Dairy Foods May 2011

INSIDE DIPPIN’ DOTS | NON-DAIRY BEVERAGE TRENDS | IFT SHOW PREVIEW

May 2011

Innovative Ideas for Dairy Processors

Functional Ingredients

Sustainable Practices

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May 2011 Vol. 112, No. 5

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

Non-dairy Beverage Flavors Whether it’s an exotic juice, flavored tea or an energy drink, today’s non-dairy beverage makers give dairy processors some ideas about ingredient and flavor trends. p. 38

Functional and Sustainable Ingredients On our cover: Flavors and ingredients are themes in this month’s issue. Cheese is an ideal vehicle for flavors, like herbs and seeds. These days, cheesemakers seek to reduce sodium without compromising the taste or shape of cheese. This month we write about flavors (see page 26), ingredients (page 46) and the IFT Food Expo (page 58). On page 110, Kraft’s Nigel Kirtley writes about the challenge of sodium reduction. The cover photo is courtesy of DCI Cheese Co., Richfield, Wis.

Better-for-you and better-for-the-environment are two themes driving innovation. Dairy products are being enhanced with antioxidants, including carotenoids, polyphenols (for example anthocyanin, flavonoids and resveratrol) and vitamins. p. 46

IFT Show Preview The world’s largest annual food science forum and exposition, the IFT 11 Annual Meeting + Food Expo, runs from June 11-14 in New Orleans. p. 58

Features News & Trends 10 Newsline Re-writing milk pricing rules; marketing efforts of Nesquik, Laughing Cow and Kraft; concerns about the dairy import tax; FDA’s new website

Products & Marketing 20 Dairy Market Trends

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Cottage cheese, sour cream and yogurt

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New Product Review Ready-to-drink tea

Departments 8 16 19 96 102 104 109 110

Ingredient Technology

Editorial People Supplier News Equipment Showcase: Caps and closures Buyers Mart Classified Ads Index of Advertisers Inside Perspective

Ingredient Technology Ethnic flavors are mainstream

30

Wellness Watch Formulating for children

34

Culturally Speaking Cultured dairy in the school lunch

REPORTS

69

Dippin’ Dots At its 120,000-square-foot facility in Paducah, Ky., Dippin’ Dots produces more than 40 varieties of ice cream, ice cream cakes, sherbet and flavored ice. In May, it launches frozen yogurt dots for franchisee and foodservice accounts. Long a favorite snack in sports arenas, the ice cream is now sold at retail.

84 Behind The Scenes 88 Labeling 94 Beyond The Filler

Kosher Pareve Gelatin for Dairy Applications A special advertising supplement by Geliko LLC begins after page 11.

Nigel Kirtley of Kraft Foods meets the challenge of sodium reduction. DAIRY FOODS Volume 112, Issue 5 (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].

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May 2011 Vol. 112, No. 5 www.dairyfoods.com

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Dairy Foods | May 2011

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From the Editor’s Desk

Dairy Cleans Up airy processors and the foods they make have a pretty good reputation for safety and cleanliness. Aside from news articles about illness traced to consumption of raw milk, recalls of pasteurized fluid milk are not common. Drinking raw milk can be dangerous, especially when the product is mishandled by the purchaser. Consumer concerns about food safety are real, and every food manufacturer needs to address these worries. The news last month about the adverse effects of pesticides in foods must have given food processors and retailers pause. In case you missed it, three new studies concluded that pesticides used in food production and around the house might affect the brains of babies whose mothers were exposed to the chemicals during pregnancy. The study revealed that the most exposed children showed a seven-point-lower IQ than children who were least exposed. Some researchers said the harmful effects of pesticides were similar to lead poisoning. Consumers are also worried about adverse effects of artificial food colorings, although the Food and Drug Administration (by an 8 to 6 ruling) said warning labels are not needed. What can dairy processors do? Start with clean ingredients, for one thing. Processors know that consumers like milk from cows not given the bovine growth hormone rBST. So they state their use of rBST-free milk on milk, cheese and yogurt packaging. Last month the Organic Trade Association said sales of organic dairy products grew 9% from 2009 to 2010 (to $3.9 billion), and captured nearly 6% of the total U.S. market for dairy products. Sales of organic fruits and vegetables grew the most, 11.8%. Consumers will pay for organically produced foods. The share of market is small, but the point is that sales are growing. Clean food starts with the raw material and carries through to production. But that’s hardly the end. Processors and distributors have to transport food safely to warehouses and retail locations, where it must be handled properly. The final link

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Dairy Foods | May 2011

Jim Carper

is the consumer who must be schooled on safe-handling practices in the home. Good manufacturing practices Dairy processors do operate clean plants. At the Wisconsin Cheese Industry Conference in La Crosse, Wis., a speaker said food safety is better than it ever has been, but inspectors are also getting better. The bar is rising and plant managers need to know best practices.

Pure, unadulterated milk Personally, I like my yogurt plain. It’s full of naturally occurring protein, calcium and vitamins. I wonder why others opt for yogurt filled with sugar and fruit. Why would someone choose a perfectly healthy, natural food that’s junked up with additives? It makes me think of the Wisconsin Dells, a beautiful natural area that is overdeveloped with motels, outlet malls, go-cart tracks and waterparks.

Clean ingredients. Clean facilities. Clean labels. This is your business. These are stories for you to tell. “Food safety should not be a competitive advantage,” said one speaker, who encouraged plant managers to share their knowledge. Representatives from the Global Food Safety Initiative talked about why GFSI certification is important, not only from a food-safety perspective, but also from a business point of view. Retailers want assurances that food manufacturing facilities are up to snuff. Plants are audited constantly; one manager said he averages more than one inspection a month. If retailers and other stakeholders could get behind one certification standard, if would simplify matters for dairy processors. I heard that parties are working toward this. The Food Safety Modernization Act now gives the Food and Drug Administration the power to issue a food recall. Previously, the FDA could only encourage manufacturers to recall unsafe foods. At the conference, I heard the story of a cheesemaker who (prior to enactment of the FSMA) refused to recall cheese contaminated with E.coli. Rather than cooperate with the FDA, the processor dug in its heels. The FDA responded by ordering a full-scale investigation of the plant, where it found dozens of unsafe practices. Conference speakers talked about the importance of developing a cooperative (not combative) relationship with the FDA. Use that relationship to educate FDA inspectors.

Some people can’t leave well enough alone. They cannot enjoy nature without a nearby Ye Olde Fudge Shoppe. Others cannot enjoy yogurt without fruit on the bottom and whoknows-what-else. Chacun à son gout. Besides clean ingredients and good manufacturing practices, a processor needs marketing. To sell cheese, you need taste and a story, says H. Hulst, an executive with Cono Kaasmakers (cheesemakers), a Netherlandsbased dairy cooperative that sells its cheese in the United States under the Beemster brand. Part of Cono’s story is its ethical treatment of dairy cows, says Hulst, who was a featured speaker at the Wisconsin cheese conference. The co-op pays a premium to farmers who graze their cows outdoors. (That scores points with the ethical-treatment-ofanimals crowd.) Another part of the story is the sweetness of the grass the cows eat. Hulst said he believes the composition of the soil in the polders (reclaimed marshland) gives the grass a better taste, and hence the milk. The polder is a UNESCO World Heritage site. If my product was linked to such a site, I’d include that in my story. Wouldn’t you? Clean ingredients. Clean facilities. Clean labels. This is your business. These are stories for you to tell.  Jim Carper is chief editor of Dairy Foods. Phone: 847-405-4009. Email: [email protected].

News & Trends

NEWSLINE... Milk Pricing Arguments Get Frothy ith Congress scheduled to take up a farm bill in 2012, milk producers and processors have ramped up their calls to reform pricing policies. The white papers (and rebuttals) started circulating last autumn. This year, the battle of ideas kicked into a higher gear. In her keynote address at the Dairy Forum in January, International Dairy Foods Association president and CEO Connie Tipton said, “We steadfastly continue to believe that dairy policies and programs should be consistent with enhancing demand rather than controlling prices and supply.” Then in April, IDFA’s three constituent organizations (the Milk Industry Foundation, the National Cheese Institute and the International Ice Cream Association) voted to support its dairy policy reform recommendations and to oppose the National Milk Producers Federation’s dairy policy package. “IDFA’s plan offers an alternative path forward that would not limit milk supply through a new mandatory government program, and will give dairy farmers the tools they need to manage volatility,” Tipton said. NMPF, Washington, D.C., represents the dairy farming community. Its Foundation for the Future is a “multi-faceted approach” that would replace “existing federal safety

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net programs with a new Dairy Producer Margin Protection Program to protect against both severe and unsustainable loss of margin; establish a Dairy Market Stabilization Program to help address imbalances that can negatively impact producer margins and reform the Federal Milk Marketing Order system,” said the organization’s Christopher Galen, senior vice president for communications. The U.S. and global economic collapse of 2008 and 2009 pushed milk pricing issues to the fore. Farmers’ costs for producing milk exceeded the price they could get for it. While prices have improved since then, both NMPF and IDFA agree that volatility is here to stay and that producers need to be protected. IDFA is pushing risk insurance as a solution and NMPF proposes a margin insurance program. A meeting of the minds In January 2010, agriculture secretary Tom Vilsack appointed 17 members from the producing and processing communities to the Dairy Industry Advisory Committee to review the issues of farm milk price volatility and dairy farmer profitability. In March 2011, the committee submitted its report containing 23 recommendations, most of which received widespread (in some cases unanimous) support from committee members.

Two Perspectives The International Dairy Foods Association would: • Replace the Dairy Product Price Support Program (DPPSP) and Dairy Export Incentive Program (DEIP) with better risk management tools for producers. • Strengthen dairy risk management tools, including forward contracting, the Livestock Gross Margin-Dairy program, catastrophic margin insurance for all dairy farmers and taxdeferred farm savings accounts. • Simplify the Federal Milk Marketing Orders program. The National Milk Producers Federation’s Foundation for the Future would: • Replace existing federal dairy support programs. • Introduce a new margin protection program to protect producer equity. • Reform milk pricing regulations set by the Federal Milk Marketing Order System. • Implement a stabilization program to address market imbalances. Sources: International Dairy Foods Association, National Milk Producers Federation

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Dairy Foods | May 2011

But the most contentious of the recommendations was the one calling for a growth management program. It passed nine to eight, with every processor member voting against it. DIAC’s report stated the committee “is not prepared to endorse a specific plan, however, we agree that a primary challenge in taming milk price volatility is to better coordinate milk marketings with milk usage over time. We do not agree on whether this should be a public or a private endeavor.” The report states: “The most compelling justification for a federal program to help the dairy industry better align milk production growth with growth in demand is that experience has amply demonstrated that, in the short run, milk prices can rise or fall dramatically when supply and demand are not aligned. Hence, if we could anticipate periods of excess supply, we might avoid or minimize the resulting drop in prices.” But the report also acknowledges: “For some, a federally mandated effort to intervene in the individual production decisions of a farm business is categorically unappealing or unacceptable. Other critics have concerns that a federal program would be very difficult to run efficiently and effectively.” Reforming the milk orders IDFA and NMPF agree that the Federal Milk Marketing Orders needs reforming. Rather than end the FMMO, NMPF said it wants to “mend” it by shrinking class prices from four to two, and eliminating the concept of end-product pricing for milk in manufactured products. IDFA would like to see the Livestock Gross Margin-Dairy (LGM-Dairy) program be made more accessible with higher funding limits. Few farmers participate in LGMDairy because they are not encouraged to do so, IDFA said. Whether a bill gets written in 2012 remains to be seen. Some observers say that next year’s presidential election campaigning could divert attention away from a farm bill. In that case, look to 2013. — Jim Carper, chief editor

News & Trends

Dairy Brands Turn to Bunnies, Laughing Cows and Baseball The Nesquik bunny will be hopping onto housewares by the end of the year. Nestlé Glendale, Calif., signed a licensing agreement with Evriholder Products, Anaheim, Calif. The deal covers licensing in the United States and its territories. Laurelle Widgerow, an assistant marketing manager with Evriholder, told Dairy Foods that specific products and number of SKUs have not yet been determined. The licensing group’s strength is in the food-storage category, she said, especially with sandwich containers and thermoses. Widgerow says the items are expected to roll out in the supermarket channel the third or fourth quarters of this year. The licensed products will be merchandised on clip strips and on counter and floor displays near Nesquik-flavored milk powder, syrup and ready-todrink products. Evriholder develops and manages licensed products for other food brands, including Campbell’s, Kellogg’s and Pepperidge Farm. The Laughing Cow, a unit of Bel Brands USA, Elk Grove Village, Ill., announced in April that it will donate at least $250,000 and as much  Look for the Nesquik bunny to appear on housewares later this year.

as $500,000 to support health and wellness initiatives at YMCAs throughout the United States. The brand launched the Life Well Laughed Project on April 1; it runs through July 15. Laughing Cow will donate $1 for each UPC code from Laughing Cow cheese wedges or Mini Babybel cheese entered at www.LifeWellLaughed.com. The company positions the individually wrapped cheeses as portion-controlled snacks. BelBrands USA is a subsidiary of Fromageries Bel, Paris. Fans of minor league baseball and Kraft Singles American cheese can double their fun this summer. The Tuesday  The Laughing Cow Night Tickets promotion delivers one announced its Life Well free ticket with the purchase of a ticket Laughed project in freeand the redemption of any Kraft Singles standing inserts. package wrapper at the box office. The plastic wrappers are collected by TerraCycle and made into consumer products. This is the third season of the promotion by Kraft Foods, Northfield, Ill. It said that in 2010, wrapper redemption increased 43% compared to 2009. The promotion runs through Sept. 6. Continued on page 12

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WA S H I N G TO N WATC H

News & Trends

IDFA CEO Expresses Concerns over New Dairy Import Tax Connie Tipton, president and CEO of the International Dairy Foods Association, Washington, D.C., expressed concerns about the impact Tipton that the implementation of controversial new assessments on dairy imports will have on trade. “We trade with more than 150 countries and continually advocate for open markets and trade policies that comply with international laws,” Tipton says. “This international tax does not help expand our U.S. dairy export markets and has been widely opposed by our trading partners.” The Obama administration reversed a Bush administration decision when the U.S. Department of Agriculture, Washington, D.C., announced the final rule on the establishment of a dairy im-

port assessment. The program was first authorized in the Farm Security and Rural Investment Act of 2002 (2002 Farm Bill) and later amended in the Food, Conservation and Energy Act of 2008 (2008 Farm Bill), with clear instructions from Congress that the program was not to be implemented if it did not comply with U.S. trade obligations. “With this decision by USDA, we are concerned about how other countries will respond to our dairy exports once they become aware of the extra administrative burden and cost with limited or no benefits,” says Tipton. U S DA will now collect 7.5 cents per hundredweight on imported dairy products and other foods with dairy ingredients, including cocoas and dough. The money collected by the government will be turned over to an advertising and promotion program

currently operated and funded by U.S. dairy farmers. The new rule stipulates that, because importers are adding funding to the program, USDA will require U.S. dairy producers and importers to jointly develop programs to build demand for imported dairy products and dairy ingredients. “It’s unclear to us why dairy producers are willing to promote dairy imports at a time when U.S. dairy imports are declining and our U.S. exports are growing,” says Tipton.

