the first microwave moisture/solids analyzer for the dairy industry in 1978 and we have been innovating ever since. CEM’s Sprint Rapid Protein Analyzer was a winner of the 2009 Presidential Green Chemistry Challenge Award given by the United States Environmental Protection Agency for its greener reaction conditions. The system provides a fast protein determination that is as accurate as Kjeldahl without the use of hazardous chemicals or high temperatures. Ideal for yogurt and other dairy products, the Sprint uses a bioscience method that “tags” the protein in a sample for accurate results that are not affected by non-protein nitrogen. In minutes, the remarkably easy-to-use Sprint System provides an accurate protein analysis without the need of a trained chemist. The SMART Trac™ II, the next generation of our popular Fat and Moisture Analyzer, analyzes fat in only 8 seconds. The SMART Trac II partners advanced, high performance NMR technology with microwave moisture/solids analysis for fast, accurate, direct results without solvents or costly recalibrations.

The SMART Turbo™ Microwave Moisture/Solids Analyzer gives you accurate, reproducible drying results. The SMART Turbo provides precise measurement of liquids, solids, and slurries. Simpleto-use with pre-programmed methods, the SMART Turbo and SMART Trac II are available with software in English, Spanish, French, German and Italian. Based in Matthews, North Carolina, CEM is a private company with offices in the United Kingdom, Ireland, Germany, France, Italy and Japan, as well as more than 50 distributors worldwide. Our systems are backed by a fully-staffed team of applications chemists and factory-trained service technicians, who are widely known for their courteous, prompt, and expert support.

CEM Corporation PO Box 200 Matthews, NC 28106 www.cem.com [email protected] (800) 726-3331

www.dairyfoods.com

125

Processing Technology

Better Foods, Safer Foods X-ray machines and metal detectors keep foods safe. Checkweighers assure foods are made to consistent sizes.  Jim Carper Chief Editor

airy processors use X-ray equipment and metal detectors to look inside finished foods to find contaminants or to assure consistency to their quality standards. Emmi-Roth Käse USA, a Dairy Foods’ Dairy 100 cheesemaker based in Wisconsin, uses both types of machines. “We have one X-ray for our Swiss line, and metal detectors on all the other packaging lines,” says Fermo C. Jaeckle, chief executive officer. “Although the X-ray is much more sensitive than the metal detection equipment, we don’t consider it a cost-effective solution for contaminant detection. We use the X-ray to determine interior body consistency and structure.” New food safety laws, a move to embracing Hazard Analysis Critical Control Point standards and the need to manufacture efficiently (by eliminating re-work, for example) are some of the issues facing dairy processors. Dairy Foods convened a virtual roundtable of equipment suppliers and asked them about what’s happening in the world of checkweighing practices and X-ray and metal detection. What follows is an edited transcript.

D

Dairy Foods: What are dairy processors demanding from their equipment? Michael Freeman, Loma Systems, Carol Stream, Ill.: More processors are looking to X-ray as their product inspection system of choice. X-ray can offer many more features than metal detection alone. Not only can it detect a wide variety of contaminants, but it can do things such as weight verification, broken or missing component detection and fill-level verification. Our X-rays can inspect blocks of cheese and conduct “hole analysis” by verifying the size and quantity of holes in blocks of cheese. We are able to confirm this in a non-destructive way. John Uber, Mettler Toledo, Ithaca, N.Y.: First customers are demanding checkweighers that are constructed to stringent hygienic standards, which are also subjected to tough cleaning routines. Additionally, producers want a checkweigher that can provide greater throughput and finer accuracies sustained over long production cycles. Customers want devices that can execute product changeovers quickly, and can be easily integrated into their overall factory floor automation systems. 126

Dairy Foods | January 2011

 The Cornerstone Beltweigh SA checkweigher from Mettler Toledo can be integrated with the company’s Safeline metal detector.

Processing Technology Bob Ries, Thermo Fisher Scientific, Minneapolis: As the requirements for food safety become more stringent, dairy processors are looking for equipment that can meet the ever-changing government regulations while protecting consumers from foreign contaminants in their foods and beverages. They are always looking for ways to improve their HACCP policies with better detection devices at critical control points and more consistent, automated methods to audit these devices. Dairy Foods: What is the top concern among your customers? Ries: The economy, of course, is the chief concern, but right behind that is how the new food safety law will affect the way our customers operate. Will [it] necessitate a huge investment in new equipment? What will it mean in terms of administrative costs, and how will it ultimately affect the bottom line? They constantly worry about not doing the right thing all the time everyday and ending up with rework, scrap, a large recall or a PR nightmare. Scott Stone, Mettler Toledo. Aurora, Ill.: Ensuring that the proper product is in its proper container and is properly labeled. Nearly 43% of all recalls are initiated due to product mislabeling. Being proactive in preventing label mix-up by inspecting 100% of all products with a vision inspection solution is an easy and inexpensive way to protect against recalls.

John Klinge, Eriez, Erie, Pa.: Contamination is a major concern. Contamination can enter the production process through raw material as well as equipment wear or failure, such as ground metal, loose bolts or nuts. Employee sabotage can also be the cause of contaminants entering the process. Freeman: Sensitivity levels are always a concern. If they are a supplier to another food processor, they are often subject to the regulations imposed by their customer. We work very closely with our customers to ensure that our products are meeting the requirements that they are required to comply with.

Inspection equipment isn’t just to make sure you didn’t ship a mistake, it’s also a measurement of how the process is performing. The more immediate the measurement, the more quickly you can react to take advantage of the new information. Dairy Foods: How are you meeting customers’ demands? Ries: [By] developing the types of breakthrough technology that not only helps our customers meet stringent food safety regulations, but provide great value as well. Our AuditCheck performance verification system option tests the metal detector at pre-set intervals throughout the day, but it also provides a “paper trail” proof that the audit was completed. It was designed to be an early warning system informing a customer there may be a problem developing long before it actually happens. Intellitrack XR software helps improve metal detection capability while also reducing false rejects. Uber: Our Cornerstone SA checkweigher was designed to meet requirements such as the USDA Dairy standards. Further, [it] is built to IP69K ingress protection specifications in order to handle tough cleaning cycles, while having a very open concept to facilitate fast cleaning and inspection cycles. Our control platform has taken the guesswork out of integrating checkweighers to the popular factory floor automation systems, such as Ethernet-IP. Dairy Foods: What changes in food safety practices or in the dairy industry have impacted your business? Freeman: We are seeing much more demand for documentation for meeting standards like HACCP, SQF and BRC. We have been Continued on page 128 www.dairyfoods.com

127

Processing Technology What Processors Seek in Equipment Suppliers Price is important when dairy processors shop for X-ray machines, metal detectors and checkweighing devices, but it’s not an overarching concern. Three processors we contacted said they seek technical support, ease-of-operation and reliability. “Technical support has become one of our most important purchasing criteria,” says Fermo C. Jaeckle, ceo of Emmi-Roth Käse USA, “If a supplier cannot help us set-up equipment properly, or is not available to service the equipment within a few hours, we won’t

buy from them.” That’s because downtime on just one piece of equipment can shut down the whole line. “For metal detectors, price is very important, since this is older technology and equipment is comparable from different manufacturers,” Jaeckle says. “X-ray is a bit newer and if we were to buy another one, the software, reliability and other features would be a more important factor than price alone.” “Price is important as well, but not the first priority,” says an ice cream processor based in

the Midwest. His criteria for selecting equipment and vendors include features of the equipment, including reliability, ease of operation and maintenance. “Typically we seek state-of-the-art technology that helps to integrate the operation, and provides information to our operators, technicians and managers.” He adds that technical support and training are also “very important elements to our decision making.” Says a cheesemaker in the Northeast, “Most important criteria are reliability, serviceability and cost.”

refining our communication packages on all of our equipment to meet the demands of our customers. If features are difficult to use, then people won’t use them. Demand for new inspection technologies has an effect on our business. Whereas we were once only a metal detection company, we have started to see a shift to more and more X-ray inspection. We are seeing how advancements in image processing and interpretation can really add value and features to our equipment. Uber: Sanitary design requirements are evolving and improving all the time, this means what was accepted practice five years ago is unacceptable today. Customers want to know more about the health of their process as it contributes to the quality of their product, and the health of their business. This means improved communications capabilities and the ability to verify what is going on in the production line. Changes in packaging materials, container and serving sizes have impacted many existing production lines requiring either new systems to be installed or modifying existing checkweighers to accommodate the new package and process requirements. Chris Acierno, Mettler Toledo, Tampa, Fla.: New Global Food Safety Initiatives are being recognized and implemented.