Continued on page 14

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Dairy Foods | May 2011

KOSHER

CREATIVELY

A SUPPLEMENT TO

BY DONNA BERRY PRODUCT DEVELOPMENT EDITOR, DAIRY FOODS

Increased consumer interest in kosher foods drives suppliers to scale-up kosher production of specialty ingredients, such as beef gelatin, an ingredient long sought by product developers.

Photo courtesy of Chick-fil-A

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rompted by concerns for health, quality and safety, Americans of all races and creed are turning to kosher foods, as such products have gained the reputation of being more carefully produced, thoroughly inspected and fully traceable. Further, due to clear labeling practices of kosher food, consumers who

have food sensitivities or allergies to certain ingredients are relying on this market to monitor their diets.

THE KOSHER CONSUMER In a consumer survey of adults who purchase kosher food, Chicago-based market research firm Mintel found that the numberone reason people buy kosher is for food quality (62%). The sec-

son ond most common reason ness is general healthfulness (51%) and the third is food rasts safety (34%). This contrasts sharply to the just 14% of respondents who say theyy puruse they chase kosher food because us rules. follow kosher religious Another 10% buy kosherr because they follow some other religious rules with eating restrictions similar to kosher.

With these beliefs, it’s no wonder dollar sales of kosher foods are projected to more than

www.geliko.com • Creatively Kosher

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double from 2003 ($7.6 billion) to 2013 ($17 billion), according to Mintel. “Consumers are happy when they can clearly see what they are going to get,” said Marcia Mogelonsky, senior research analyst for Mintel. “With recent food safety scares causing people to rethink even the most familiar food products, we can expect more adults to turn to kosher food as a way to ensure food safety and quality.

“Vegetarians and healthconscious consumers are also inf luencing the kosher sales numbers,” she says. “There is a major opportunity for kosher manufacturers to build sales within this category. This category is positioned to build, specifically as sales of organic and health-oriented foods continue to rise. Due to increased awareness of food safety and preparation procedures, more consumers feel that specific ko-

sher products are more healthful than their mainstream, non-kosher counterparts.” Rabbi Dovid Jenkins, a rabbinic coordinator with the Orthodox Union (OU), New York, the world’s largest and most respected kosher certification agency, explains that part of the appeal of kosher is the strict guidelines kosher manufacturers must follow to ensure cleanliness, purity of ingredients and safety.

“Kosher food manufacturing is supervised by a rabbi and includes examination of all ingredients as well as processing and packaging equipment,” he says. “The OU’s standards are extremely rigorous. In fact, a food can be denied kosher certification when a single non-kosher ingredient is present, even if that ingredient is only one-tenth of one percent of the whole product. “In order for a food, beverage or supplement to be OU-

GELATIN FUNCTIONALITIES

USAGE LEVEL*

BEVERAGE

Juice

Removal of turbidity; brilliant clear

0.002% to 0.015%

Smoothie

Provides smooth mouthfeel; thickener

1.0% to 10.0%

Wine W

Removal of turbidity and tannins

0.002% to 0.015%

Gummy candy W

Provides smooth texture and mouthfeel; has a delicate chew; thermoreversible gel melts in the mouth; excellent clarity; neutral color and taste; assists in flavor release

5.0% to 9.0%

Marshmallow

High-degree of gel firmness; good foam formation and stabilization; thermoreversible gel melts in the mouth

1.5% to 2.5%

Nougat

Good foam formation and stabilization; thermoreversible gel melts in the mouth

0.2% to 2.0%

Ice cream W

Binds water; controls size and distribution of ice crystals; stabilizes overrun

0.1% to 1.0%

Yogurt

Binds water; prevents syneresis; contributes to slippery mouthfeel

0.2% to 1.0%

Gelatin W

Thermoreversible gel melts in the mouth; excellent clarity; neutral color and taste; assists in flavor release

1.5% to 2.5%

Mousse/pudding

Good foam formation and stabilization; thermoreversible gel melts in the mouth; prevents syneresis

0.5% to 2.0%

Aspic

Gelling agent

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Low-fat luncheon meat

Water-binding; fat replacement

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Sausage W

Coating; adhesive agent

MEAT

DESSERT

DAIRY

APPLICATION

CONFECTION

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1.0% to 5.0% * Usage level is dependent on grade of gelatin and desired texture in final product.

Gummy Candy photo courtesy of National Starch. Yogurt photo courtesy of Angela McKeller. Gelatin photo courtesy of Superfos. Sausage photo courtesy of Linkery.

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Creatively Kosher • Geliko Kosher Gelatines

GELATIN — AN IRREPLACEABLE HYDROCOLLOID G

certified kosher, all of the ingredients must be OU-certified,” he adds. “Our clients have told us that the OU symbol gives them a competitive edge in the crowded marketplace. The cost of kosher certification is minimal when compared to the return on investment, as some products have experienced as much as a 65% increase in sales after certification.” The impressive aforementioned data are driving many food manufacturers to revisit product formulations that do not qualify for OU-certified kosher. In many instances, there might be only one ingredient preventing a fi nished product from being certified kosher. When the food was originally formulated, a kosher version of that ingredient may not have been available. Today, suppliers that anticipated the boom in kosher foods have identified processing technologies to industrialize production of kosher specialty ingredients. One such company is New York-based Geliko LLC, a global leader of OU-certified kosher gelatin and gelatin hydrolysate.

KOSHER GELATIN DEBUTS Product developers know that no single ingredient can replace the functional characteristics

G Globally recognized as a safe and highly functional natural ingredient, gelatin has been used for centuries as a means to gel and thicken foodstuffs. (See chart for key applications and functionalities.) ri Gelatin ingredients are made from the connective tissue of mammals. Connective tissue, also called collagen, is the structural protein found in bones and skin. Commercially available edible gelatin is 84% co to 90% protein, 8% to 12% water and 2% to 4% mineral salts. As an ingredient, gelatin is characterized as a hydrocolloid, a term that refers to a range of polysaccharides and proteins that emulsify, foam, gel, stabilize, thicken, inhibit ice crystal formation and even control the release of flavors. Their primary function — binding water — is alluded to in the name, where the prefix “hydro” means water and “colloid” means a gelatinous substance. Hydrocolloids do not lower water activity, so they do not have an effect on microbial activity, but they have a huge impact on texture and stability. Almost all processed foods rely on one or more hydrocolloids. “Some hydrocolloids, such as Geliko Kosher Gelatin, form thermoreversible gels, where gelation occurs after the hydrocolloid dissolves in solution and is cooled. When heat is applied, the gel melts or dissolves. This is best exemplified by gelatin dessert, which melts in the mouth at body temperature,” says McKibbin. Gelatin is tested and graded according to the strength of the gel it produces upon dissolution in water. The grade is based on the Bloom Test, with the more rigid the sample, the higher the Bloom number and grade. The Bloom number of commercially available edible gelatins is between 80 and 280. “There are other hydrocolloids that form non-thermoreversible gels. In other words, once the gel is formed, there is no going back to liquid form,” says McKibbin. “Some hydrocolloids form no gel at all, such as Geliko Kosher Gelatin Hydrolysate. These hydrocolloids are excellent binders and thickeners.” Gelatin hydrolysate is produced from the same raw materials as gelatin, and has the same regulatory status and nutritional value. The differences occur during processing. “Whereas gelatin is obtained by the partial enzymatic hydrolysis of collagen, gelatin hydrolysate results from the complete enzymatic hydrolysis of collagen,” says McKibbin. “The end result is an ingredient with different application and functionality.” In addition to extensive use in the food and beverage industries, gelatin ingredients have a long history in the pharmaceutical industry, as gelatin encapsulates and protects a variety of prescription and over-the-counter capsules. Further, select gelatin ingredients are now being used in the cosmetics industry in products that claim to protect skin, hair and more. And, research suggests that gelatin ingredients, in particular gelatin hydrolysate, when consumed orally, can help treat bone and joint discomfort.

of beef gelatin. (See sidebar on gelatin’s functional attributes.) Yet, many have historically foregone use of this label-friendly ingredient in order for a product to be OU-kosher certified, as the ingredient was not available. With industrial-scale commercial production now underway for Geliko, product developers no longer need to compromise quality for OU certification. “We believe kosher gelatin was the piece of the puzzle preventing many products from being OU certified,” says Zach Rubin, president and CEO of Geliko.

Rubin explains that gelatin is derived from collagen, a substance found in the skins and bones of animals. “Standard beef gelatin is produced from the trimmings and splits of cattle purchased in bulk from leather processors. To make our

kosher gelatin, we source the entire hide from cattle that has been slaughtered and certified kosher following the strictest kosher guidelines.” “Purchasing the entire hide ensures full traceability and eliminates the chance of non-

The Orthodox Union was founded in 1898 and today is the world’s largest, most respected kosher certification agency. The agency certifies more than a half million products from around 4,500 manufacturers produced in nearly 9,000 plants in 83 countries. The OU symbol is one of the world’s best-known trademarks.

www.geliko.com • Creatively Kosher

3

KOSHER PAREVE GELATIN FOR DAIRY APPLICATIONS Kosher laws are very strict concerning the segregation of milk and meat; thus, one might wonder how gelatin derived from cattle can be used in dairy products. The good news is that it can, as a result of the unique full-hide sourcing of kosher ritually slaughtered cattle by Geliko. “The process renders the hides pareve, which means the OU kosher gelatin can be used in OU kosher dairy products,” says Rabbi Jenkins. What is pareve? Foods that do not contain either meat or dairy ingredients are termed pareve, which indicates a neutral state. All fruits, grains and vegetables in their natural state are kosher and pareve. A pareve item becomes kosher dairy or kosher meat when it is cooked together with dairy or meat, respectively. This is important because of the waiting period kosher law requires between consuming certain food items. For most orthodox Jews, one cannot consume dairy until six hours after eating meat; however, on the reverse, meat can be consumed about an hour after eating dairy. With hard cheese the wait is about two hours. It all has to do with food residue and aftertaste in the palate. Highly functional ingredient Gelatin’s functionality in many dairy products is irreplaceable. Now with OU kosher gelatin, processors can switch gelatins and apply for OU certification. In yogurt, the star of today’s dairy case, gelatin stabilizes the creamy mixture by interacting with the gel formed by the casein curd. This prevents syneresis and at the same time provides lubricity to the yogurt’s mouthfeel. The latter is a particularly useful attribute in low-fat and nonfat yogurts. The same is true with sour cream. Ice cream and other frozen dairy desserts benefit from gelatin’s ability to interact with overrun (air) that is whipped into these products prior to freezing. Gelatin stabilizes the matrix, immobilizing free water and slowing undesirable ice crystal formation that often develops during freeze-thaw situations. In processed cheese and cheese spreads, gelatin acts as an emulsifier and water binder. This contributes to a creamy mouthfeel and improved spreadability. With low-fat and nonfat cottage cheese a little bit of gelatin in the dressing will thicken the product, adding body without adding fat. Ready-to-eat aerated dairy desserts such as mousse and pudding rely on gelatin for form stabilization. Gelatin also contributes a rich, creamy mouthfeel, which allows for a fat reduction in the final product.

kosher hides from entering our gelatin manufacturing process,” says Rubin. “Whole hides are much more expensive than hide trimmings or splits. Some dairies and other food manufacturers are fi nding they can manage costs by sourcing the gelatin directly from us instead of going through a blender. They appreciate the value of OU kosher certified gelatin.”

MODERN MANUFACTURING Gelita, the world’s largest gelatin producer, is contract manufacturing Geliko’s kosher gelatin product line. The pro-

4

cess employed renders the gelatin ingredients pareve, which means that even kosher ice cream can be made with kosher beef gelatin. Gelita starts by thorough cleaning and pre-treatment of the kosher cattle hides with an alkali process followed by an acid treatment, which renders the collagen soluble in warm water. After rinsing, gelatin is

extracted from the raw materials using a continuous or a multi-stage extraction process. High-performance separators concentrate and purify the gelatin, which is then sterilized and extruded through perforated disks to form “noodles.” The gelatin noodles are dried, coarsely ground and placed in quarantine for quality control testing.

Photo courtesy of Vitamix

“Only when comprehensive physical, chemical and biological testing has been completed is the product released for further processing, which includes granulation into specific particle size,” says Mindi McKibbin, specialist-edible technical services at Gelita. “All phases of manufacturing, from raw material sourcing, processing, production and packaging are meticulously monitored by Geliko, Gelita and the OU to ensure consistently high quality, safe and completely traceable OU kosher gelatin ingredients. “The kosher gelatin ingredients have the same functionality in food applications as the standard versions, which means product reformulating is not necessary,” McKibbin concludes. “There are foods, beverages and supplements in the marketplace today where gelatin is the only ingredient preventing OU-kosher certification. Now there’s nothing holding them back.”

Geliko LLC, New York, is the global leader in OU kosher gelatin and gelatin hydrolysate produced from kosher cattle hides. Geliko Kosher Gelatin products are distributed by FIT Technologies, Miami, and Gelita USA, Sioux City, Iowa. For more information, visit www.geliko.com, or call Geliko’s President and CEO Zach Rubin at (212) 876-5620.

Creatively Kosher • Geliko Kosher Gelatines

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content to create ice cream and sorbet type products under the appropriate labeling standard without adding any taste, aroma or unwanted viscosity of it’s own. Fibersol®-2 is the fiber you want so your

The FDA Food Safety Modernization Act (FSMA) consumers and your dairy signed into law in January by President Obama called their FULL potential! for a more consumer-friendly recall search engine. That’s why the Food and Drug Administration (FDA), Washington, D.C., introduced a consumer-friendly website that enables Americans to search for food and other product recalls easier and quicker. The search results provide data from news releases and other recall announcements in the form of a table, which organizes information from news releases on recalls since 2009 by date, product brand name, product description, reason for the recall and the recalling firm. The table also provides a link to the news release on each recall for more detailed information. The new display provides links in a scroll-down format. Under FSMA, FDA was required to provide a consumer-friendly recall search engine within 90 days after the law went into effect. Further, for recalls conducted under FSMA, it requires FDA to indicate whether the recall is ongoing or completed. The status information will be provided for those recalls for which FDA either ordered a mandatory recall or provided the opportunity for a voluntary recall under FDA’s FSMA authority. “The new search page not only provides consumers with an easy-to-read table of information on products they are searching for, it also represents the delivery of one of the first major actions called for under the Food Safety Modernization Act,” says Mike Taylor, FDA deputy commissioner for foods. “That delivery is on time and right on target, and we appreciate the involvement of stakeholders.”

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Upstate Niagara, Hiland, Others Win Awards for Innovative Products The Milk & Cultured Dairy Products Symposium, which was hosted by the International Dairy Foods Association, Washington, D.C., and took place March 21-23 in Rosemont, Ill., handed out several awards for most innovative products.

14

Dairy Foods | May 2011

In the most innovative cultured dairy product category, for instance, Upstate Niagara Cooperative, Buffalo, N.Y., won first place for its all-natural vanilla yogurt parfait pumps. Meanwhile, Hiland Dairy Co.,

News & Trends

Springfield, Mo., won for its cottage cheese snack cups; Prairie Farms Dairy, Carlinville, Ill., was named for its low-fat cottage cheese snack cups; and Old Home Foods, New Brighton, Minn., won for its lowsodium cottage cheese. California Custom Fruits and Flavors, Irwindale, Calif., place first in the most innovative milk and cultured dairy prototype flavor category for its orange carrot cranberry fruit and vegetable yogurt. Upstate Niagara Cooperative came in second for its intense low-fat lemon lime milk. Donna Berry, Dairy Foods’ product development editor, presented the awards alongside Tic Gums, White Marsh, Md., the sponsor of the event.

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 (Left to right): Donna Berry (Dairy Foods), Donna Klockeman (Tic Gums Inc.), Earl Christiansen (Upstate Niagara Cooperative), David Rambo (California Custom Fruits and Flavors), Eva Balazs (Upstate Niagara Cooperative) and James Gregg (Tic Gums Inc.)

AMPI Reports Sales Growth Some Midwest farmers received good news regarding sales figures. According to the Associated Milk Producers Inc. (AMPI), a Bloomington, Minn.-based dairy marketing cooperative owned by 3,000 dairy producers, sales growth continued in 2010. For instance, sales of packaged and processed cheese grew 5%, while butter sales increased by 7%. Other areas of increased product sales included pudding and cheese sauce (10%) and ice cream mix (19%). AMPI processes milk, manufactures dairy products and packages them for customers at 12 plants throughout the Upper Midwest. The industry saw increased global demand for dairy proteins, which led to improved milk prices following the depressed markets of 2009. AMPI sold more than 28% of its powdered dairy products internationally. IFT Booth #2737 However, despite strong sales and profitable operations, a year-end market drop devalued product inventory and resulted in a $1.5 million loss for the cooperative. AMPI members still shared $12.9 million from the previous year’s earnings and member equity.

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News & Trends

PEOPLE Agro Farma, Norwich, N.Y. Francoise Mattice has been appointed chief financial officer, responsible for leading the company’s strategic priorities for growth while collaborating closely with operations to accelerate the performance of current and future initiatives. Thiel Cheese & Ingredients, Hilbert, Wis. Gary Kerrigan has joined as vice president, operations. Previously, he held senior management and R&D positions with Dairy Farmers of Americ a and Kraft Foods. Sargento Foods Inc., Plymouth, Wis. Brian Riesterer has been named senior research scientist, responsible for managing the development of value-added products, including sauces and processed foods. Previously, he

served as the R&D manager at Thiel Cheese & Ingredients and as an associate researcher for the Center for Dairy. Moobella Inc., Taunton, Mass. Karl Winkler has been named vice president of engineering, responsible for directing the research, design and development of MooBella’s innovative foodservice ice cream machines. Friendly Ice Cream, Wilbraham, Mass. Andrea McKenna has been named vice president, marketing and chief marketing officer, succeeding Skip Wheldon, who resigned in March. Wisconsin Milk Marketing Board, Madison, Wis. David Moore has been named a regional marketing manager, Southwest, while Matt Nolan holds the same position for the North Atlantic. Both will work with

a wide variety of retail and foodservice accounts, including specialty and grocery stores, distributors, restaurants and chefs to build usage of Wisconsin cheese in their businesses. International Food Network, Ithaca, N.Y. Gilbert Leveille, John Ruff, Pamela King and Harry Messina have been added to the newly formed advisory board. Leveille is a renowned industry figure and is past president of the Institute of Food Technologists and the American Society of Nutrition. Ruff retired in 2008 from a 36-year career with Kraft Foods, and has led research programs in sugar and salt substitutes, food safety initiatives and “greenfield” site startups. He recently served on the Institute of Medicine committee on strategies to reduce sodium intake. King served for 26 years in various financial management positions at Kraft Foods, retiring in 2009 as senior vice

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Dairy Foods | May 2011

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News & Trends Story continued from page 15

PEOPLE president and corporate controller, responsible for more than $40 billion in revenue and $67 billion in assets. Messina, an attorney and partner in the business and finance department of Woods Oviatt Gilman, has served as IFN’s legal counsel since 1990. Wild Flavors International GmbH, Zug, Switzerland Cosimo Trimigliozzi was appointed chief operating officer of the newly formed business unit of the Wild Flavors GmbH, which has been created in addition to the two existing operating business units. Trimigliozzi joins Wild after a 24-year career at Roche and Givaudan, where he held various responsibilities, including assignments in the United St ates, Asia Pacific and Switzerland.

“We stepped up our policy-making efforts this past year, urging lawmakers to enact legislation that would decrease milk price volatility and increase dairy farmer profitability,” says AMPI chairman of the board, Paul Toft. In 2010, AMPI also produced 6 billion pounds of milk, invested in the cooperative’s manufacturing network, upgraded whey drying, cheese processing and butter packaging equipment and served customers such as McDonalds, Sysco and Aldi, who continue to rely on AMPI to make the product marketed under their label. Additionally, more than half of the cooperative’s $1.7 billion in sales came from consumer-packaged dairy products.

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Wixon Inc., St. Francis, Wis. AnnMarie Kraszewski has been hired as a food technologist, responsible for developing new prodKraszewski uct formulations and supporting customers in the industrial ingredients group, with a focus on snacks. She previously served as a food scientist for Kerry Ingredients & Flavours. Palmer Wahl Instrumentation Group, Asheville, N.C. Victor Garza will be managing the Monterrey, Mexico, international sales office, designed to serve the needs of the Mexican and South American industry. Garza brings more than 10 years sales experience, a background in electronic systems engineering and first-hand knowledge of the Central and South American markets. Garza is bilingual and will be working with distributors and end users to determ i n e t h e b e s t p ro d u c t f o r t h e i r application.

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Continued on page 18 www.dairyfoods.com

17

News & Trends

B R I E F LY … Turkey Hill Dairy Powered by Wind Turkey Hill Dairy, Lancaster County, Pa., receives a quarter of its annual electricity needs from the new wind turbine power project at neighboring Frey Farm. In part-

nership with PPL Renewable Energy and Lancaster County Solid Waste Management Authority, the Frey Farm Wind Turbine project includes two wind turbines that generate about 25% of Turkey Hill

Dairy’s annual electricity needs. That equals enough power to produce six million gallons of ice cream and 15 million gallons of iced tea each year. The turbines were installed on Oct. 28, 2010, and officially began producing power on Jan. 10. Choctal Purchased by SheerBliss Ice Cream Maker Ben Stanley Holdings, Sunrise, Fla., the owner of SheerBliss ice cream, acquired Choctal Inc., Pasadena, Calif. Choctal is best known as the originator of “single origin” chocolate and vanilla ice cream flavor profiles. Choctal will continue to operate as its own brand and be a partner brand of Ben Stanley Holdings. Founder Marc Boatwright will continue with the brand, while Gary Barron, president of Ben Stanley Holdings, will assume the role of president and CEO. Fonterra Launches Online Trading Platform for Dairies Fonterra, a farmer-owned New Zealand dairy co-operative, opened the doors to its online trading platform, globalDairyTrade, by allowing other dairy companies to sell products as well. When globalDairyTrade was launched in July 2008, it was designed so that other sellers of dairy products would eventually join the platform. Having other sellers on board will add more volume and will lead to even more reliable price discovery. Fonterra will offer milk protein concentrate (MPC) and Rennet Casein. Central Valley Fund Invests $3.5MM in Mexican-style Novelties, Ice Cream The Central Valley Fund, a Davis, Calif.based private investment fund focused on middle market Central Valley companies, invested $3.5 million in Paleteria La Michoacana, LLC, a producer, marketer and distributor of Mexican-style premium ice cream and frozen novelties. The capital will be used to support management as it continues to capitalize on growing demand across a wide variety of food and grocery retailers.

18

Dairy Foods | May 2011

News & Trends

SUPPLIER NEWS Printpack received a silver award from the Flexible Packaging Association’s 2011 Annual FPA Achievement Awards for printing excellence of its Wyman’s of Maine wild blueberry juice. The new Printpack label offers 360-degree billb oard space for b older graphics, a resized logo and more product information on eight-color flexographic printing. DCI Process Systems acquired Statco Engineering to form the largest privately owned sanitary process equipment provider/system integrator in the United States. Statco currently operates from six offices and two fabrication facilities, specializing in equipment supply, process design and project integration services. Statco also manufactures UHT-based thermal processing systems and casing equipment for the dairy industry. DSI operates from two offices and one fabrication facility, manufacturing product blending equipment for the beverage industry and integrating beverage plant process improvement initiatives. Jack Luechtefeld will continue in his role as president of DSI.

Siemens introduces Simatic PCS7, a portfolio of proven, advanced solutions designed to optimize food and beverage plant operations and maximize profit-

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Hawk Measurement purchased Fluidic Flowmeters LLC, allowing the companies to participate in the $18 billion global process measurement market. Fluidic Flowmeters’ product line will be covered under Hawk Measurement’s 24-month warranty on all applications. Intelligrated and Swisslog formed a strategic alliance to provide highly integrated material handling solutions for the food, beverage and retail markets in North America. Swisslog’s warehouse automation products and integration services will be available alongside Intelligrated’s U.S.-manufactured technologies and regional network.

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©2011 Tate & Lyle • www.tateandlyle.com

www.dairyfoods.com

19

New Products & Marketing

DAIRY MARKET TRENDS

Cultured Comeback  Marina Mayer

Executive Editor

t used to be that cultured products were used as components of something larger — cottage cheese for casseroles, sour cream as a condiment or dips for, you guessed it, dipping. Even yogurt adds a creamy value-added touch to pastries and sweet goods. Good thing many of today’s consumers are in search of added value. That’s why the cultured category is making a comeback.

I

Yogurt leads the way According to Chicago-based SymphonyIRI Group, yogurt sales rose 8.6%, for the 52 weeks ended March 20. Chobani, produced by AgroFarma, New Berlin, N.Y., rose the most of any Top 10 brand — sales skyrocketed 223.7%, dollar share increased 4.7% and unit sales were up 212%, all thanks to its lineup of nonfat and low-fat Greek yogurt, and its newly introduced item, Chobani Champions, for children. Chobani is the fourth bestselling brand, according to SymphonyIRI. Johnstown, N.Y.-based Fage Total Greek yogurt, in seventh place, clocked in a 66.7% increase in dollar sales and an 86% increase in unit sales. Meanwhile, No. 1 Yoplait Light and No. 3 Original brands experienced an uptick in sales, with 7.8% and 0.8% respectively. Produced by General Mills, Minneapolis, sister brand Yoplait Go Gurt jumped 12% in sales, SymphonyIRI data says, due in part to its freeze-to-thaw Go Gurt selection. Sales of cream cheese collide Sales figures for the cream cheese segment outline some rollercoaster results, say SymphonyIRI data. In the brick cream cheese category, Weight Watchers International, Jericho, N.Y., garnered a 1,685.4% hike in dollar sales for its selection of point-valued offerings, followed by Yoder’s, developed by I&K Distributors, Delphos, Ohio, and Raskas, made by Schreiber Foods, Green Bay, Wis., at 72.5% and 51.1%, respectively. In SymphonyIRI’s “all other forms” category, noteworthy mentions include Mimosa (a 123.2% increase in sales); Kaukauna Connoisseur (up 110.1%), produced by Bel Brands USA, Elk Grove Village, Ill.; and Dairy Fresh whipped (up 92.2%), made by Dairy Fresh Corp., Greensboro, Ala. On the other hand, sales of some brands fell. For example, WisPride cream cheese balls (by Bel Brands USA) experienced an 85.2% decline in sales, while Smithfield all other forms, owned by C-USA/Alouette Foodservice, Hanover, Md., dipped 66.8%. Other brands displaying a drop in sales include Moondarra balls (-52.4%) from Moondarra Cheese in Australia; Clawson 20

Dairy Foods | May 2011

Quarterly Sales of Yogurt Reporting Period 13 weeks ended

Dollar Sales (millions)

% change vs. yago

Unit Sales (millions)

% change vs. yago

12/26/10

$976.6

+8.6

926.9

+4.8

9/26/10

$1,096.7

+9.9

1,041.8

+6.2

6/27/10

$1,092.3

+9.2

1,066.8

+7.1

3/28/10

$1,057.1

+5.6

1,074.0

+4.2

12/27/09

$899.6

+5.9

884.4

+7.2

$998.4

+3.5

980.9

+4.8

9/27/09

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

all other forms (-51.4%), made by England-based Long Clawson Dairy Ltd.; Einstein Bros. whipped (-37%), sold by Boston-based Einstein Bros. Bagels; and J&J whipped (-20.3%) from J&J Snack Foods Corp., Pennsauken, N.J. Cottage cheese category displays curdling results It used to be that cottage cheese came in one flavor — Original. Nowadays, consumers can spice up just about any meal with, for example, cucumber dill-flavored cottage cheese. However, the category as a whole has experienced some more flavorful days. Dallas-based Daisy brand cottage cheese underwent the highest sales jump in the category, with a 15.2% hike. Private label followed with a 3% increase in sales (however, it took the No. 1 spot with $337.1 million in sales). Despite its triple-churned creamy cottage cheese options, Breakstone’s Cottage Doubles, produced by Kraft Foods, Northfield, Ill., experienced a 12.9% decline in sales, while sales for Breakstone’s dipped 2.1%. Prairie Farms Dairy, Carlinville, Ill., underwent a 10.4% drop in sales. Sour cream sales go a bit sour Sales of sour cream increased 2.8%, though unit sales dropped 0.6%. Sales of No. 1 Daisy rose 11.1% and No. 9 Hood, processed by HP Hood, Lynnfield, Mass., rose 23.5%. No. 10 Kemps, produced in St. Paul, Minn., showed a 10.2% increase in sales. Sales soured for No. 5 Friendship Dairies, Friendship, N.Y., (down 16.5%), while No. 3 Breakstone’s displayed a 10.3% drop and No. 7 Knudsen (like Breakstone’s, developed by Kraft) dropped 9.3%. 