Being proactive in preventing label mix-up by inspecting 100% of all products with a vision inspection solution is an easy and inexpensive way to protect against recalls.

 Loma upgraded its IQ3 metal detector with the addition of a multilingual dual line display panel.

Regulatory bodies such as SQF, BRC and IFS are driving new levels of HACCP compliance.

Klinge: Regulations coming from the U.S. Food and Drug Administration and Department of Agriculture and the respective HACCP program are pushing liability into food processors’ laps. These changes have resulted in an increased use of metal detection and X-ray inspection equipment. Eriez has seen a rise in the use of X-ray inspection systems. Factors that have traditionally plagued metal detectors, such as foil packaging and conductive products, do not affect X-ray machines. X-ray inspection systems have become a very popular choice for yogurt manufacturers that use packaging with foil lids. Dairy Foods: What new technology or features have you incorporated into your equipment? Ries: Intellitrack XR enhances dairy product safety by replacing phasing and providing a higher level of protection for manufacturers and consumers alike. IXR learns the actual Continued on page 130

128

Dairy Foods | January 2011

Inspect. Package. Prosper!

Visit our demonstration centers to choose the right inspection & packaging machinery. For cheese and other dairy products, Heat and Control provides the latest technology for weighing, conveying, inspection, and packaging. Visit our demonstration centers where you can test our equipment to select the best individual machine or production line for your products. • Ishida multihead weighers • Ishida checkweighers • Ishida X-ray inspection systems • CEIA metal detectors • Conveyors, accumulators, distribution systems • Container fillers & tray sealers • Packaging platforms • Real-time line management & control systems

Ishida’s new USDA Dairy accepted weighers reduce package overweight & changeover costs.

See us at WestPack Booth 5070

One Call Delivers 800 227 5980

www.heatandcontrol.com/d1

Processing Technology sinusoidal X and R signals the product creates as it passes through the metal detector. Once the signals are stored in memory, Intellitrack XR cancels them out by subtracting a signal that is equal to but the exact opposite of the product’s X and R signal. Since IXR knows the product signal and removes it—any signal left over is quickly identified as suspect. This all new dual channel (X and R) cancellation algorithm can eliminate the risk of a foreign metal object going undetected in many cases where phasing will mask out the metal signals. Because products like sliced cheese can change over time, IXR also tracks and adjusts product signals on the fly to assure high-performance and to eliminate false rejects. The result is up to 50% smaller diameter metal can be detected in many previously difficult metal detection applications. Freeman: The most significant feature is our variable-frequency technology. Our IQ3 line creates a magnetic field that is adjustable by the user [who can] pre-program up to 100 unique product profiles. It also allows a “no compromise” inspection solution. You no longer have to choose a frequency that is “good enough” for your whole production range, and potentially deal with either an over-sensitive (false rejects) or under-sensitive (metal makes it to the customer) metal detector.

Changes in packaging materials, container and serving sizes have impacted many existing production lines requiring either new systems to be installed or modifying existing checkweighers to accommodate the new package and process requirements. Uber: At Pack Expo, we showcased two new products. ProdX software enables users to connect their checkweighers and metal detection and X-ray inspection devices to a common PC or IT network. This allows the user to monitor device health and status both at the line and at a remote location. ProdX enables users to see and record in real-time all packages, which have been rejected as well as any actions, alarms or events, which have occurred on any of the devices. InTouch Remote Services for checkweighers allows our inplant technical support team “to see what they see” without having a technician on-site through a totally secure remote connection. The program includes a monthly checkweigher “Health Check,” which provides a status report. 130

Dairy Foods | January 2011

 The Eriez E-Z Tec DSP metal detector includes a continuously welded series stainless steel frame.

Dairy Foods: Any tips or ideas you can offer a plant manager? Ries: Start investigating X-ray inspection systems. Cost and reliability are constantly improving. X-rays, many times, can find smaller contaminants than metal detectors and those contaminants can be other materials in addition to metal. In some application, the X-ray system can be used to inspect the product inside the package too by measuring approximate mass, counting objects and determining area to detect packaging errors. Freeman: Look at the provider’s market focus. Are they focused on food, or are they selling primarily to other areas like scientific instruments/laboratories or homeland security? If their focus is not food, will they be the most knowledgeable? Uber: Constantly evaluate the status of the information received from the production line. Inspection equipment isn’t just to make sure you didn’t ship a mistake, it’s also a measurement of how the process is performing. The more immediate the measurement, the more quickly you can react to take advantage of the new information. Acierno: Make inquiries with your manufacturers to see how the equipment can be optimized and utilized to the most foolproof methods. Most metal detector installations can be improved to prevent metal from reaching the consumer. DFR

EXTRAS Eriez .......................................................................................... www.eriez.com Loma Systems .......................................................................www.loma.com Mettler Toledo .......................................................................www.us.mt.com Thermo Fisher Scientific ................................www.thermoscientific.com

SUPPLIER CAPABILITIES SPOTLIGHT

Thermo Scientific Thermo Scientific product inspection solutions help our customers protect their brands by ensuring the quality and safety of their products. For more than 50 years, we’ve earned a reputation for delivering reliable solutions through our application knowledge, equipment performance and unmatched customer care. Thermo Scientific X-ray Inspection Systems Around the world, Thermo Scientific X-ray inspection systems provide complete protection from metal, glass, stone and other dense foreign objects. Our x-ray systems inspect packaged, bulk or piped product. Thermo Scientific Metal Detection Systems For protection against metal contaminants, Thermo Scientific metal detection systems provide a high level of performance, ease of use and reliability--typically achieving up to 20% better sensitivity than competitive units. And to ensure you get the right system for your application, we offer hundreds of standard head styles plus custom apertures and systems. Thermo Scientific Checkweighers To ensure the accuracy for your weighing applications, Thermo Scientific checkweighers combine the latest in weighing technology with a variety of weighframes that include general purpose to more demanding, highrate and high-accuracy systems. Thermo Scientific ε scan™ In-line Analyzer When you need to “see what’s inside the pipe,” Thermo Scientific ε scan™ in-line analyzer measures fat, moisture and protein in pumped food products, ensuring product quality to customer’s standards and saving on raw material costs, as well and saving time, money and energy. Customer Care To keep your Thermo Scientific equipment running at its peak performance levels, we 132

Dairy Foods | January 2011

provide a complete range of services, parts and repairs. Our experienced service technicians ensure that our Thermo Scientific products constantly perform to the most demanding customer requirements. We even stock parts in several locations worldwide to minimize customer downtime. In addition, we offer technical support via telephone and Internet to address basic questions and troubleshooting issues. Finally, our global team of factory-trained and certified technicians offers preventive maintenance, field service repair and comprehensive service contracts. Thermo Scientific Product Inspection Service When you suspect a contamination incident, our product inspection and recovery facilities offer a confidential, dependable

way to have product thoroughly inspected for a variety of contaminants—including metal, glass, stone, bone and rubber. We can inspect virtually all types of container materials, including metalized film and foil. We can also detect missing or mis-packaged product using the most advanced, non-destructive techniques that maximize product recovery and minimize financial loss. For more information about Thermo Scientific, products and services please visit us at www.thermoscientific.com/productinspection, or call 1-800-227-8891.