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New Products & Marketing

NEW PRODUCT REVIEW Not many people can turn down a corned beef and Swiss sandwich on St. Patrick’s Day. And thanks to Finlandia, Parsippany, N.J., the Swiss on that sandwich can be lower in fat and sodium and still taste great. Just in time for the March 17 holiday, the company rolled out Finlandia Lacey Swiss, an imported, all-natural, reducedfat cheese in 5-pound loaves. This service-deli product contains no added hormones, and is naturally lactose free and a great source of calcium. According to the American Heart Association (AHA), Dallas, adults should eat two to three servings of fat-free or low-fat dairy per day. Additionally, AHA advises children to eat two or more servings and teenagers and older adults, four

servings per day. This gets easiier and tastier with innovative options such as Finlandia Lacey Swiss. From the first bite, one can taste full Swiss flavor. This is due to the fact that it is aged 60 days, more than most other low-fat cheeses on the market. La Farge, Wis.-based Organic Valley, the nation’s oldest organic farmer-owned cooperative, now offers New York Fresh milk, a locally produced milk for its consumers in the New York metropolitan region. The milk is produced on the cooperative’s family farms in the Empire State and bottled, distributed and sold in the region, ensuring fewer miles from farm to table. New York Fresh milk is available in skim, low-fat, reduced-fat and whole varieties in quart, half-gallon, gallon and a new 96-ounce size. True to the iconic Organic Valley wood-cut design, the New York Fresh cartons feature farmer-owners who produce the milk on their pastures and an introduction to their farm stories. The packaging also displays the Pride of New York logo. The milk comes from 121 local farms and is bottled at Mountainside Dairy, Roxbury, N.Y.

Inspired by the success In of o frozen kefir made for Starfruit Cafes, the foodservice venture of Lifeway Foods Inc., Morton F Grove, Ill., the comG pany is entering the p retail frozen categor ry r with a packaged frozen kefir. New f Lifeway Frozen Kefir L is i a 90-calories-perserving frozen yogurt s alternative packed a with better-for-you w bacteria. This tart, b yet y tangy frozen treat comes in one-pint c containers in four flaco vors — mango, original, pomegranate and strawberry. The original flavor is also available in a 3.6-ounce single-serve size packaged with a spoon.

NOTEWORTHY I NTROD UCTION S Velvet Ice Cream, Utica, Ohio, adds Peanut Butter Overload and French Vanilla to its Su-preme ice cream line. This peanut butter-based ice cream includes peanut butter swirls and d peanut butter cups. French Vanilla is similar to Velvet’s Olde Tyme Vanilla and includes passteurized egg for rich flavor. St. Paul, Minn.-based Old Home Foods Inc., is reducing the sodium in its cottage cheese se by one third. Taste does not change thanks to the power of the minerals in sea salt, which is what the company now uses.

22

Dairy Foods | May 2011

New Products & Marketing

“Frozen yogurt is still a strong growth segment, and our Starfruit Cafe business is riding the same wave. Our same-store sales grew nearly 50% last year, our average store ticket rose 20% and we’ve seen demand expanding from an afternoon dessert to both a breakfast and lunch meal replacement,” says Julie Smolyansky, CEO. “Taking the product to grocery stores around the country with the introduction of Lifeway Frozen Kefir is the next logical step. Now fro-yo fans can get their fix with the nutritional tritional benefits of kefir wherever ver they live and whenever they want — even when they’re at home. me.” Good things come in small mall packages. Make that small cups! ups! The Skinny Cow brand’s new 5.8-ounce singleserve, low-fat ice cream cup line contains only 150 to 170 calories and 2 to 3 grams fat, depend-ing on flavor, of which h there are five. Caramel el Cone is vanilla ice cream m with chocolate-covered ed chunks of crunchy cone and swirls of caramel. Chocolate Fudge Brownie starts with chocolate ice cream to which fudgy brownie chunks are added. Cookies ‘N Cream and C Strawberry Cheesecake taste like the classic American cl desserts, while de Dulce de Leche Du appeals to ap Hispanic taste Hi buds. bud It is caramel-f me lavored vored ice cream loaded with lay layers off rich caramel. The suggested re retail price rice is $1.49 per cup, but can often be found und on sale for a dollar. The Skinny Cow line is produced by Dreyer’ss Grand Ice Cream Inc., Oakland, Calif., a division of Nestlé USA, Glendale, Calif., which is owned by Nestlé S.A. of Vevey, Switzerland. The Icelandic Milk & Skyr Corp., New York, expands its

siggi’s brand with small and simple drinkable yogurts that are a concentrated source of the oldest and best-known probiotic culture: Lactobacillus acidophilus. “Since 2005, siggi’s has been committed to making skyr, an Icelandic-style, all-natural yogurt with a short and simple ingredient list containing five strains of live active cultures,” says Siggi Hilmarsson, CEO. The drinkable yogurt comes in blueberry, plain and strawberry flavors. Available in four-packs

of 3.7 fluid-ounce bottles, the product debuts nationwide this month and has a suggested retail price of $4.99. 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.

I N T E R N AT I O N A L In the United St ates, fiber claims have increased within the dairy category, but for the most part have been limited to cultured products, primarily yogurt. In other parts of the world, fiber has made its way into fluid milk. In Italy, Parmalat sells Fibresse Milk as part of its “Well Being Milk” line. This fiber variant is designed to help with intestinal function — a benefit that is described in detail on the package. Poland’s Bakoma Milkus chose the increasingly popular flexible stand-up pouch for its new drinkable launch: Chocolate Milky Dessert. Desse Though this chilled drink is nothing more than t simple chocolate milk, the product name and a pack aging extend the t usage occasion from hydration to dessert. The 8 0-gram pouch offers key benefits to parents — portability because of the single-serve format and reusability because of the screw cap — but the “squishable” nature of the package makes it appealing to children. Bright Dairy in China recently launched a kidoriented cheese product. This chilled treat appears to be a hybrid dairy product, bringing together attributes of traditional cheese, cream cheese and yogurt in a unique tub format, complete with a spoon. Flavored like fruit punch, the product can be consumed as a snack, as a spread or mixed with fruits or vegetables.

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

23

New Products & Marketing

NEW PRODUC FOCUS ON TEA Marketing communications firm JWT, New York, identified green tea as one of the Top 10 trends in its Food and Beverage Trends for 2011 report. According to JWT, green tea has become a functional ingredient — high in both antioxidants and caffeine — and will increasingly be seen in beverages (from lattes to cocktails) and desserts (ice cream, pastries and more). On the beverage side, a number of innovative ready-to-drink (RTD) green tea beverages are making their way into the retail channel, and more are expected ch to roll out for summer the summ months.

For example, from January to June, Lancaster County, Pa.-based Turkey Hill Dairy offered limited-edition Light Wildberry Green Tea. In July, Light Blueberry Tea will appear on store shelves. And Unilever, Englewood Cliffs, N.J., is growing its refrigerated iced tea line with a 59-ounce carton of Peach Mango Green Tea. Renewal Laboratories, San Diego, recently ventured into RTD tea with the first all-natural bottled teas enhanced with omega-3 fatty acids. Sold under the Go In brand, which has the tagline of “Ingredients that Go In,” the teas are available in sweetened and unsweetened varieties. They contain high-purity fish oil, a source of the heart-healthy

CT REVIEW: omega-3s docosahexaenoic noic acid (DHA) and eicosapenntaenoic acid (EPA). Marley’s Mellow Mood is a line of relaxation teas and sodas inspired by Bob Marley, the globally recognized musician who, when jammin,’ sang about unity, freedom, peace, empowerment and love. Marley Beverage Co. was created by the family of Bob Marley, paying homage to their father and patriarch by launching and promoting a wide range of healthy, natural drinkss that contain ingredients that put people into what they call, “Marley’s Mellow Mood.” Marley Beverage Co. is manufacturing and marketing the new drinks in a joint partnership with ViVa Beverages, Southfield, Mich. RTD tea comes in two varieties — The R Green Tea with Honey and Black Gree Tea with Raspberry, Passion Fruit and Peach. P According to the company, the Ac drinks have been meticulously dri formulated with an exotic blend fo d of o all-natural botanical ingredients sourced from around the world. Chamomile, valerian s root, passionflower, melatonin, rose hips and lemon balm are among the time-tested calming and stress-reducing ingredients that the Marley family has crafted into firsti of-its-kind relaxation beverages. The cans and bottles are wrapped in signature colors — green, yellow and red — w and picture the classic Bob Marley image: relaxed, smiling and truly happy. Read more about this product on page 44. Ingredient suppliers are taking tea innovation to the next level. For example, at the recent Natural Products Expo l West, a dairy protein supplier sampled a prototype raspW berry-flavored green tea that delivered 5 grams of highb quality whey protein in an 8-ounce serving. Expect to see more innovative concepts at the IFT 11 Annual Meeting + Food Expo, June 11-14 in New Orleans. 

Ingredient Technology Photo courtesy of Doehler

Beyond Chocolate, Strawberry and Vanilla The top three ice cream flavors are not going away, but today’s consumers have become more adventurous in all of their food choices.  Donna Berry Product Development Editor

onsumers love tickling their taste buds with Italian, Mexican and Asian cuisine, so much that all three have become so mainstream, they’re hardly considered ethnic anymore, according to Chicago-based Mintel. Interestingly, when many of us think of flavors for dairy foods, we think chocolate, strawberry and vanilla…and for those of us willing to think beyond sweet applications, French onion and ranch likely come to mind. But the fact is, dairy can carry so many flavors, as the inherent mellow, creamy taste of milk and milk products complements everything from cucumber to curry. Mintel reports that even lesser-known ethnic fare has enjoyed robust product growth in recent years, as ethnic-food lovers and their palates are hungry for more exotic ingredients and flavors. In 2010 alone, Mintel’s Global New Products Database tracked a 150% increase from 2009 in new food items that contained “Caribbean” in the product description. “Japanese” product launches soared more than 230% from 2009 to 2010. Meanwhile, “Thai” product launches saw a 68% increase from 2009 to 2010. “Italian, Mexican and Asian cuisine are the more mainstream, popular ethnic cuisines,” says David Lockwood, senior analyst at Mintel. “But Thai, Caribbean and Japanese foods are seeing healthy growth, and consumers seem to be getting more comfortable with a wider variety of ethnic flavors.”

C

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Dairy Foods | May 2011

Twenty-three percent of ethnic food users say they were spurred to try them after reading cookbooks that include recipes for dishes that are popular in other countries. Additionally, 18% developed a taste for ethnic chow after travelling abroad and 25% say they were introduced to their favorite ethnic fare because they live in a diverse neighborhood where the food and ingredients are readily available. This data are supported by a presentation made by Kim Holman, a marketing director with a flavor supplier, at the Research Chefs Association conference in Atlanta. She explained that flavors marketed as extreme, adventurous and “take me away” are driving new product development in the United States. “Consumers are increasingly interested in trying new flavors,” Holman said. “This is due to a combination of factors, including a more ethnically diverse population and more frequent overseas travel.” She explains that the urbanization of America has improved consumer awareness and willingness to try ethnic cuisine. “Sometimes ethnic flavors need to be modified with a familiar taste for consumers to be willing to try it,” she says. “Sort of like when kiwi got teamed up with strawberry, or goji with blueberry.” In addition to increased use of ethnic flavors, there is a trend with two-directional crossover of savory ingredients into sweet foods and sweet ingredients into savory foods, according to Food Flavors and Ingredients Outlook 2011, the eighth edition of Continued on page 28

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

Ingredient Technology

Top 10 Flavors for 2011 Sweet 1. Chocolate Soufflé 2. Honey Vanilla 3. Red Velvet 4. Caramel Macchiato 5. Yumberry 6. Coconut Crème Photo courtesy of Sam’s Club 7. Sweet Potato 8. Ginger Peach 9. Mint Citrus 10. French Toast

Beverage 1. Blood Orange 2. Yumberry (*2) 3. Coconut Water (*1) 4. Maqui Berry 5. Cupuacu (*8) 6. Elderflower 7. Caramel 8. White Grape 9. Rambutan 10. Snake Fruit

Source: Bell Flavors & Fragrances

Photo courtesy of Weber Products

Savory 1. Black Garlic (*5) 2. Rich Umami (*3) 3. Truffle Oil 4. Aged Cayenne Pepper 5. Nuc Maum 6. Calamansi Lime 7. Demi Glace 8. Harissa 9. Aji Panca 10. Paneer Cheese

Photo courtesy of Cabot

* Ranking in previous year’s report.

 These lists were tabulated using three methods: 1) Tracking flavor sample requests during a 12-month period; 2) Trend-scouting flavors by analysts in four continents and 3) Compiling flavor trends from external resources, market research firms, media and other credible sources. Results for sweet flavors suggest that consumers like what is familiar and find comfort in certain foods. With beverage flavors, consumers continue to be drawn to the distinctive tastes and powerful nutrients found in exotic superfruits. And finally, because many consumers are traveling more and sampling new savory flavors from around the world, there is increased desire to bring these global taste experiences home and infuse them into the daily diet. Photo courtesy of Culinary Institute of America

the annual series by market research publisher Packaged Facts, Rockville, Md. The report provides an example of the use of olive oil to extend into a wide range of desserts and sweet goods, including ice cream and gelato, cake and muffins. The report also says that when it comes to fruits and fruit flavors, expect to see more figs, pears, cherries and blackberries, along with the superfruit combination of blueberry and pomegranate. Sensory science in action Ethnic, exotic and superfruit (and vegetable) flavors are great, but some of these flavors, as well as certain functional ingredients that are now being added to dairy foods, can possess undesirable off tastes, in particular bitter. “A lot of people are very sensitive to the bitter taste of medicines, calorie-free sweeteners and certain foods,” said Ioana Ungureanu, a research scientist with a flavor company who described the concept of “bitter blockers” at the 241st National Meeting & Exposition of the American Chemical Society in Anaheim, Calif., in March. “We’d like to be able to make their diets more enjoyable by masking the off-putting flavors of bitterness. Blocking these flavors we call off-notes could help consumers eat healthier and more varied diets.” This concept of bitter blockers is supported by a study published in the March issue of Chemical Senses. According to the paper, there is an unusually high level of variation in bitter-taste perception across people. “Just like some people are color blind, some people are taste blind and simply can’t taste bitter things that others can,” according to John Hayes, assistant professor of food science at Penn State’s College of Agricultural Sciences, State College, Pa., and lead author. “It turns out that different bitter foods act through different receptors, and people can be high or low responders for one but not another. “Those bitter tastes are sensed through different pathways,” he explained. “And this doesn’t affect just bitterness. Since bitter and sweet are in opposition in the brain, if you experience more bitter28

Dairy Foods | May 2011

 Many flavor trends begin in foodservice. Ingredient suppliers track these trends and create flavorants that enable product formulators to create foods that closely mimic culinary creations.

ness from a food, you also perceive less sweetness. This means not all foods taste the same to all people.” Previous studies have shown that variations in sensing bitter taste influence people’s diet choices, and subsequently their health. For example, people who are more sensitive to bitterness eat 25% fewer vegetables, according to Hayes. While his study did not measure finicky eating, Hayes contended it still may provide new insight into pickiness. “Some people may not be acting whiny when they say they don’t like certain foods — they actually experience those foods differently,” he said. As flavorists progress with advancements in the development of bitter blockers, consumers might be able to enjoy a more diverse diet that includes better-for-you foods and flavors such as dark chocolate and green tea. 

CUST M FORMULAT ONS Dairy product innovators have come to rely on ADM Cocoa for foor consistency c nsis co and quality. But what really sets us apart are the added extras you can’t get anywhere else. Like custom formulations. Our technical experts can help you create a one-of-a-kind, category-leading product your customers will crave. To find out more about how ADM’s technical expertise can give you an advantage, visit us at adm.com/ambrosia.

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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. © 2011 Archer Daniels Midland Company

800-558-9958 | [email protected] | www.adm.com

Ingredient Technology

WELLNESS WATCH Photo courtesy of Anytime Fitness

Donna Berry

 Donna Berry Product Development Editor

ccording to the hot-off-the-press Packaged Facts report Kids’ Foods and Beverages in the U.S. 2011, one of the greatest opportunities in kids’ products is dairy foods designed for children’s nutritional needs and taste preferences, and marketed specifically to them as a kids’ food. The report estimates that retail sales of all types of foods for children hit the $10 billion mark at the end of 2010. This includes sales from all retail channels and reflects an increase of 25% from 2005. “The kids’ food market gained attention after the turn-of-the-century, but never really had a fair chance to gain momentum as the recession entered the picture,” says Don Montuori, vice president-publishing, Marketresearch.com, Rockville, Md. “In 2009 and 2010, a number of marketers — in particular, dairy processors — turned up the heat, and started getting aggressive in this very important food marketing segment. As a result, Packaged Facts projects that the market will grow by 40% from 2010 to 2015.

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“Dairy products comprised just a little over one-fifth of the kids’ food market in 2010, with beverages and frozen foods in first and second place, respectively. But really, the products representative of the first two categories are kid-friendly items such as juice boxes and French toast sticks,” says Montuori. “With the dairy category, the products are ‘really’ just for kids.” Really, just for kids Recently introduced innovative dairy foods for children include Chobani Champions, the first-ever Greek yogurt made for kids. Manufactured by Agro Farma Inc., New Berlin, N.Y., Chobani Champions come in two flavors: Honey-Nana and VeryBerry. Free of preservatives, artificial flavors and milk treated with synthetic growth hormones, each serving is an excellent source of vitamin D, a good source of bone-building calcium and comes loaded with protein. Sold in four-packs, Champions are packaged in 3.5-ounce cups to better accommodate a child-size appetite.

Another example is YoBaby 3 in 1 Meals from Stonyfield Farm, Londonderry, N.H. YoBaby Meals’ are a unique combination of yogurt, fruit and vegetable purée, which helps moms give their preschoolers a trio of important food groups at every meal. Three varieties are available: Pear & Green Bean, Peach & Squash and Apple & Sweet Potato. The yogurts are also fortified with vitamin D and zinc. Last year, CFM Beverages, Atlanta, introduced Mega Moo Vitamin Milk, a three-flavor line — chocolate, strawberry and vanilla — of fortified milks designed for kids’ nutritional needs. Shelf stable for up to 250 days, these value-added milks are loaded with a daily dose of recommended vitamins. They also contain less sugar than most other flavored milks, without the addition of anything artificial. Each 8-ounce carton provides only 135 calories, making it one of the most nutrient-dense milks in today’s marketplace. In February, New Britain, Conn.-based Guida’s Milk introduced Healthy Moo for school milk programs. The initial flavors are chocolate, which contains 25% less sugar than the leading brand, and strawberry, which has 30% less sugar. Further, the new product uses 100% sugar instead of fructose sweetener. The company plans to

 Healthy Moo from Guida’s Milk, New Britain, Conn., is a new flavored milk line for school milk programs. Continued on page 32

30

Dairy Foods | May 2011

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Ingredient Technology

The Kids’ Dairy Products Market Yogurt Drinks/Dairy-based Smoothies/Kefir; 17.9%

Cheese; 2.6%

Milk/Flavored-milk Beverages; 41.4%

Yogurt (cups, tubes, etc.); 38.1% Source: Kids’ Foods and Beverages in the U.S. 2011, published by Packaged Facts

 Dairy foods represent about one-fifth of the $10 billion kids’ food market. Milk has the largest share (41.4%), while cheese is the smallest piece of the pie (2.6%), presenting marketers with an opportunity to innovate and target this demographic.

expand to the retail market in the near future, hopefully just in time for summer vacation. Numerous kids’ dairy foods debuted at Natural Products Expo West this March, including quite a few yogurts. And it’s no wonder, as market research firm NPD Group, Port Washington, N.Y., identified yogurt as the No. 1 food eaten as a snack by children 2- to 17-years old.

For example, The Hain Celestial Group, Melville, N.Y., showcased Earth’s Best Organic Baby Yogurt, which is scheduled to hit retailer’s refrigerators this summer. This new whole-milk yogurt is loaded with nine live and active cultures, including probiotics, and has been formulated for a baby’s nutritional needs, with each 4-ounce cup delivering 25% of the Daily Value for calcium, vitamin D and zinc, 2 grams fiber, 5 grams protein and other important vitamins and minerals. Made with no refined sugars, the yogurt gets its sweetness from the addition of organic fruit and fruit juices. It will come in four-packs of four different varieties: Apple, Banana Mango, Peach Pear and Vanilla Prune. Right Track Global LLC, Irvine, Calif., debuted Dr. Sears Family Essentials Cool Fuel fortified, ready-to-drink shakes. Each 8-fluid-ounce serving contains 18 essential vitamins and minerals, 8 grams protein, 5 grams fiber and 100 milligrams of omega-3 fatty acids from fish oil. The drinks are sweetened with dried cane syrup and stevia. The protein comes from milk protein isolate, while the fiber is fructooligosaccharide. The gluten- and lactose-free shakes contain no artificial flavors, colors or sweeteners and 60% less sugar than competitive brands. Varieties are: Chocolate, Chocolate Banana and Vanilla. Another company from Irvine — Orgain — manufacturers of a namesake organic ready-to-drink nutritional shake for adults, debuted a version for children appropriately called Orgain Healthy Kids. Based on the company’s proprietary organic protein blend consisting of whey protein concentrate and milk protein concentrate, the drinks also contain 10 different organic fruits (acai, apple, banana, blueberry and raspberry) and vegetables (beet, carrot, kale, spinach and tomato), as well as 25 vitamins and miner-

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Dairy Foods | May 2011

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Ingredient Technology

 Cool Fuel shakes are described as “advanced nutrition for kids.”

als. The gluten-free shake delivers 8 grams protein and 2 grams fiber per 8.25-fluid-ounce serving. Nutrients kids need So what nutrients are the most appropriate for fortification of kids’ dairy foods? The answer is really almost everything, as many children have small appetites when it comes to “real” foods and they would rather fill up on nutrient-void sweets and treats. Fortification typically addresses healthy growth and development, as well as protecting against disease. For healthy bone development, children need adequate protein intake, but also sufficient levels of bone-building minerals and vitamins, such as calcium, phosphorus, magnesium and vitamin D. Adequate levels of other essential micronutrients, such as zinc, vitamin C and vitamin K, are also needed by the growing child to assure optimal skeletal health. Other important nutrients for growth include folate, vitamin B12, as well as other B vitamins, which are needed for DNA replication and red blood cell formation and iron, which bolsters immunity and protects against developing anemia. And probably the most buzz in recent years has been around omega-3 fatty acids, in particular docosahexaenoic acid (DHA) and eicosapentaenoic acid (EPA), which are both naturally found in certain marine oils. These fatty acids are important for visual and brain development in infants, and also play an important role in balancing the availability of anti-inflammatory signals produced by immune cells. Because children don’t tend to eat a lot of fatty fish, supplementation is important. What to avoid? New product rollouts suggest that anything artificial, in particular colors, flavors and preservatives, is taboo. The negative press surrounding food dyes is definitely being considered by formulators, as well as the use of certain sweeteners. The good news is that dairy processors start with a base — milk — that comes loaded with important nutrients for kids. In conclusion, Montuori says, “Dairy is such a natural for kids, which is likely why so many processors develop products specifically for this demographic.” The products just reviewed and others will continue to drive category growth. “The compound annual growth rate for kids’ dairy products was 11.3% from 2005 to 2010, and we project it will be near this through 2015. Drinkable cultured dairy products will experience the greatest growth, with milk and yogurt both very strong categories,” says Montuori. “There’s a lot of opportunity within the cheese segment. Kids love cheese. So why not fortify string cheese with ingredients kids need more of, such as omega-3 fatty acids, and put a cartoon character on the package?” 

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Ingredient Technology

CULTURALLY SPEAKING

Put Cultured Dairy Products on the School Lunch Menu s early as the 1800s, it was recognized that the nutritional status of children could be improved through organized public and private feeding programs. Charitable organizations and local municipalities throughout many parts of Europe established programs through grassroots efforts. Over time, many European cities gained some public support to facilitate feeding programs within schools. In the United States, a similar evolution of school feeding programs occurred in the 1900s. While many states had laws to allow school districts to provide meals to children, many school boards and local governments did not have the resources to meet the growing needs, particularly during the Great Depression. But in 1946, President Harry Truman signed the National School Lunch Act to provide nutritionally balanced, low-cost or free lunches to children. The Child Nutrition Act of 1966 further extended, strengthened and expanded the National School Lunch Program. Today, the program serves more than 31 million children each day in approximately 100,000 public and private schools and residential child-care institutions. Dairy foods such as milk, cheese and yogurt are key components of the meals and snacks offered in nutrition programs, including the National School Lunch Program, School Breakfast Program, Special Supplemental Nutrition Program for Women, Infants and Children, Special Milk Program and the Child and Adult Care Food Program. It is estimated that combined, these programs offer nutritional assistance to more than 54 million children and adults. Still, the diets of children and adolescents do not meet current national dietary recommendations to maintain health and support optimal growth and development.

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Dairy Foods | May 2011

Calcium, magnesium, potassium, vitamin E and fiber are five key nutrients of concern (nutrients limited in diets of children and adolescents). Many dairy products are nutrient-rich and can be a key source of the calcium, magnesium and potassium in the diet. Unfortunately, more than half of the children ages 2-8 and three-quarters of the children ages 9-19 do not consume the recommended daily servings of low-fat and fat-free dairy products. The National School Breakfast Program and the National School Lunch Program provides 40 million meals daily and each of these meals is required to offer fluid milk, cheese and yogurt. Cultured dairy products, including yogurt and cottage cheese, can be a part of many child nutrition feeding programs. Most recently, the Healthy, Hunger-Free Kids Act of 2010 provided an additional $4.5 billion in new child nutrition program funding over the next 10 years. Setting new overall limits on calories, salt intake and saturated fat in school menus represents a challenge that needs some research and development attention. Yet low-fat and fatfree dairy foods remain acknowledged as nutrient rich and a significant source of nutrients for growing children and teens. Dairy’s essential nutrients Because dairy foods offer a unique package of nine essential nutrients (calcium, potassium, phosphorus, protein, vitamins A, D and B12, riboflavin and niacin), they will continue to be encouraged in child nutrition programs. Additionally, because dairy foods are nutrient-rich, they can actually represent good nutrient value (more nutrients at a lower cost per serving). This is particularly important given the tighter budgets school foodservice directors face today. Congress, through its actions over the years, already has recognized the connec-

Phillip Tong

tion between good nutrition and children’s ability to develop and learn. The benefits of good nutrition have been associated with cognitive function (academic performance, school attendance, punctuality and memory). Additionally, there is much scientific evidence to support how dairy foods consumption contributes to bone health, healthy blood pressure and healthy body weight in children. If administrators of child nutrition programs understand the connection between good nutrition (and the role dairy foods play) and health and wellness, then children might become lifelong consumers of dairy foods. Yogurt and cheese can be included as meat alternatives in all meals. The popularity of cultured dairy products today offers a new window of opportunity to expand offerings in child nutrition programs. New product opportunities Processors should consider ways to introduce new convenient, economical forms of cultured dairy foods that fit well in school snack, breakfast and lunch programs. National and state dairy councils, among others, have done an excellent job preparing information for dieticians, foodservice professionals, students and other groups to ensure they know how dairy foods can be an important part of child nutrition programs. You would be wise to leverage this information in your efforts to secure child nutrition customers. Finding ways to fit a wide array of nutritious, good tasting, convenient dairy products into child nutrition programs is good for the dairy industry. But most of all, it is the right thing to do for our nation’s children.  Phillip S. Tong is professor of Dairy Science and director of the Dairy Products Technology Center at California Polytechnic State University, San Luis Obispo.

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Ingredient Technology

THARP & YOUNG

10 Factors Affecting Color in Ice Cream hat needs to be considered when coloring ice cream? Color is almost always added to frozen desserts to enhance the visual appeal of the finished product. In some instances, no additional color may be necessary or desirable (for example, when using pure vanilla extract, cocoa powder, fruits or egg yolk solids). In any case, the color of the finished product must be compatible with the dominant flavor of the product. It is important to note that color can be lightened by factors that increase the number of particles that reflect light. Those factors include increasing overrun and reduction in air bubble size, increased levels of naturally occurring casein micelles and decreasing the size of fat globules. Beyond color due to mix ingredients (milk fat, casein micelles, vanilla, egg yolk solids, cocoa and others) and colors added from inclusions (fruit, fruit juices and the like), exempt colors (so-called “natural”) and non-exempt (artificial) colors can be added to frozen desserts. As long as the colors are generally recognized as safe (or GRAS), this is allowable. Color is affected by the following factors: Amount and type of color. It is obvious that adding more or less color can be critical to sensory appeal. In addition, whether a color is natural or artificial can affect color stability and, ultimately, the color of the finished product across its shelf life. Unlike many exempt colors, non-exempt ones yield extremely accurate, precise and stable colors. Color and composition of mix. Variables in the levels of fat, total solids, type of milk-solids-not-fat, specific ingredients and others can affect the color of any given mix. Ingredient selection. The color of mix ingredients themselves (for example, egg yolk) can alter the color of any mix. In addition, the nature of the color (the color extract) and the nature of the mix can cause color variability. Processing. High-temperature treatment of ingredients or the mix itself can darken the mix and thus detract from the shade and brightness imparted by any given color. Marketing needs. Market requirements can dictate particular amounts, shades and types of colors used. Ice cream processors must take care to select the proper amount and type of colorant to add to meet market expectations for any given flavor. Regulatory limitations. The use of colors must be restricted to those that are GRAS or be an approved food additive.