© 2010 Thermo Fisher Scientific Inc. All rights reserved. Copyrights in and to the Piggy Bank photograph is owned by a third party and licensed for limited use only to Thermo Fisher Scientific by Punchstock.

Turn instant feedback into fast payback.

Here’s an idea you can take to the bank: Thermo Scientific

e scan

analyzer gives you instant in-line analysis of fat, protein, moisture and other key properties in your food matrix.

e scan

™

analyzer uses Guided Microwave Spectrometry to see

through the pipe and provide you with complete analysis of your entire product—not just the surface like NIR technology. It lets you know when you’re in the zone and helps keep you there. It delivers the information you need to control the content of your mix and the quality of your product. Discover how

e scan analyzer can help you save time, money, and

raw materials—with payback in as short as two months. To learn more, call +1 (800) 227–8891. Email [email protected] or visit www.thermoscientific.com/escan.

Moving science forward

Thermo Scientific

e scan analyzer—

The fast, easy and accurate way to measure key constituents in food as it goes through the pipe, so you can make corrections on the spot.

SUPPLIER CAPABILITIES SPOTLIGHT

Spraying Systems Co. The Broadest Range of SprayDry® Nozzles Available New SV Series SprayDry® Nozzles with Swirlchamber Design SV nozzles from Spraying Systems Co. provide comparable performance to competitive swirlchamber style nozzles but feature many important differences: • Delivery in days, not weeks • Lower cost • Special tungsten carbide material provides longer wear life • Quick assembly and disassembly • Higher standard pressure ratings – hand-tight up to 10,000 psi There are more than 700 different swirlchamber and orifice combinations. Free validation samples are available to qualified prospects upon request. SK and SB SprayDry Nozzles with Core Design Available with hundreds of core and cap combinations, SK and SB SprayDry nozzles are available with Maximum Free Passage (MFP), anti-bearding and hand-tight features to extend production runs and minimize maintenance. WhirlJet® SprayDry® Nozzles with Whirlchamber Design WhirlJet SprayDry nozzles feature large orifices for producing large particles in high-volume operations. Commonly used for spray drying coffee and tea, these nozzles are available in a wide range of styles and sizes.

Tel: 1.800.95.Spray www.spray.com

134

Dairy Foods | January 2011

Fax: 1.888.95.Spray [email protected]

Plus Dozens of Ways to Clean Dryers, Vessels, Storage Tanks and More Spraying Systems Co. also has a wide range of products for cleaning dryers and vessels up to 100 ft. in diameter. Solutions range from a high-impact fluid driven machine for removing sticky residues to nozzles and spray balls for general cleaning and rinsing.

Spray Nozzles

Spray Control

Spray Analysis

Spray Fabrication

New SV SprayDry® Nozzles with Swirlchamber Design #OST,ESSs,AST,ONGERs3HIPIN,ESSTHAN4WO7EEKS SV Series SprayDry nozzles provide comparable performance to competitive nozzles. But, that’s where the similarity ends. SV SprayDry nozzles: U Are less expensive U Are readily available shipping in days, not weeks UÊÊFeature swirlchambers and orifices made from a special tungsten carbide material with superior wear resistance UÊ Are easily assembled and disassembled – all components are securely retained in the cap for easy handling UÊ Are rated at higher standard pressures – hand-tight up to 10,000 psi (690 bar) With more than 700 different swirlchamber and orifice combinations, you’ll find the performance you need.

Spraying Systems Co.: The Pioneer in Spray Drying UÊ D Ê eveloped the first commercially-available nozzles for spray drying in the 1940s

Eliminate delivery delays and start saving with SV SprayDry nozzles. Call 1-800-95-SPRAY for free validation samples* today.

UÊ SÊ prayDry became a registered trademark in 1951 UÊ Spraying Systems Co. has the largest selection of SprayDry nozzles available. In addition to the new swirlchamber design, core and whirlchamber designs are also available

1-800-95-SPRAY | spray.com |

Swirlchamber *To qualified prospects.

Orifice

Specify and order standard nozzles spray.com/ispray

Packaging Technology

Keeping It All Together Equipment for casing, stacking and palletizing keeps dairy products safe, neat and protected from damage on the loading dock, in transit and at their destination.

stack-and-wrap process combines two or more lines into a centralized automated palletizing/stretch-wrapping station. While conveyors deliver an empty pallet to each stretch wrapper, product is delivered from two production lines to the palletizing cell. The robotic arm builds layers of product on each of the wrappers. The palletizing system was engineered by Schneider Packaging Equipment (www.schneiderequip.com) with stretch wrappers from Lantech (www.lantech.com). The economical and compact adhesive top case sealer has a heavy-gauge stainless steel frame, continuous motion side belt case drive and contoured flap folders to ensure square cases. Model 136HM sealer from A-B-C Schneider Packaging Packaging Machine (www.abcpackaging.com) is built for drop-in installation on a standard 15-inch line elevation. It can adjust to a full range of case sizes from 8 inches long by 6 inches wide by 5 1/4 inches high to a maximum of 24 inches by 16 inches by 17 inches high. The Trayfecta tray former from Delkor (www.delkorsystems.. com) automatically forms and glues a variety of retail-ready dis-play trays at a speed of 35 trays per minute. The former is designed d so it can feed into a variety of the company’s packaging lines. Onee packaging line can produce multiple shipper styles. Changeoverr is controlled by a single touch screen HMI. In a demonstration, a line was converted from running a Spot-Pak package to the retail-ready display tray. The changeover was completed in 10 secondss and the filler did not have to be turned off. The Trayfecta Retaill Ready Former has a compact footprint and is equipped with Allen n Bradley controls. Stainless steel construction is standard. Krones’ Checkmat 761 CR-CX (www.krones.com) uses X-rays to verify that the complete number of primary packs are present Delkor in a sealed carton. In addition, four cameras check all four sides of the carton for correct label positioning, correct barcode and correctly applied sealing tape. The combination of X-ray and camera-based monitoring enables complete end-of-the-line inspection to be performed.

A

136

Dairy Foods | January 2011

Equipment

A-B-C Packag

ing Mac

Krones

chine

Packaging Technology

Polypack

Oystar Jones

P Processors seek more economical and efficient means of packaging. Polypack’s (www.polypack. m com) shrink bundlers eliminate cardboard cases c and traditional plastic milk crates. Gable-top a milk cartons are shrink-wrapped with cardboard m inserts strategically placed between the rows to in give added stacking strength to the bundle packs. gi These bundles are palletizable and significantly Th reduce waste in schools, hospitals and other instire tutions because there are no more boxes to be brotut ken down and thrown out. This also means there are no more heavy plastic milk crates to hose down and stack for the delivery driver. Legacy 3 from Oystar Jones (www.oystar.rajones. L com) com is a constant-motion, small-center cartoner. The machine’s flexibility allows a wide range of cartoning mac at speeds as great as 400 cartons a minute. Featured sp upgrades, according to the company, include an ergoupgr nomically designed straight-in, low-level carn tton magazine, quick changeovers (thanks to ttool-less adjustments) and a variable-velocity ccarton feed design. A “quick clean” bucket convveyor eliminates catch points and provides full vvisual compliance. Model FL1000-SW from Columbia Machine (www.palletizing.com) combines M a heavy-duty, small-footprint palletizer with a fully integrated stretch wrapper. With no modification, the machine can simultanem ously stack and stretch-wrap a wide vario eety of package types, including cases, trays, ttotes, film-only and display packs for the beverage and frozen food industries. The b FL1000-SW palletizes 10 cases a minute (10 F ccase per layer pattern) or more, depending on the case size and pallet pattern. o Hexacomb Billboard from Pregis (www. hexacomb.com) is a pallet alternative that h