Tharp & Young

W

Learn more at the clinic For more on colors and colorants in ice cream and other frozen desserts, join Bruce Tharp and Steven Young at Tharp & Young on Ice Cream Technical Short, Workshops and Clinics, Nov. 30-Dec. 2 in Las Vegas. Go to www.onicecream.com or call 610-9754424 or 281-596-9603.

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Dairy Foods | May 2011

 The color of ingredients used in ice cream mix affects the color of the finished product. Other factors include fat content, overrun and production temperatures. Photo courtesy of Roselani Ice Cream.

Finished weights. As the amount of air is increased and air cell sizes are reduced, the finished product will lighten in color. This means that the level and/or type of added color might have to be increased or modified to provide the exact color desired. Color stability. Typically, artificial colors (non-exempt colors) are most stable, although when bleached, they tend to lose color completely. Natural colors or extracts used as sources of color are typically labile to physical and chemical processes. These can include oxidation/reduction reactions, pH changes, microbiological growth, heat-induced changes and exposure to light. Uneven color. When color is added at the flavor tank or via injection of inclusions, streaking and “bleeding” across the frozen dessert can occur. This is unsightly and may not reflect the true nature of the product. If bleeding becomes excessive, the final product may fail to show discrete separation of an inclusion and the mix. Also, mottling can be produced when streams of product from two or more freezers are blended before packaging, due to variation in the color of the mix or in the level of overrun. The effect of such variations can be avoided by use of an in-line mixer that thoroughly blends the multiple streams. Unnatural. Unnatural color is any color that may not be compatible with the characterizing flavor. For example, dark gray or dark red may be deemed “unnatural” if the frozen dessert is meant to be a strawberry-type product requiring more bright red color. Whatever type or level of color is used in whatever mix, color plays an important role in the perception of flavor. Any compromise on color puts both visual appeal and flavor at risk. Thus, care in selection of the right amount and type of color is critical to success.  Bruce Tharp is principal of Tharp’s Food Technology, Wayne, Pa. Steve Young is principal of Steven Young Worldwide, Houston.

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Non-dairy Beverages

 Marina Mayer

Executive Editor

alking down the beverage aisle in a supermarket is like walking into a carnival. There’s a lot going on — the colors, the graphics, the flavors, the packaging, the reflection from the glass bottles, the clean labels of all-natural ingredients, superfruits, antioxidants and B vitamins — it’s all very inviting. Whether it’s an exotic juice, flavored tea, an energy-filled drink or a blend of all of the above, many of today’s non-dairy beverages can give dairy processors some ideas about ingredient and flavor trends, especially as many of them leave consumers thirsty for more.

W

Juice with the extra jolt Many juice brands already offer that flavorful, all-natural, functional option, but nowadays, they also deliver wholesome, reduced-calorie options in an earth-friendly, ergonomic package. “Consumers expect more out of their beverages, and many brands are responding,” says Rick Zimmerman, senior vice president, marketing and innovation for Sunny Delight Beverages Co., Cincinnati. “On SunnyD, for example, we have reduced the sugar and calorie level by 50% over the past several years — our products now contain 60 calories per serving versus 120-130 in 2007.” 38

Dairy Foods | May 2011

Whether it’s an exotic-flavored juice or RTD tea, or an amped-up or relaxed-down drink, the non-dairy beverage aisle keeps consumers coming back for more.

The folks at SunnyD also cut calories on other fan favorites — Tangy Original and Smooth-style juice went from 90 to 60 calories per 6.75-ounce serving. SunnyD also reformulated its Veryfine Fruit Punch to 60 calories per 8-ounce serving. “SunnyD is now completing the national rollout of formulas across our entire line that reduce sugar and calories while maintaining the great SunnyD flavor that consumers have loved since 1964 when the brand was launched. This is important, as moms have told us they are looking for alternatives to soda, and SunnyD now has 40% fewer calories than most regular sodas,” Zimmerman adds. Plus, SunnyD is rolling out three new flavors — orange/carrot with vitamin A, lemon/lime and raspberry lemonade — and completed a national introduction of its updated packaging, including its new gallon containers. “Over the past two years, we have been working with retailers and consumers to find ways to make our most popular size — gallons — even better,” Zimmerman says. “Now, we are investing $70 million in capital improvements to install new lines in all four SunnyD plants. We call the new gallon our Quad Bottle because it provides important benefits in four areas.” For example, the Quad Bottle is said to offer superior ergonomics due to its roomier handle, off-center spout and square shape Continued on page 40

Non-dairy Beverages

for easy storage. The square bottle is also stronger, thus dramatically reducing the need for corrugate by replacing current cases with trays, Zimmerman says. The brand’s mission is to brighten the flavor and spirit of America, he says, and the bottle’s updated graphics enhance the brand’s in-store visibility and better differentiate its flavors. Old Orchard Brands goes beyond natural and into “simplicity,” according to Kevin Miller, vice president of marketing. “Today’s consumer wants to see just one or two ingredients on the label and ideally fewer calories per serving,” he adds. That’s why the Sparta, Mich.based company introduced Cranberry Naturals, a line of cranberry juice blends naturally sweetened with Truvia. Featuring just a hint of natural sugar and 70 calories per 8-ounce glass, Cranberry Naturals comes in Classic Cranberry, Cranberry Blueberry, Cranberry Pomegranate, Cranberry Grape, Cranberry Apple and Cranberry Raspberry offerings.

one thing to develop a great“It’s on tasting juice, but it’s entirely another ju develop one that is low in sugar, to deve great-tasting and all natural,” grea Miller says. “Busy moms and Mi families that value better-forfam yyou food is exactly who we ccater to, and we do so by ccreating juices that speak to ttheir needs.” In March, Naked Juice, Monrovia, Calif., launched a bevy of flavor innovations that are said to meet on taste and nutrition. For instance, Berry Veggie F Machine and Orange M Carrot smoothies are vegC eetable-rich smoothies full

Coffee In a Can Seattle’s Best Coffee, a division of Starbucks Corp., Seattle, launched iced canned lattes as part of its “Anywhere Great Coffee is Needed” campaign. The line includes Iced, Iced Vanilla and Iced Mocha latte options housed in 9.5-ounce cans with 130 calories each. To beat the summer heat, it also introduced Cookie Dough JavaKula blended ice coffee, which is made with cold brewed coffee and a combination of cookie dough syrup and white chocolate sauce, topped with a chocolate baton, whipped cream and chocolate chip cookie crumbles. 

40

Dairy Foods | May 2011

Taking One for the TEAm Tea consumption has nearly doubled nationally over the past decade, says Penny Baker, director of marketing for Dairy Enterprises Inc./Smith Dairy Products Inc. That’s why the Orrville, Ohio-based processor introduced new tea flavors — diet tea with lemon, 50/50 tea lemonade blend and peach tea. Each flavor contains no preservatives, is made with natural flavorings and comes in half-gallon bottles. “These flavors round out our tea line that already includes a Southern Style sweet tea, our best seller, and tea with lemon,” Baker notes. “The size and potential growth of the beverage market provides plenty of opportunity for innovation in both product and packaging, as well as higher profit margin items,” she adds. “Local and artisan products are popular in other beverage segments (beer, for example). Why not in the non-dairy segment, as well?” 

of essential vitamins, whereas Tropical Smoothie With Coconut Water (a juicy blast of pineapple and mango flavor) and Peach Guava Smoothie With Coconut Water are made with high-quality ingredients and boast 35% fewer calories. Both are excellent sources of vitamin C, as well as other essential vitamins. “The introduction of Naked Juice’s two reduced-calorie smoothies provided consumers looking to achieve a weight-loss goal or maintain a healthier diet with an alternative that didn’t require a sacrifice on taste,” says Chris Malnar, marketing director. “Additionally, Naked Juice knows that when it comes to their juice drinkers, one size doesn’t necessarily fit all. That’s why we offer bottle size varieties with flavors in 10-, 15.2-, 32- and 64-ounce sizes, meeting the needs of consumers in the way that’s most convenient for them.” Naked Juice is also in the process of transitioning to reNEWabottle packaging that’s made with 100% recycled materials, and plans to present two new reduced-calorie flavors — Lychee and Citrus Lemongrass, Malnar says. R.W. Knudsen Family lightened up the juice aisle with a new lineup of sweetened with Truvia Light! Juices, available in 32-ounce bottles. They come in cranberry, pomegranate and blueberry (the latter is suggested to be blended with yogurt and fruit to create a breakfast smoothie). Meanwhile, Ocean Spray Cranberries Inc., LakevilleMiddleboro, Mass., developed Sparkling Juice drinks, which are said to provide the same taste of Ocean Spray juices, but with bubbles. The rise and fall of the energy crisis When it comes to beverages, it seems as though there’s a “cure” for every type of mood. Need some sleep? Take a swig of a relaxation beverage. Need to stay awake? Opt for a more amped-up liquid solution. All of this back and forth can cause even the most stable consumer to experience an energy crisis. Thankfully, many of today’s energy (and even the calming) drink providers Continued on page 42

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Non-dairy Beverages

provide an assortment of options, so that consumers can feel energized and relaxed at all times. Bai Brands LLC is making a splash into the energy-infused waters with its low-calorie, antioxidant-rich Bai5 Congo Bear flavor, which hit store shelves in March. Made with a coffee superfruit, sweetened with Stevia and containing 5 calories per serving, this functional drink attracts consumers of all kinds. “Bai is an attractive option for consumers who want to fortify their healthy lifestyles with a low-calorie, energy-boosting beverage that tastes great and is easy to enjoy on the go,” says Ben Weiss, founder and CEO of the Princeton, N.J., company. “The infusion of the coffeefruit provides a higher concentration of antinti oxidants than other superfruit ingredients commonly found in functional beverages, such as highly respected pomegranate and acai.” Bai Brands plans to launch three new varieties packaged in 14-ounce glass bottles, scheduled to debut June 15. Xyience, Las Vegas, maintains its stance in the energy drink sector with innovations such as its Xenergy Xtreme Fruit Punch, which made its first appearance at the Ultimate Fighting Championship, Feb. 5 at the Mandalay Bay hotel in Las Vegas. The 16-ounce can features UFC welterweight fighter Dan Hardy on the front, making Xyience the official energy drink of the UFC.

Flax Milk Hits Store e Shelves Flax USA Inc., a fifth-generation family farm located in Goodrich, N.D., introduced Flax Milk, available nationwide in Original and Vanilla flavors, boasting 60 and 50 calories per serving, respectively. The benefits of flax milk include 1,100 milligrams of omegas per 8-ounce serving, which is as much calcium as dairy milk, vitamin D2 and vitamin B12 combined, it’s all-natural and soy-, lactoseand gluten-free, contains zero cholesterol and saturated fat and boasts a 22-month shelf life. “[Flax milk] is an easy way to get your omegas and calcium without the calories,” says Stephanie Sonju Stober, owner and president. “Enjoy it on cereal, drink it by the glass and add to smoothies, dip cookies in it, etc.” 

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Dairy Foods | May 2011

Bottled Water Brands Undergo Packaging Makeover As part of its ongoing effort to reduce its carbon footprint, Danone Waters of America redesigned its 1.5-liter evian bottle. The new option is made of up to 50% recycled polyethylene terephthalate (PET), remains 100% recyclable, uses 11% less plastic and reduces the company’s ecological impact by 32%. The White Plains, N.Y., company installed an environmental policy that aims to reduced CO2 emissions by 40% through the end of this year. Meanwhile, Evamor Products Inc., a subsidiary of Wm. B. Reily & Co., Covington, La., revamped the logo, label and packaging of its Natural Artesian Water line with the help of flowdesign, a Northville, Mich.-based packaging design consultant. The new logo, for instance, features a gray ball balancing on a gray horizontal plane to represent the 8.8 pH balance. (Evamor uses water from a rare underground aquifer that’s naturally infused with alkaline). The brand name appears in a white font on a dark blue background and the bottle itself appears in an hourglassshape style for easier gripping. 

“Xyience’s primary point of difference is a superior tasting product with no sugar, no calories and only two carbohydrates,” says John Lennon, president. “The energy boost comes from the B-complex vitamins contained within our product.” While some companies provide energy-boosting beverages, others are in business to slow it down. Such is the case for Take 10 Beverages with its line of Take 10 to Relax and Take 10 to Sleep, introduced in June 2010. Designed as a natural alternative to pharmaceutical prescriptions, these “sleep aids” come in 2-ounce bottles. “Due to the amazing popularity of energy drinks and ‘shots,’ we’ve found that retailers are used to the 2-ounce bottle size, and they’ve made appropriate space in the store to sell liquid dietary supplements. We took that approach and applied a quiet sup design and shoulder-less bottle so the product’s silhoudes ette really stands out from the energy shot crowd,” says Jason Mascari, chief product officer of the Grand Rapids, Ja Mich.-based company. M Unlike those businesses that are out to produce the next energy shot or sleep-induced beverage, The FRS Co., Foster City, Calif., is on a mission to “perfect the C performance of the human body,” and began doing so p by offering a healthy protein drink that addresses sevb eeral elements of recovery after a work out, according to Deepak Masand, vice president of marketing. “We proD vide carbohydrates to fuel the body, B vitamins to help vi the body metabolize the protein, antioxidants to fight th free radicals, which attack the cells, anti-inflammatories fre to reduce swelling and stiffness and quercetin with amino acids to boost immunity, as well as protein to rebuild lean aci muscle tissue. You will find 7 grams of soluble fiber in each mu bottle,” Masand says. bot For example, Healthy Protein is a protein-infused drink F that also acts as a meal replacement or liquid meal option for dieters, while the Healthy Energy option provides healthy Continued on page 44

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Non-dairy Beverages

energy without the crash in ready-to-drink cans, resealable bottles, chews, powder and concentrate. “As we innovate, we look to new ingredient trends such as a plant-based ingredient like wheat grass, which contains most of the vitamins and minerals needed for human maintenance. It’s a whole meal and a complete protein with excellent sources of calcium, iron, magnesium, phosphorus, potassium, sodium, sulphur, cobalt and zinc. Another highly desired ingredient is antioxidants, such as cupuacu, from the Brazilian rainforest. Cupuacu belongs to the same family of raw ingredients in chocolate called cocoa; thus offering a high flavonoid content.  But unlike cocoa, it has no caffeine. This fruit also contains essential fatty acids, such as the omegas 3 and 6.  This mix of antioxidants and essential fatty acids make it an ingredient to follow in the fight to maintain a healthy heart and cardiovascular system. Another ingredient of interest is spirulina. Providing an unusually high amount of complete protein, spirulina contains all essential amino acids and is between 55-77% by dry weight, depending upon the source,” Masand notes.  GoodBelly’s beverages are said to promote digestive health.

It’s a team effort Also A in the mix are ready-to-drink teas and coconut water, the latter which is growing in popularity. Last year, ViVa Beverages LLC introduced Marley’s Mellow Mood, a line of 100% natural, caffeine-free relaxation teas and sodas, says Paul Fuegner, chief marketing officer for the Southfield, Mich., company. Marley’s Mellow Mood is formulated p with exotic valerian root, passionflower, w melatonin, rose hips and lemon balm. (See New N Product Review on page 25 for photos and additional information.) “Marley’s Mellow Mood is designed to reduce stress and relieve tension, while calming the soul and easing the mind,” he adds. “Marley’s Mellow Mood is available in two t varieties: lightly carbonated sodas (berry and citrus flavors) in 12-ounce aluminum cans, and ready-to-drink cold teas (green tea with honey, black tea with raspberry and passion fruit and peach flavors) in 16-ounce glass bottles.” ViVa Beverages also introduced Quick Beverages, a line of 2-ounce liquid sleep and relaxation aids that are made from a proprietary blend of all-natural, time-tested botanical ingredients, available in a zero-calorie, sugar-free berry flavor. SPI West Port Inc., South San Francisco, Calif., developed new varieties under the ALŌ Drink line of all-natural, aloe vera-infused drinks — ALŌ Enrich (pomegranate, cranberry and aloe) and ALŌ Appeal (pomelo, pink grapefruit, lemon and aloe). SPI West Port also launched Coco Exposed, a line of pure coconut water combined with real aloe vera pulp, juice and fruit juices, says Henry Chen, president. “Coconut water, often referred to as nature’s sport drink, is a great natural hydrator and an excellent source of potassium, which can help prevent cramping. Each bottle of Coco Exposed 44

Dairy Foods | May 2011

10 Flavor Trends & Label Claims in Non-dairy Beverages 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Calorie reduction Orange-carrot combinations Superfruit formulas Use of coconut water “No-sugar added” claims Sweetening with stevia All natural Plant-based ingredients (such as wheat grass) Relaxation properties Protein-infused

 Quick from ViVa Beverages is sold as a sleep and relaxation drink.

contains at least 418 milligrams of potassium,” he says. Coco Exposed comes in goji berry and lychee, passion fruit and pineapple, wheatgrass, mangosteen and mango and peach and kiwi flavors. Also in the coconut water arena is One World Enterprises LLC, dba: O.N.E. Coconut Water, Los Angeles, with its new offerings — O.N.E. Kids and O.N.E. Active. “O.N.E. Kids is the first coconut water product made specifically for kids in a carton juice box (6.25 ounces). It is a lowcalorie and sugar juice with no added sugars, colors or preservatives,” says Rodrigo Veloso, founder and CEO. “O.N.E. Active is i a natural sports drink with a coconut water base.” Meanwhile, in March, GoodBelly, Boulder, Colo., presented GoodBelly Probiotic Coconut Water, GoodBelly Tropical Green and GoodBelly StraightShot, all infused with the company’s patented probiotic strain, Lp299v, to promote digestive health, according to Alan Murray, chief executive officer. “GoodBelly Probiotic Coconut Water is a light and refreshing coconut water with 20 billion live and active probiotic cultures of Lp299v per serving and no added sugar. GoodBelly Tropical Green is in a base of organic fruit juices with an added blend of antioxidants, vitamins and mineral-rich organic greens like spinach, spirulina and more, which are combined with billions of live and active cultures of Lp299v. Our Tropical Green drink is also lower in calories and sugar than the leading green juice brand. GoodBelly StraightShot is our most simple and economical probiotic option with 20 billion live and active probiotic cultures per serving in a delightful and gentle non-dairy base with no added sugar,” he adds. Today’s assortment of exotic-flavored juices and drinks pack quite the punch. And, as processors continue to develop new beverages, it’s no wonder consumers are thirsty for more. 

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Adding functional ingredients and employing sustainable practices are increasingly more common in the dairy foods product development lab  Donna Berry Product Development Editor

T

he Dairy Council of California recently published its Top 10 Nutrition Trends for 2011. No. 5 reads: Sustainability is increasingly a factor in consumer food decisions.

What is sustainability? Defining sustainability is a challenge because it is an ongoing process with many facets. In some instances a number can be tied to an effort. For example, “On-going dairy research efforts to reduce greenhouse emissions have resulted in a 63% reduction in the industry’s carbon footprint since 1944,” says Lori Hoolihan, nutrition research specialist at the council’s Irvine offices. But other sustainable efforts are transparent, but equally, if not more important. Many of these are addressed by the Food and Agriculture Association of the United Nations (FAO), which issued this statement in November 2010: “Sustainable diets are those diets with low environmental impacts, which contribute to food and nutrition security and to healthy life for present and future generations. Sustainable diets are protective and respectful of biodiversity and ecosystems, culturally acceptable, accessible, economically fair and affordable; nutritionally adequate, safe and healthy; while optimizing natural and human resources.” 46

Dairy Foods | May 2011

But most consumers are unaware of all these aspects of sustainability, in particular, nutritional adequacy. “Most sustainability discussions do not include nutrition as an important part of food decisions,” says Hoolihan. “But the nutrient density of foods must be considered, as good nutrition supports health and wellness, and can assist with disease prevention. This ultimately contributes to the sustainability of mankind.” Processors must communicate that milk and many other dairy foods are some of the most nutrient-dense foods in today’s marketplace. “The list of positive nutritional health benefits in milk is long and is growing,” she says. “Research supports disease prevention and health promotion from vitamin D, calcium, protein, probiotics, whey, and the overall package of nutrients that milk provides.” Dairy is also the ideal delivery vehicle for fortification. The refrigerated, short shelf life that many dairy products have is a compatible environment for functional ingredients that further contribute to the nutrient density of milk and milk products. Start with raw materials For many dairy foods processors, the most important ingredient to consider when addressing sustainability is milk.

Photo courtesy of Arla

Cover Story

Cover Story

Red Barn Family Farms, Appleton, Wis., subscribes to a simple belief, according to founders Terry and Paula Homan, and that is, “the healthiest cows produce the best milk.” Terry, a practicing veterinarian who regularly observes the 350-plus cows on the eight local sustainable Wisconsin family farms that supply milk for the manufacture of Red Barn Family Farms cheese and packaged milk, says, “We believe that when farms truly excel at animal husbandry — when the animals have a comfortable life and are treated well — the results will be obvious. “Our farms are certified by the American Humane Association, ensuring that our farms meet the conditions required to use the American Humane Certified seal on all finished products,” he says. And what does that seal mean to consumers? According to an independent public opinion survey conducted in 2007 for the American Humane Association, Englewood, Colo., the “humanely raised” label was No. 1 in importance over “organic” and “cagefree,” other terms that have been associated with the sustainable food manufacturing movement. Nearly 60% of those surveyed indicated a willingness to pay more for foods with a humanely raised label. And just this past year, Chicago-based foodservice market research firm Technomic reported that more than half of consumers point to animal welfare as one of the most important social issues in the food business. “The American Humane Certified seal assures our customers that the milk comes from cows free from rBST supplementation, free from animal byproducts in their feed and free from performanceenhancing antibiotic use, and they always have access to fresh water and a diet that maintains full health and vigor. Our cows are free to live and grow in a humane environment under conditions and care that limit stress,” says Homan. “We make sure they are free to enjoy a healthy life, benefiting from disease and injury prevention and rapid diagnoses and treatment. They are free to express normal behaviors and live in an appropriate and comfortable environment that includes sufficient space, proper facilities, shelter, a resting area and company of the animal’s own kind. “We also have our own Red Barn Rules, which are unique and go above and beyond the American Humane Association certification. They are the cornerstone of what we believe makes the best milk,” he explains. “Our rules assure that farms are run by families who earn their livelihood on the farm and do the majority of the animal care work. Twice each year, each cow is individually assessed by a veterinarian — usually me —and given a health score. Further, criteria are measured in the milk verifying the outstanding cleanliness of the milk as well as the health of the cows. Premiums are awarded to each farm based on the milk quality measures and the health scores.” Homan uses that milk to produce a number of cheeses and fluid milk products. The company’s most recent innovation is Weinlese Cheddar Blue cheese, which is an original recipe handcrafted in micro-batches by Seymour Dairy Products Inc., Seymour, Wis. Weinlese, which means “vintage” in German, was developed by award-winning Wisconsin cheesemaker Mike Brennenstuhl. “We aimed to create a Wisconsin original cheese with soul,” Brennenstuhl says. “This is the kind of cheese that speaks to you. It starts like a cheddar and finishes like a blue.” Featuring a sweet and nutty, creamy and mellow flavor, Weinlese boasts a unique appearance with golden hue and green veins. “Weinlese is crafted with a passionate consciousness for the earth and the animals who produced the milk,” Homan says. “It’s a true partnership of premium ingredients: exceptional milk paired with exceptional cheesemaking.”

Photo courtesy of Wisconsin Milk Marketing Board

 A better-for-you and better-for-the-earth sandwich can include cheese made from milk that makes a sustainable production claim. The cheese can also be enriched with functional nutrients such as bone-building calcium and vitamin D and brain-developing omega-3 fatty acids.

The Certified Humane Raised and Handled label is another third-party certification for humane treatment of animals. Issued by Humane Farm Animal Care, Herndon, Va., Redwood Hill Farm & Creamery Inc., Sebastopol, Calif., was the first goat dairy farm in the United States to carry the label. The company recently entered the cows milk kefir, sour cream and yogurt category with the Green Valley Organics Lactose Free brand, and purchases milk from a local dairy that also meets certified humane standards. “Our new line was designed to help the millions of Americans who are lactose intolerant to be able to once again enjoy nutrientdense dairy foods,” says Jennifer Bice, owner. “We use only the highest-quality organic ingredients, and our products provide all the protein, calcium and other nutritional benefits of milk from organic, Certified Humane Raised and Handled dairy cow farms. “As the only dairy brand to offer Flourish — a custom blend of 10 live, active probiotic cultures that promotes optimal digestive and immune system health — our new lactose-free products help bring harmony and happiness to troubled tummies,” says Bice. “Consumers should strive to get three servings of calcium-rich dairy in their diet every day for optimal (a.k.a. sustainable) bone health. And because yogurt and kefir are functional foods, they provide a synergy and health benefit beyond the traditional nutrients found in the food. Lactose-intolerant consumers can finally enjoy real dairy and the functionality of yogurt and kefir without worrying about the after effects.” The role of organic It is important that marketers remember that sustainable does not mean organic; however, according to the Organic Trade Association, Brattleboro, Vt., organic agriculture is a sustainable production process. This is because organic refers to the way agricultural Continued on page 48 www.dairyfoods.com

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products are grown and processed, and this system of farming maintains and replenishes soil fertility without the use of toxic and persistent pesticides and fertilizers. The following excerpt is from the definition of organic that the National Organic Standards Board adopted in April 1995: “Organic agriculture is an ecological production management system that promotes and enhances biodiversity, biological cycles and soil biological activity. It is based on minimal use of off-farm inputs and on management practices that restore, maintain and enhance ecological harmony.” “Organically produced food cannot be described as being more nutritious than conventionally produced food,” says Roger Clemens, president-elect for the Institute of Food Technologists, Chicago. “Nor can organically produced foods be described as being safer, as scientific evidence indicates that organic foods run a greater risk of being contaminated with pathogens. In fact, organic foods do have pesticides, just not those found in conventional agricultural practices. Thus, when it comes to contributing to a sustainable diet, organic is not necessarily any better than a conventional food. For example, an organic lollipop is not more sustainable than conventionally produced yogurt just because the ingredients in the lollipop are certified organic.” However, many consumers and processors feel very strongly about organic and its impact on the world and the body. “I think that one of the most important parts of ingredient sourcing is knowing what ingredients to leave out in order to make the best possible product, which in our case is organic ice cream,” says Neal Gottlieb, founder, Three Twins Ice Cream, Petaluma, Calif. “We are a certified organic producer and only use

Photo courtesy of National Restaurant Association

Cover Story

 Farmers markets are often the first point of entry into the marketplace for small, local dairy processors. The markets give consumers access to locally produced, farm-fresh milk, cheese and cultured dairy foods and the opportunity to personally interact with producers and learn about their products. As of mid-2010, there were 6,132 farmers markets operating throughout the country. This is a 16% increase from 2009. Continued on page 50

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Made with Sustainable Ingredients Weinlese Cheddar Blue cheese is an original recipe handcrafted in micro-batches by Seymour Dairy Products Inc., Seymour, Wis., for Red Barn Family Farms, Appleton, Wis. The cheese is made with American Humane Certified milk from local family farms. Pacific Foods of Oregon Inc., Tualatin, Ore., uses Fair Trade Certified tea in its aseptically packaged organic tea beverages. Ben & Jerry’s, a brand of Unilever, Englewood Cliffs, N.J., introduces Late Night Snack ice cream. This treat starts with Fair Trade Certified vanilla ice cream, to which fudge-covered potato chip clusters and a salty caramel swirl are added. 

ingredients that are individually certified organic. There are certain benefits to exclusively purchasing organic ingredients, such as the fact that workers in organic fields are not exposed to chemical pesticides and herbicides that those working in conventional agriculture are often exposed to.”