Columb

ia Mach

ine

incorporates porates an additional outer edge wrap (see photo on page 138). It consists of kraft paper layers laminated to a white clay-coated outer surface onto which logos, brands or store names can be flexographically printed in a repeating pattern. A logo on a pallet is particularly valuable for products sold in warehouse stores. In addition to providing a branding platform, the edge wrap also improves pallet strength and durability. The use of 80% virgin fibers and the wrapped fiberboard feet help make the pallets water resistant. Each pallet can handle static loads of up to 6,000 pounds. Westfalia Technologies’ (www.westfaliausa.com) new dairy case palletizing system is capable of handling plastic and wood pallets. The system palletizes two full pallets per minute. Each pallet holds nine stacks of dairy cases stacked six high for a total of 54 cases on each pallet. Constructed of all stainless steel materials, it is ideally suited for washdown environments found in the dairy and beverage industries. Phoenix (www.phoenixwrappers.com) offers a new, more affordable rotary ring stretch-wrapping machine that is said to reduce labor and film costs. The new line uses a unique wrapping ring concept that eliminates the need for extra film passes up the load to secure top wraps and then back down to the clamp for final tail treatment. This process produces a savings of at least 30 feet of stretch film while still applying the same required load retention wraps, the company states. There are two small footprint models; one rated at 40 rpm and 100 or more loads per hour and the other rated at 21 rpm, 70-plus loads per hour. Both offer an 80-inch wrap height capacity. Continued on page 138 www.dairyfoods.com

137

Packaging Technology

Pregis ologies QComp Techn

Westfalia

Phoenix

Econocorp

138

Dairy Foods | January 2011

The Econoseal E-System 2000 from Econocorp (www. econocorp.com) can accommodate 1,500 paperboard or corrugated cartons per hour. The base machine, including a hot melt glue system or tuck closure system, handles a broad range of carton sizes and takes up minimal floor space. The ergonomically friendly machine automatically erects cartons onto a single product loading station. It allows an operator to load product with the help of a stainless steel guide shelf, or can be equipped with optional automatic product loading conveyors and devices. Date/lot coding devices and other options can be incorporated into the design. The basic machine frame is 60 inches long by 32 inches wide. QComp Technologies (www.qcomptech.com) and Combi Packaging Systems (www.combi.com) have partnered on highspeed picker and case packing systems. QComp’s high-speed (Delta-style robot) picker systems complement Combi’s case and tray packing machines. QComp is a robotics integrator that designs and builds automated robotic manufacturing cells and materials handling systems. Combi Packaging Systems is a maker of end-of-line packaging equipment, including case erectors, tray erectors, case sealers, case packers, ergonomic hand-packing stations and case labelers. DFR

SUPPLIER CAPABILITIES SPOTLIGHT

BluePrint Automation BluePrint Automation was founded in 1980 to provide fully automatic case packers for flexible bags. Since then, our company has become a worldwide leader in packaging automation. With 20+ years in the dairy industry, BPA is a multinational packaging automation company focused on three areas of expertise: • Primary Packaging: Sophisticated vision-guided robotics picking individual packaged and unpackaged items for loading into your containers or Horizontal Form, Fill and Seal machines. • Secondary Packaging: Case and tray packing solutions for flexible and other tough-to-handle packages (i.e. bags of cheese). Ask us about Retail Ready Packaging! • Complete Packaging Automation Systems: Turnkey packaging solu-

tions taking total control of your packaging line from the end of processing through palletizing! Backed by thousands of successful installations in over 30 countries, BluePrint systems are constructed for around the clock operation and known worldwide for their quick change over, flexibility, speed and simple design. Be sure to check out our new website! During your visit you can learn more about our company, view videos, browse

recent industry news and search for a solution that is right for you using our “pick a pattern” solution wizard. All this and more at www.bpa-flexolutions.com. BluePrint Automation 16037 Innovation Drive Colonial Heights VA 23834 804-520-5400 phone 804-526-8164 fax sales@bpa-flexolutions.com www.bpa-flexolutions.com

www.dairyfoods.com

139

SUPPLIER CAPABILITIES SPOTLIGHT

Harpak-ULMA Packaging, LLC With today’s extraordinary demand

140

State of the Art Technology

Specifically for the Dairy Industry

for packaging excellence, Harpak-ULMA

Harpak-ULMA is the exclusive North

Our extensive experience in the dairy

stands alone. Our unique experience

American distributor of G.Mondini

industry includes a wide variety of pack-

allows us to offer completely integrated

Tray Sealing, Filling and Meal Assembly

aging solutions, from packaging applica-

packaging and handling systems. Our

equipment. The G.Mondini name is

tions for cheese to Dairypack for yogurt

team of experts systematically reviews

renowned for quality and reliability

– and everything in between! Please visit

the individual needs of each customer to

across every piece of equipment - from a

our website to explore the multitude of

develop cost effective, efficient packag-

single seal semi-automatic system to the

capabilities that we offer. Sticks, blocks,

ing solutions. A deep understanding of

more complex ready-to-eat meal pack-

sliced, stacked, shingled, wedge, yogurt,

our customers’ requirements enables our

aging line in either heat seal or modified

ice cream bars, novelty items, pouches,

engineers to produce thoughtful, innova-

atmosphere.

tubs, you name it - we can help!

tive, concise solutions. Harpak-ULMA

ment in Research and Development

stands by our customers offering instal-

plays an important role in ensuring

lation, training and ramp-up assistance

design innovation and technological

Harpak-ULMA Packaging, LLC

while the customer gains confidence and

excellence, ensuring the best solutions

175 John Quincy Adams Rd.

momentum. Our integrated packaging

for our customers.

Taunton, MA 02780

Harpak-ULMA’s

invest-

lines include denesters, fillers, convey-

Harpak-ULMA has added RAMA car-

ors, F/F/S, tray sealers, vertical bagging,

toning and case packaging equipment to

FAX: (508) 884-2501

stand up pouches, zipper technology,

our line of products. Together with our

www.harpak-ulma.com

scales, automated product handling, pick

offering of robotics, Harpak-ULMA pro-

[email protected]

and place robotics, check weighs / metal

vides a full line packaging solution that is

detectors, cartoning, case packing, and so

a completely integrated, automated pack-

much more!

aging system!

Dairy Foods | January 2011

PHONE: (800) 813-6644

SUPPLIER CAPABILITIES SPOTLIGHT

International Dairy Foods Association THE DAIRY INDUSTRY’S ANNUAL OPPORTUNITY TO INNOVATE, LEARN AND GROW. Please join us at IDFA’s International Dairy Show, September 19-21 in Atlanta, Georgia. Prepare for an event designed to meet the rapidly changing needs of the global dairy industry. From development, procurement, processing, packaging, distribution, sales or marketing the role you play in the food industry is constantly evolving. The International Dairy Show is your resource for innovation, education and networking. The event will feature a Consumer Trends and Product Development educational track to inspire you. Enhance your recipes and product offerings by visiting the suppliers in the Ingredients, Flavorings & Seasonings pavilion. Then evaluate all of the packaging and innovations to bring your products to life. You’ll only find this at the International Dairy Show.

142

Dairy Foods | January 2011

This unique event is specially designed to help you reduce your production costs, find solutions to your problems and make your company more competitive...all while networking with your peers. You and your staff simply cannot afford to miss the International Dairy Show. Don’t be left out, to register or exhibit visit at www.dairyshow.com. See you in Atlanta!

International Dairy Show Robin E. Cornelison International Dairy Foods Association (IDFA) 1250 H St., NW, Suite 900 Washington, DC 20005 Phone: 202.737.4332 Fax: 202.331.7820 Email: [email protected] Web: www.dairyshow.com

EVERYTHING YOU NEED IN ONE SHOW INGREDIENTS TRENDS PACKAGING PROCESSING TECHNOLOGY SUSTAINABILITY

TO REGISTER OR EXHIBIT VISIT WWW.DAIRYSHOW.COM. ATLANTA, GA • SEPTEMBER 19–21, 2011 Use this code when filling out your registration form: A1DF11

Equipment Showcase

Cheesemaking Equipment Through new engineering developments, Urschel now offers a wide variety of grating heads that offer cuts from coarse granules to different types of shreds for cheese, coconut, nuts and carrots. Grating heads present added flexibility to slicer/shredder Models CC, CC-D, CC-DL and CCX-D. These grating heads incorporate four posts with corresponding fasteners, upper support ring, locking lower support ring and a grating screen. A multitude of interchangeable grating screens are available to easily switch from one style to another. Urschel Laboratories, Inc. 219/464-4811 Urschel www.urschel.com Cryovac parchment-print bags provide the distinctive appearance of traditional parchment paper along with packaging safety for any kind of cheese or smoked and processed product. Available in any color, the parchment printing technology offers complete print coverage. Cryovac parchment-printed materials are available for forming and non-forming rollstock and in bag sizes up to 12.5 inches wide. The printing option is also available for horizontal form/fill/seal rollstock applications. Sealed Air Corp. 800/391-3645 www.cryovac.com Reiser and Vemag developed an innovative cheese block forming system that eliminates waste by repurposing cheese trim, ends, scraps and other pieces to produce cheese blocks. At the heart of the system lies the Vemag Portioner. The Vemag features a powerful double-screw pump that provides the highest levels of portioning accuracy. An extruder attachment produces a shaped block with consistent thickness and width. A cutoff device controls the length of the block and ensures clean, even edges. Reiser Reiser 781/821-1290 www.reiser.com

dftv 144

Dairy Foods | January 2011

The LC22 cheese cubing machine from Marchant Schmidt was designed to automatically reduce the size of cheese blocks or cut off into cubes and feed them directly into a shredding machine. By integrating the LC22 cuber with a shredder, it allows for a low-cost solution and requires minimal floor space. The system can operate up to 2,000 pounds per hour. Marchant Schmidt Inc. 920/921-4760 www.marchantschmidt.com The new Curwood UltraSeal packaging films for natural shredded cheese are engineered to achieve high-integrity ultrasonic seals on high-speed VFFS equipment. Ideal for up to 5-pound gas-flushed packages, Curwood UltraSeal films resist abrasion, flex cracking and puncture while extending shelf life. They are also available in plain or printed. Curwood 800/544-4672 www.curwood.com The Tetra Tebel Alfomatic cheddaring machine from Tetra Pak produces consistent and accurately salted curd. It provides the flexibility to produce Cheddar, both milled and stirred curd, and pasta filata types of cheese. Most of the whey is separated from the curd at the wedge-wire inlet screen. The Tetra Pak design of the screen ensures an even curd distribution across the perforated draining belt. The whey from the inlet screen is collected and can be pumped onto a second fines-saving, wedge-wire screen. The fines are reintroduced to the main product flow ending up as premium product. The stirrers are designed to be parked so curd can pass when milled curd is produced. In the case of stirred curd production, the specially designed chip mill area allows the curd to bypass the chip mill. Salt is applied to the curd on a weight-for-weight

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

Equipment Showcase basis and thoroughly mixed in a rotating mixing drum. To meet USDA regulations and as a basic hygiene rule of thumb, hollow sections inside the machine have been eliminated or can at least be inspected. Tetra Pak 847/955-6000 www.tetrapakprocessing.com

FoodTools

FoodTools added an innovative optical guarding to the CS-3S to improve safety and sanitation. A state-of-the-art safety light curtain system allows for easier access during the production process, while providing a dependable guard against accidental injury. The CS-3S slices wheels, wedges, blocks and loafs of cheese products. FoodTools 805/962-8383 www.foodtools.com

Karl Schnell’s grinder range provides a fully fledged grinding range consisting of angled and automatic grinders in various sizes and versions. These machines can be adjusted to specific applications with a wide variety of cutting sets and can be universally implemented for different products. For instance, KS offers hole plates with drill hole diameters down to 1.6 mm. The key benefits of such small grinding holes are: efficient and faster mixing with powders, advanced safety during the cooking cycle, repeatable heat holding time and less risk of re-contamination. Plus, the rugged construction of the grinders is well matched for heavy-duty operation in daily practice. Karl Schnell Inc. USA 920/982-9974 www.karlschnell.com

Harpak-ULMA offers cheese packaging solutions for sticks, blocks, sliced, stacked, shingled and wedge shapes. From traysealed deli slices and form/fill/seal grated cheese to thermoformed vacuum packs for cheese wedges and cartoned, retail-ready product, Harpak’s complete, fully automated packaging lines meet all of a processor’s cheese packing requirements, from start to finish. Harpak-ULMA Packaging, LLC 800/813-6644 www.harpak-ulma.com www.dairyfoods.com

145

SUPPLIER CAPABILITIES SPOTLIGHT

Stanpac Good people who make great packaging Stanpac continues to add new products to its complete packaging line up which allows our customers to differentiate themselves in the marketplace. Spoon’ n Lid novelty packages are now available in several sizes with either a cover all or plug style over cap The Flex E Fill tm. line of filling equipment easily handles the complete production process of cup dispensing, filling, application of a tab lid, dropping in of either a plastic or wooden spoon and the snapping on an over cap prior to exiting the filler onto the discharge conveyor. When you are finished with your novelty run changeover is easily accomplished and you can run pints, quarts, 48, 56 or 64 ounce scrounds or rounds for the rest of the day. The Flex E Fill tm may be the most flexible filler out there and has been the work horse of the industry for decades. For more than 60 years, Stanpac’s focus has been on Dairy. With locations in Texas and Ontario we are able to serve our customers from coast to coast and beyond. Product safety is job one with the most stringent electronic controls and procedures available to keep your customers safe. Innovation in the area of tamper evidence is one of our strengths with 7 patents in more than 20 countries. Everything but the Milk – Stanpac is rooted in dairy. Way back in the early years Stanpac manufactured closures for dairies bottling milk in glass bottles. Today we continue in that great tradition by providing dairies and processors glass refillable milk bottles, closures, crates and carriers. We are proud supporters of the International Home Delivery Association A network or service technicians throughout the country assist our customers with new projects, startups and preventive maintenance programs. Our

146

Dairy Foods | January 2011

sales associates are there to help you achieve your goals. We want to be your first choice for packaging. Stanpac is large enough to handle your big projects and small enough to handle them in a fast efficient manner. Some say that we are not number one. We agree. You are!

Stanpac www.stanpacnet.com 905-957-3326 VP Sales Andrew Witt

Your Complete Ice Cream Packaging Solution

(3 to 64 ounce ice cream packaging plus our Flex E Fill Equipment = One Happy Customer!)

Let’s put our heads together.

You asked, we delivered. = more shapes and sizes of ice cream packaging = order quantities that work for you = the Flex-E-FillTM line of filling equipment With legen’dairy’ customer service, a complete line of products, equipment and our focus on the dairy industry, Stanpac is your one-stop packaging solution.

Contact us for more information.

Packaging Perfection for Over 60 Years. The Evolution of a Great Company Continues.

905.957.3326 | stanpacnet.com

SUPPLIER CAPABILITIES SPOTLIGHT

Tindall Packaging, Inc.

Tindall Packaging Inc., founded in 1971 by Frank Tindall, began as a service/ consultant company, and was hired by different ice cream plants that were on the brink of bankruptcy to be streamlined and become a profitable operation. Frank Tindall was asked by several different production managers to automate their bulk can production. This led to the birth of the Tindall Model 135 Bulk Can Filler in 1974. From there to the present, Tindall Packaging has developed several different fillers for the ice cream industry, also venturing into the cultured and deli filling equipment. Tindall Packaging has also ventured into other areas, such as designing and installing marble drop equipment for the spray paint industry to designing and building equipment for the bait industry with the unique worm packaging system. Tindall Packaging Inc. is still a small family run corporation run by Frank and Marianne Tindall, son Dave, with the latest addition being their son, Pete, age 14. Tindall Packaging Inc. has always strived to design and build simple, low maintenance, cost saving equipment to meet the individual plants needs. Their fillers range from the 890 Semi Automatic Filler to be run with batch freezers to the fully automatic fillers used with continuous freezers such as the models 135 three gallon bulk can filler, 136 one to three gallon bulk filler, 294 4/5 quart pail filler, 814 pint, 815 quart, 816 half gallon round plastic or paper fillers, 817 non round filler, 460 non round higher speed filler, 772 6oz. to 10 pound filler for pumpable cultered or deli products, 317 ice cream or cream cheese cake filler, etc. Whatever your needs might be, Tindall Packaging

148

Dairy Foods | January 2011

Inc. can supply the industry with fully automated equipment. Tindall Packaging has fillers for round, non round, paper, plastic, square, bag filling equipment and bulk containers.

Tindall Packaging, Inc 1150 East U Ave. Vicksburg, MI 49097 Ph: 269/649-1163 www.tindallpackaging.com

Machine featured, model 790 Semi Automatic Filler with fully automatic lidder.

by Tindall Packaging The New Redesigned Model 817 for Non Round Containers Using Innovative Technology to Run 48 Through 64 Ounce Containers. Uses Continuous, Volumetric Fill, at Speeds up to 40 Containers Per Minute. Price $34,500.00 THE ONLY NON ROUND FILLER MADE EXCLUSIVELY TO FILL NON ROUND CONTAINERS AVAILABLE FOR UNDER $100,000.

Our New Filler, Model 225 to Run 4 to 10 Oz. Containers at speeds up to 225 per Minute. Call for information. 269-649-1163; 269-329-4310 [email protected]

Tindall Packaging 1150 East U Avenue • Vicksburg, MI 49097 Phone 269-649-1163 • www.tindallpackaging.com For more info, please email [email protected] et

Buyers Mart

PLANT EQUIPMENT Omega Engineering

R & D INGREDIENTS Hyrdosol SIG Combibloc

DCT Series Pneumatic Grippers from Omega Engineering are angular grippers with a 180-degree jaw opening allowing complete release of a directly fed part. Gripper forces range from 7.5 to 25 pounds. These pneumatic grippers are compact and designed for confined spaces and harsh environments due to the shielding that repels chips and other particulate from the internal drive mechanism. Plus, these grippers can be used up to 5 million cycles in typical applications and 10 million with maintenance at -30 to 180°F. Omega Engineering Inc. 203/359-1660 www.omega.com Axon Corp.

Axon introduced ThermoRay, a radiant heat shrink tunnel that can be mounted directly onto most conveyors, eliminating the need to purchase a separate stand. Operators adjust the tunnel’s height with an integrated hydraulic lift. A blower helps to ensure even heat distribution for uniform film shrinkage. ThermoRay’s design gives customers the flexibility of using the tunnel for both tamper banding and shrink sleeve labeling. Plus, the new tunnel reduces overall energy cost by lowering electricity requirements by 20%. Axon Corp., a division of Pro Mach 800/598-8601 www.axoncorp.com 150

Dairy Foods | January 2011

SIG Combibloc introduced carton packs with a perforation that extends all the way across the top, enabling consumers to open the pack across the top without the use of additional tools and to obtain every last drop of the product. Suitable for chunky and highly viscous products, the combiblocCompact is the first package to contain this perforation. It comes in 200- to 500-millimeter volumes and can be filled using one single filling machine. In addition, the carton gable rises five millimeters higher, giving the consumer a firmer grip when opening. SIG Combibloc Inc. 610/546-4200 www.siggroup.com Hanna Instruments introduced the HI 900 Series titration systems, offering complete solutions for sample analysis. The innovative 900 Series can perform any kind of potentiometric, redox and precipitation titration, features 100 pre-programmed user methods and can conduct end-point and inflection-point titrations. During the titration, temperature and measurement units are displayed or the user can choose to activate real-time graphing that shows the exact curve profile of the titration on screen. Other features include: Hanna’s Clip-Lock exchangeable burette system, automatic burette volume recognition and a programmable propeller stirrer with integral feedback control. Hanna Instruments Inc. 800/426-6287 www.hannainst.com Buchi introduced NIRMaster, a stand-alone FT-NIR spectrometer designed with hygiene in mind, making it a tool of choice for routine quality control work in harsh environments. The NIRMaster is available in food-grade polymer and stainless-steel housings and includes a built-in PC, as well as ready-to-use calibrations for the food, feed, dairy, meat and bakery industries. Its internal laser reference eliminates the need for frequent, expensive instrument standardizations, saving users time and money. Buchi Corp. 877/MYBUCHI www.mybuchi.com

Hydrosol developed a new system of dietary fibers, giving low-fat milk drinks a creamier mouthfeel. Stabisol GR AI is a functional system that consists of vegetable fibers and reduces fat by up to 50% and lowers formulation costs. Hydrosol Produktionsgesellschaft mbH & Co. +49 (0) 41 02 / 202-003 www.hydrosol.de

Heat and Control Inc.

Heat and Control introduced the CEIA THS 21e metal detector, designed to continuously test and calibrate itself to maintain peak inspection performance. Its one-button sensitivity preview provides an estimate of the size and contaminant material and its easy-to-use auto-learn system accurately scans products in one pass, reducing set-up time and inspection errors. It also features an electronic platform for superior stability, a stainless-steel casing and keyboard and conformal-coated circuit boards for IP65K washdown. Heat and Control Inc. 800/227-5980 www.heatandcontrol.com

If leading edge manufacturing and automation technologies are your priorities, save the date for the food industry’s PREMIER CONFERENCE in 2011.

SAVE the DATE APRIL 3-6, 2011 The Ritz-Carlton, Palm Beach, Florida

WHO SHOULD ATTEND: ● Vice Presidents of Operations ● Plant Managers ● Vice Presidents of Engineering ● Plant Maintenance Managers ● Plant Engineers ● Directors of Engineering ● Owners and Presidents ● Sustainability Directors

FEATURED SPEAKERS INCLUDE: KEYNOTE > Carlos del Sol, Vice President Global Engineering Systems, Campbell Soup Company; Peter Hock, Senior Director of Continuous Improvement, ConAgra Foods; Al Koch, Director of Engineering—Global Biscuit, Kraft Foods Nabisco; Peter Monkeiwicz, Vice President of Operations, Kayem Foods, Inc.; Bob Palczewski, Engineering Director, Celebration Foods; Alex Posada, Project Engineer, Campbell Soup; Diane Wolf, Global Vice President, Safety and Environmental Sustainability, Kraft Foods; Ed Delate, Vice President Global Engineering and Corporate Social Responsibility, Keystone Foods

ALL NEW AGENDA FOR 2011 TO INCLUDE: ● Project Economics: Getting Paybacks on Your Plant Automation Projects ● Overall Equipment Effectiveness Across the Enterprise ● Implementing a Powerful Corporate Social Responsibility Plan ● Developing Quality Systems in Food Plant Operations ● Quantifying Your Energy Inputs ● Improving Packaging Line Efficiency Via Robotics, Machine Control and Changeover Speed

PRODUCED BY

WWW.FOODAUTOMATIONCONFERENCE.COM

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].

AUCTION

AUCTION ALL NEW & INSTALLED 2008 WESTERN DAIRY SPECIALISTS AUCTION: Dec. 1 - Reno, NV area

Complete Facility also Available as Turnkey Operation! • (10) All S/S Silos 10,000 to 60,000 Gal. • (2) Uniloy R2000 6-Wide Blowmolders • Tetra-Pak HMRPX618 Separator • Tetra-Alex Model 400 Homogenizer • Tetra-Pak 7,500 GPH HTST System • Tetra-Pak Skim Milk R/O System • Serac ESL Filler & Dimac Bundler • Robot Palletizer - Material Handling • (3) Vilter Skid-Mounted 300 hp Refrig. Compressors, (3) Evaporative Condensers

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 for more information.

SOFTWARE

www.harrydavis.com

HARRY

DAVIS & COMPANY

Visit Our Web Site for Details & Online Bidding! Call for Color Brochure

412-765-1170

SERVICES

X-RAY INSPECTION SAVE YOUR PRODUCT AND YOUR GOOD NAME HACCP Compatible solution for detecting foreign particles in your product.

• Metal • Stone • Glass • Plastic • Bone • Rubber

FAST RESPONSE FREE TESTING

Call CXR COMPANY • Warsaw, IN 800-817-5763 • fax 574-269-7140 www.cxrcompany.com 152

Dairy Foods | January 2011

Owl

Software Program Product Development Nutrition Labeling Reformulation Least Cost Formulation Batching Reverse Engineering

Software Toll Free: 888.621.9063 573.442.4126 Fax: 815.301.9103 www.owlsoft.com [email protected]

Advertise in our Classified Section. Contact Suzanne Sarkesian at 248-786-1692 or check out www.dairyfoods.com!

EQUIPMENT FOR SALE

PRODUCT SAVER The Unpackager.... Reclaiming Machines.... Product Saver technology differentiates our system from all the rest. Our high throughput design will process products quickly and efficiently. Compacted containers are product-free. Reclaims products from off-spec packaging. Will process free-flowing liquids and viscous products. Powder reclaim systems available as well. Free product testing and demos.

Product Saver 40A Stonehill Road, Oswego, IL 60543 • T: 800-547-9370 • F: 630-554-7805 E-Mail: [email protected] • www.productsaver.com

ANDERSON ICE CREAM FILLER PARTS 5/27/09 TDSawvel0609.indd 1

1:33:09 PM

OVERHAUL TECH SUPPORT FOR ANDERSON & WCB FILLERS 56OZ 456N 456-1 555-4 588 64OZ CLUTCH REBUILDING SERVICE OVER 25 YEARS EXPERIENCE

Ser v ing Wit h

STOMBERG PACKAGING

Pride Since 1

94 6

6396 Myrtle Lane Rockford, IL 61108 CALL 815-226-0843 FAX 815-229-8430

BLOW MOLD TRAINING Need Training? Call the Doctor! BRUCE MEYER - Blow Mold Engineer P.O. Box 1373 Huffman, TX 77336 Ph/Fax: 281-324-5031 Cell: 281-831-2072 www.blowmoldtraining.com • [email protected]

dfx0310Class-Blowmold.indd

1

2/8/10

EMPLOYMENT

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 8:55:23 AM 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

HTTP://WWW.JUDGEINC.COM www.dairyfoods.com

153

EQUIPMENT FOR SALE

NEW & USED CARTS 80 G A L B O S S Y S 120 G A L B O S S Y S WHEEL CARTS • 4 WHEEL CARTS FOLD-UP CARTS Z I N C P L AT E D • S TA I N L E S S S T E E L FOLDING • RIGID

SQUEEZE YOUR WASTE INTO PROFITS!

THE PYTHON SEPARATOR It opens, empties, and compacts containers of dairy products and juices.

www.pythonseparator.com CALL today for a competitive quote!

McClaren Machine and Tool, LLC 202-17th St., Brodhead, WI 53520 P: 608.897.4017 • F: 608.897.2958

Great Lakes Separators Now Available: Reconditioned ALFA-LAVAL and WESTFALIA Separators Consultants: Dick Lambert, Rick Veneer and Bill Gooderham

MILK BOSSYS

Call Dave Lambert (920)863-3306

ICE CREAM DOLLY FOLD-UP CARTS

“The Original Ice Cream Dolly” els New Mod in Available e! id Tall and W • Many Models Available • All Models Foldable • Lightweight / Heavy Duty

A&E Aluminum Products, LLC (800) 444-8969 • (410) 620-3915 Fax: (410) 620-3917 www.Aluminumcarts.com Contact: Pat Brown All major credit Cards Accepted

WANTED TO BUY

3 WHEEL CARTS

Many Different Used and New Items Available Call or Write for Free Catalog!!

LOWEST PRICES EVER Cart - Mart

A Division of Matco P.O. Box 686 • Itasca, IL 60143

C ALL D ENNIS D ORAN 1 - 8 0 0 - 62 8 - 3 1 8 3 OORR 630-539-1195 630-628-6655 FAX 630-628-6855 630-604-0349 WEBSITE: martforcarts.com

Advertise in our Classified Section. Contact Suzanne Sarkesianat 248-786-1692 or check out www.dairyfoods.com! 154

Dairy Foods | January 2011

Ad Index

Company Name

Page No.

Company Name

Page No.

ADI Systems Inc.

47

H.S. Crocker Company, Inc.

117

ADM Cocoa

69

Harpak, Inc.

141

Admix, Inc.

92

Heat and Control

129

Ampco Pumps Co.

19

International Dairy Foods Association

79,143

Aseptomag

25

iTi Tropicals

16, 36

ATS Engineering, Inc.

11

Marketplace

29

Autocrat Premium Coffee & Syrup

67

MasoSine

55

Bentley Instruments

12

Matsutani ADM

Blue Print Automation

139

MilkPEP

63

California Custom Fruits & Flavors

41

Mintel International

77

Cargill Salt

75

NAVBIA

31

CEM

81

Neogen

53

Chr Hansen, Inc.

5

Robert Reiser & Co.

119

Cognis Nutrition & Health

49

Rocket Products, Inc.

103

Curwood

83

Roquette America, Inc.

57

Danisco USA Inc.

65

S&D Coffee

101

Delkor Systems, Inc.

BC

Sensient Food Colors

23

Donaldson Company, Inc.

109

SensoryEffects

15

DSM Nutritional Products, Inc.

39

Separators, Inc.

37

EFCO Products Inc.

51

Sidel

95

Eriez Magnetics

121

Spraying Systems Co.

135

Evergreen Packaging Equipment

21

SPX Flow Technology Segment

IBC

Federal Mfg. Co.

97

Stanpac Inc.

147

FOGG Company

33

Sudmo North America, Inc.

35

Fortress Technology

131

T.D. Sawvel Co. Inc.

99

Foss North America

111

Tetra Pak, Inc.

113

Fristam Pumps, Inc.

6

Thermo Fisher Scientific

133

Fruitcrown Products Corp.

89

TIC Gums

85

GEA Niro Soavia NA

123

Tindall Packaging, Inc.

149

GEA Process Engineering, Inc.

IFC

Tygard Machine & Manufacturing Co.

32, 46

GEA Tuchenhagen North America

59

Union Pacific

90, 91

GEA Westfalia Separator, Inc.

43

Urschel Laboratories, Inc.

9

Gertrude Hawk Ingredients

71

Weber Scientific

17

44, 45

www.dairyfoods.com

155

Inside Perspective

Rediscovering Protein, A Healthful Dairy Nutrient rotein is getting a fresh look in nutrition circles and it’s catching on with consumers. Long a key nutrient in the health portfolio of milk and dairy foods, a plethora of studies on protein drinks and supplements are creating considerable attention for protein’s ability to control appetite, optimize muscle mass and help with blood glucose control, weight management, sports recovery and even bone health. Consumers are reacting by increasing their protein intakes and seeking out products that boast high-quality protein, such as whey. Approximately one half of Americans say they are trying to consume more protein, according to the 2010 Food and Health Survey conducted by the International Food Information Council.

For “Health Connections,” we recently discussed this with Douglas Paddon-Jones, with the Department of Physical Therapy and Internal Medicine at the University of Texas Medical Branch, Galveston. According to Paddon-Jones, the problem is that we take in more than the Recommended Daily Allowance for protein during certain meals— typically dinner. His research shows that about four ounces of high-quality, protein-rich food

Expanding our thinking of protein There are a couple of shifts occurring that provide vast potential for future milk and milk-product education and marketing efforts. According to Dairy Council of California’s “Health Connections” newsletter editor Mary Jo Feeney, the first shift is the rethinking of protein as a macronutrient (an essential nutrient required in large amounts for optimal health). For the first time, the 2010 Dietary Guidelines Advisory Committee looked at the relationship between protein and health outcomes. Past committees did not consider protein separately because average protein intake was considered adequate. With obesity continuing to be a public-health challenge and with new research demonstrating the array of benefits of protein, the role of high-quality protein in weight loss is getting a second look. Another shift comes from research that recommends spreading protein intake throughout the day and consuming approximately equal amounts at each meal rather than our current habit of “end-loading” our day with protein, or eating most of our daily protein at dinner.

is the maximum amount of protein that can be used by the body at one time. Exceeding this amount, which we inevitably do with end-loading, is like “trying to put 90 gallons of fuel into a 30-gallon tank – it spills over.” Shifting some of the protein consumed at dinner throughout the day’s meals and snacks will help optimize the potential for muscle growth and other benefits. Distributing protein intake throughout the day is an opportunity for milk and milk products as it could lead to some dietarypattern changes as consumers incorporate more high-quality protein foods, such as milk, yogurt and cheese, into their breakfast and lunch meals.

P

156

Dairy Foods | January 2011

Peggy Biltz

• Average protein intake in older adults is much lower than in younger adults. • Across ages and gender, animal sources of protein provide at least 60% of total protein intake, with milk and milk products being the biggest provider of animal protein. • Participants who took in more protein from animal foods were more likely to meet the protein recommendations.

Studies of protein drinks and supplements show protein’s ability to control appetite, optimize muscle mass and help with blood glucose control, weight management, sports recovery and bone health.

The primary source of animal protein Seeing the potential in a fresh positioning for protein, Dairy Council of California teamed with the Food Science & Nutrition Department at California Polytechnic State University, San Luis Obispo, to conduct targeted research to quantify protein intakes in adults, identify primary sources of protein and assess daily patterns of protein intake. Here are a few of the key research findings:

• The distribution of protein throughout the day was not optimal, with intake at dinner making up about one-half of total daily intake. This research presents opportunities to encourage higher protein intakes, especially in older adults who may not be meeting their needs; to highlight the importance of dairy foods as a primary source of highquality protein; and to work with consumers to optimize their protein intakes throughout the day. Protein is one of many nutrients found in milk and milk products that contribute to optimal health. It is important as an industry that we take what we learn from research and pass it on to the consumer. The staff at Dairy Council of California does this daily through our school and health professional nutrition education programs, and online through our websites, social and traditional media channels. Together, we should look for opportunities to put a fresh face on protein as a superstar dairy nutrient.  Peggy Biltz is chief executive officer of the Dairy Council of California, Sacramento, Calif.

SUPPLIER CAPABILITIES SPOTLIGHT

Delkor Systems, Inc. Delkor Systems, Inc, (Minneapolis, MN) has long been known outside the dairy industry as one of the leading manufacturers of cartoning equipment. The company has a wide range of equipment designs specifically engineered for topload cartoning applications, accounting for approximately 40% of Delkor’s new machinery sales. At the September 2010 International Dairy Show in Dallas, Delkor demonstrated its cartoning line for a tube yogurt application.

The line consists of three

separate machines. The first is Delkor’s Trayfecta® carton former, which is an all servo design that forms either paperboard or corrugated cartons by either glue or lock-style. The formed carton then moves to the Delkor loading device, which for tube yogurt is a custom design that links directly to the filler, and is able to load a variety of pack patterns and flavor combinations at speeds up to 60 pack patterns per minute.

The loaded tube yogurt car-

ton then moves into Delkor’s Capstone carton closer, which incorporates Delkor’s patent pending Intelligent Positioning technology.

As the carton moves into

the closer it is analyzed by the Intelligent Positioning controls for a deviation in carton position. If a deviation is present, the carton closer is able to make the precise correction on the individual carton, even at speeds up to 150 cartons per minute.

is particularly well suited to Retail Ready

within the dairy industry are forming a

as it is capable of forming a wide range of

display tray for dairy cups or case form-

either corrugated or paperboard display

ing of the top-load flange-seal case, which

trays.

offers the same corrugated footprint as a

In many cases the Trayfecta for-

mer can be added to an automated case

wrap-around case.

packer or Spot-Pak® packaging line as a

change-over design of the Trayfecta, it

Retail Ready option.

can convert from one package format in

Two of the most

popular uses for the Trayfecta former

Due to the tool-less

just a couple of minutes.

No other carton closing machine in the world has this capability. Other dairy industry applications for Delkor’s cartoning line include a variety of ice cream novelty as well as Retail Ready applications. The Trayfecta former

www.dairyfoods.com

157

SUPPLIER CAPABILITIES SPOTLIGHT

SPX Flow Technology

APV is globally recognized for providing high quality process engineering solutions and helping customers improve their plant’s performance and profitability. Equipment options include a range of homogenizers, plate heat exchangers, pumps, valves and process systems.

(SSHE) technology and continuous butter and emulsification equipment. Supplying plants ranging from individual machines Anhydro combines a total of more than

to complete process lines, GS equipment

250 years of specialization and experi-

designs are the fruit of intensive develop-

ence in evaporation, drying and dewa-

ment and continual refinement, result-

The Waukesha Cherry-Burrell brand

tering equipment for the dairy, food and

ing in top quality systems that help you

enjoys a rich history of process innovation

beverage, brewery, chemicals, starch and

process the widest range of products and

and application expertise.

pharmaceutical industries. Anhydro sys-

increase your competitive edge.

includes positive displacement pumps,

Equipment

tems and equipment are renowned for

centrifugal pumps, mix proof and single

their design, engineering, process qual-

seat valves, fittings and Votator brand

ity and efficiency. Spanning from spray

scraped surface heat exchangers.

dryers, fluid bed and tube bundle dryers to evaporators, presses and brewery conveyors, customers have a wide range of flexible and fully customizable solutions to choose from. With over 85 years of experience in mixing technology, process knowledge and brand innovation, the LIGHTNIN brand enjoys a global reputation for durable, long-lasting mixers, agitators, aerators, and flocculators for fluid process systems and offers a full spectrum of impeller designs for

158

SPX Flow Technology 611 Sugar Creek Road Delavan, WI 53115

The Gerstenberg Schröder (GS) brand is

diverse applications. In addition, a world-

internationally recognized for high qual-

wide service network for mixer & gearbox

www.spxft.com

ity food processing equipment. GS spe-

repair including a replacement parts pro-

tel: 800-252-5200

cializes in scraped surface heat exchanger

gram is also available.

fax: 262-728-1904

Dairy Foods | January 2011

$"4&
1"$,*/(
8*5)
3&5"*-
3&"%:

"5

:063
$0.."/%

%FMLPST
$BTF
1BDLJOH
TPMVUJPOT
QSPWJEF
VOJRVF
áFYJCJMJUZ YJCJMJUZ With today’s rapidly changing retail environment one cannot afford ford to have a packaging line that only produces one package style. A Delkor case packer is designed with the versatility to run a variety of package formats, s, including Retail Ready . . . all with tool-less change-over.

8F
FOHJOFFS
PVS
NBDIJOFT
UP
QSPUFDU
ZPVS
JOWFTUNFOU NFOU

F.P.O

To see it in action, visit delkorsystems.com/retail-ready-packaging.html

packaging innovation at work.

T

' 0 3 . * / (
r
- 0 " % * / (
r
$ - 0 4 * / (




800-328-5558 delkorsystems.com