Stonyfield Farm, Londonderry, N.H., the world’s leading organic yogurt company, recently launched “Just Eat Organic!” This year-long organic education campaign includes two efforts designed to get people talking about organic. The first is a music video by Gary Hirshberg, Stonyfield’s president and CE-Yo. The second is online space for people to share personal stories about what organic means to them. (See photo and caption on page 56.) Hirshberg’s rap video tells the story of America’s switch from family farms to modern agriculture, which let “big agriculture” profit while consumers became addicted to convenient foods that are bad for their health. As Hirshberg raps, “Cancer rates are steadily rising, in kids and moms and dads. A baby born in Birmingham, Boise, Bend or Boston, now has in her cord blood almost 300 toxins. The U.S. Cancer Panel Study makes me ill at ease ‘cause 41% of us will get this disease. Cut out unnecessary chemicals is what they prescribe. So to avoid getting sick, just change the stuff you imbibe!” The Stonyfield Moms, three employee volunteers, rap the upbeat chorus, “So if you love your body, love your children and you love your planet, there is hope for the future, so there’s no need to panic. The solution is a simple one. It’s easy to understand it. To protect your family, body and earth…just eat organic!” According to the company, which is now in its 28th year, its use of organic ingredients helps keep more than 180,000 farm acres free of toxic, persistent pesticides and chemical fertilizers known to contaminate soil, drinking water and food. Drivers of product development By now it should be clear that better-for-you and better-for-theenvironment ingredients are the key drivers of innovation in dairy Continued on page 52

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Dairy Foods | May 2011

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Cover Story

foods product development. Functional ingredients that add value to dairy foods and contribute to a more sustainable diet are plentiful. Many are available organic certified, while others are on the National Organic Program’s approved list of ingredients. Some make claims of sustainable production, including Fair Trade, family owned, farmstead and local. Here are the top 12: 1. Antioxidants. Not only are foods that have always contained known antioxidants, including carotenoids, polyphenols (e.g., anthocyanin, flavonoids and resveratrol) and vitamins now being flagged for their antioxidant content, other foods, such as dairy products, are being enhanced with these ingredients. Such ingredients may be added directly (e.g., vitamin-E fortified) or indirectly (e.g., made with anthocyanin-rich blueberries). Antioxidants are believed to help neutralize free radicals, which are unstable molecules associated with the development of a number of illnesses, including cancer, cardiovascular disease and agerelated conditions such as Alzheimer’s. However, there are many types of antioxidants and they do not all function the same. 2. Calcium. The role of calcium in bone health resonates with consumers. As a result, an increasing number of dairies are now adding extra calcium to their products to create a point of differentiation in the crowded dairy case. 3. Cocoa. The health and wellness benefits associated with cocoa consumption continue to drive the use of high-quality chocolate in all food categories, including dairy products such as frozen desserts and milk. The majority of science into the potential benefits of cocoa revolves around cardiovascular health; however, within the past year, studies have shown that cocoa flavanols may also exert a prebiotic effect, much like soluble fiber.

The Power of Fair Trade Consumers are increasing their commitment to Fair Trade faster than ever, and sales of Fair Trade Certified products increased 24% to $170 million during 2010, according to a new report from Fair Trade USA, Oakland, Calif. The report also states that more than 700 companies offer Fair Trade-certified products. Schaumburg, Ill.-based market research firm SPINS reports that in 2010, sales of Fair Trade-certified products at mainstream channels grew faster (26%) than those of specialty grocers (22%) and natural grocers (16%). “The volume of growth in mainstream grocers was more than three times larger than the volume of growth in the natural and specialty channels, traditionally the leading retailers of Fair Trade-certified products, where we continue to also see significant growth,” says Cate Baril, director of business development, grocery and ingredients. Coffee, the flagship Fair Trade category, grew 33%, due to the increased variety of Fair Trade coffees available through a broader assortment of retail supermarkets. Ready-to-drink tea and coffee grew 39% thanks to commitments from brands such as Adina and Honest Tea. In sweeteners, Fair Trade supporters indulged in wholesome sweeteners among others, driving an increase of 17%. Frozen desserts increased 4% and chocolate rose 19%. 

It is important to point out that these benefits are associated with cocoa, not chocolate. Cocoa is a component of chocolate, which means that chocolate ingredients are a diluted source of cocoa and marketers who want to make cocoa claims must ensure Continued on page 54

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Dairy Foods | May 2011

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Cover Story

that the chocolate ingredients being flagged in product formulations contain a high percentage of cocoa flavanols. 4. Coffee. A growing body of research shows that coffee drinkers, compared to non-drinkers, are less likely to have type 2 diabetes, Parkinson’s disease and dementia, as well as have fewer cases of certain cancers, heart rhythm problems and strokes. Coffee and milk are about as

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perfect a marriage as it gets. Coffee ingredients have application in milk beverages, ice cream and even yogurt. 5. Conjugated linoleic acid. CLA is a fatty acid naturally present in cows milk and certain animal meats; however, not at levels high enough for humans to reap the health benefits associated with their consumption. This is due to changes in the Western diet, where average intake of CLA

has fallen as a result of consuming mostly fat-free and low-fat dairy products, as well as leaner cuts of meat. The benefits associated with consuming efficacious levels of CLA include a reduction in body fat and increased lean muscle mass. CLA is available in a concentrated form that is GRAS for dairy foods applications. 6. Fiber. Fiber is a well-recognized food component. In the past five to 10 years, fiber has become an identifiable food ingredient that consumers understand. However, the only similarity that all fiber ingredients have is that they are not digested by the body. Functional benefits differ from fiber to fiber, and include increased mineral absorption to prebiotic functionality. 7. Green tea. Known for its powerful antioxidant and disease-fighting properties, in particular against cancer and heart disease, green tea has also been shown to help lower cholesterol, burn fat, stave off dementia and assist with eye health. Green tea comes in many ingredient forms, including as a concentrated extract that is virtually tasteless. 8. Nuts. The health image of nuts was given a boost in 2003 when FDA approved a qualified health claim for nuts that linked most nuts as part of a diet low in saturated fat and cholesterol to a reduced risk of heart disease. Many tree nuts and peanuts complement creamy dairy products. Not only do they add flavor, texture and eye appeal, they are loaded with nutrients that interest today’s health- and wellness-seeking consumer. In most dairy applications, diced, sliced and slivered nuts are best when formulating multi-serving items. The smaller particles disperse throughout the product allowing each serving a healthy dose of the inclusion. Processors should choose various cuts and sizes based on the final appearance, texture and mouthfeel that they are trying to achieve. 9. Omega-3 fatty acids. Alphalinolenic acid (ALA), docosahexaenoic acid (DHA) and eicosapentaenoic acid (EPA) are the talk of the food formulating world. Natural sources of DHA and EPA are oily fish. Fish are sources of DHA because of the DHA-rich microalgae in their food chain. Thus, there’s also a DHA ingredient derived directly from microalgae. ALA is found in plants such as flax and chia, as well as certain tree nuts. It is important to note that only DHA and EPA contribute to the many health benContinued on page 56

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Dairy Foods | May 2011

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An Interesting Perspective on Sustainability

 “Just Eat Organic!” is a new year-long organic education campaign from Stonyfield Farm, Londonderry, N.H. It includes a music video by Stonyfield CE-Yo Gary Hirshberg, which can be viewed at www. justeatorganic.com. It also offers online space called “The Organic Moment” (www.yourorganicmoment.com) for people to share personal stories about what organic means to them.

efits associated with consuming omega-3 fatty acids. ALA can be converted into DHA and EPA. However, the body converts it rather inefficiently and with much variance among consumers based on external and internal factors. DHA and EPA are essential at all stages of life. For infants up to the age of three, DHA is essential for the development of the brain and eyes. After the age of three, both DHA and EPA are important for cognitive function, and research suggests that these fatty acids may improve behavior and learning disorders, including Attention Deficit Hyperactivity Disorder (ADHD) and Developmental Coordination Disorder (DCD). Additionally research indicates that EPA and DHA may reduce inflammatory conditions such as asthma, childhood depression and reduce the risk of type 1 diabetes. 10. Probiotics. Though dairy processors around the world have been scrutinized and at times penalized for making probiotic health claims, processors continue to add these beneficial bacteria to all types of dairy foods with hopes that educated consumers recognize the value. Formulators are encouraged to ask suppliers for clinical documentation supporting a bacteria strain’s probiotic status. Further, processors should be conservative when making any content or health claims. Unsubstantiated claims and misuse of the term will dilute the value of clinically proven probiotics and their contribution to the sustainability of man. 11. Vitamin D. The sunshine vitamin has been linked to bone health, immune health, lower risk of several cancers, reduced heart attacks and fewer falls by the elderly, as well as other health and wellness benefits. Vitamin D is also gaining a great deal of attention in the nutricosmetics business, as some believe that vitamin D helps maintain mineral levels in the skin, which in turn maintains the skin’s moisture levels. Dryer skin is more easily damaged and less firm. 12. Whey proteins. Consumers are looking for new, natural ways to curb their hunger and using whey protein as an ingredient in food and beverage products is a way to reach these consumers. Research supports the role of higher-protein diets in promoting satiety. This may help people manage hunger and crav56

Dairy Foods | May 2011

The Dietary Guidelines Advisory Committee’s report provided recommendations for food and nutrient intakes that USDA used to develop the 2010 Dietary Guidelines for Americans. This 445-page document contains a wealth of information that never made it into the official guidelines, including sustainability implications for the dairy industry. La Mirada, Calif.-based Roger Clemens, a member of the committee, and president-elect for the Institute of Food Technologists, Chicago, explains that the report notes several food groups and dietary components that are under-consumed and may be low enough to be of concern. “For example, among adults over the age of 50, 75-90% do not meet the recommended intake of 2.5 to 3 cup equivalents of dairy products daily,” he says. But, if this population, along with all other Americans, tried to consume enough dairy to meet the recommendations, they would be surprised to learn that it is not possible. U.S. farmers do not produce enough fluid milk. “Current milk production is not sustainable,” says Clemens. “A 2006 report from USDA’s Economic Research Service, based on 2002 data, indicates that an additional 107.7 billion pounds of milk was needed to support the 2005 Dietary Guidelines recommendations for fluid milk and milk products. This is equivalent to a 66% increase in the number of dairy cows, feed grains and grazing acreage. To meet 2015 expectations, a more appropriate increase is nearly 80%.” The dairy industry is not alone. Vegetable and fruit growers face the same dilemma. “Recommended fish intakes are the most unrealistic of them all,” Clemens adds. “If all Americans consumed two servings of fish a week, the world would run out of fish within a very short period.” With dairy, it would be safe to say that the industry should be careful what it wishes for. On the one hand it is great news that the Dietary Guidelines continue to emphasize the importance of consuming dairy products, and in fact, for the 4- to 8-year-old age group, recommended daily servings increased from two in the 2005 report to two and a half in 2010. On the other, it is not viable for farmers to produce enough milk to enable every American to meet their recommended daily intake. Because these are just recommendations, and historically Americans have not been good about following them, it is doubtful that supply will not be able to meet demand. “But it is definitely another bullet point for the dairy industry to consider when addressing sustainability,” Clemens concludes. 

ings between meals or reduce the desire to reach for unnecessary snacks between meals. Further, in combination with strengthtraining exercises, whey proteins can help boost the rate at which the body makes lean muscle. To conclude, dairies would be wise to follow the ambitions of Caffè Classico Foods LLC, Concord, Calif. “We are always striving to source the highest-quality ingredients and focus on all-natural sources from responsible companies,” says Larry Leser, president. 

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IFT Show Preview Photo courtesy of Alex Demyan and NewOrleansOnline.com.

 A local sax player entertains

 Donna Berry Product Development Editor

housands of food scientists, suppliers, marketers and others from around the world will gather in New Orleans this June 11-14 at the IFT 11 Annual Meeting + Food Expo. As the largest annual food science forum and exposition in the world, attendees and exhibitors have the opportunity to exchange thoughts, ideas and recent innovations. Experts from companies, government agencies and research institutions provide insight during more than 1,000 presentations covering topics ranging from new health and safety benefits and product innovations to the latest consumer favorites, fears and trends. There are a number of sessions geared specifically to dairy processors. (See Must-see Symposia, page 60.) In addition, throughout the technical meeting, make sure you check for dairy-related research presented at the poster session. Join other food scientists at the IFT Awards Celebration on Saturday at 5:30 p.m. to honor recipients of the prestigious IFT Achievement Awards and newly elected IFT Fellows. This is your opportunity to congratulate your colleagues for their outstanding achievements and contributions to the field of food science and technology. During the celebration, IFT president Robert Gravani will recap the past year’s IFT accomplishments and introduce Roger Clemens, the incoming IFT president and

T

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Dairy Foods | May 2011

pedestrians along the Mississippi River. The nickname Crescent City alludes to the course of the river around and through New Orleans.

president-elect. Following the awards ceremony is a networking reception where attendees can connect with old friends and meet new ones while enjoying New Orleans-style cuisine and entertainment. This year’s keynote session will be in the format of a panel discussion and takes place on Sunday morning (8:30 to 10:15 a.m.). Entitled “Delivering Science: Changing the Image of Food Science in the Marketplace,” the panel features author Michael Specter. In his book, Denialism, How Irrational Thinking Hinders Scientific Progress, Harms the Planet, and Threatens our Lives, Specter argues that by turning our backs on scientific impartiality, we are abandoning rational thought in favor of hearsay, rumors and vague promises. As a result, he sees this impacting consumer purchasing decisions and promulgating a rush to organic foods, as well as vitamins, dietary supplements and “natural” cures that may

Expo Hours Sun., June 12 Noon to 5:00 p.m. Mon., June 13 10:00 a.m. to 5:00 p.m. Tues., June 14 10:00 a.m. to 4:00 p.m.

IFT Show Preview

Photos courtesy of New Orleans Convention and Visitors Bureau

 New Orleans is home to hot sauce. Make sure you stop by one of the many shops that showcase hundreds of condiments that can spice up your product development endeavors.

 What’s New Orleans without a visit to its famous party bazaar on Bourbon Street?

do no good or may even cause harm. Most importantly, he gives voice to the growing fear that denialism, as he calls the phenomenon, will stifle scientific inquiry and progress, prevent us from solving solvable problems such as famine in third-world countries, and create new windows of opportunity for devastating diseases to appear in the world. Plan to join Specter and a panel of food industry experts in a discussion of this trend and its effect on the food industry. All IFT members are also invited to the annual IFT Town Hall Meeting, which takes place on Sunday (4:45 to 5:45 p.m.). Attendees will have the chance to learn more about IFT’s current programs and services and to ask questions of members of the Board of Directors. A scientific forum This year’s food science forum is organized around key focus areas within the industry, and is based on core sciences that provide the foundation for all things related to food science. This track structure was designed to meet food professionals’ needs by focusing on topic areas of great interest and importance. It also simplifies the program’s structure to make it easier for you to find your sessions.

The program involves experts from private and public companies (manufacturers and suppliers), government agencies and research institutions. Topics range from new health and safety benefits and product innovations to the latest consumer favorites, fears and trends. The key focus area program tracks are Food Safety & Defense; Food, Health & Nutrition; Food Processing & Packaging; Product Development & Ingredient Innovations; Sustainability; Public Policy, Food Laws & Regulations; and Education & Professional Development. The core science program tracks are: Food Chemistry, Food Microbiology, Food Engineering and Sensory Science. And don’t forget the Dairy Foods Division Open Leadership/Member Breakfast on Sunday (7:00 to 8:30am) at the Hilton Riverside. On the expo floor From beignets to jambalaya, New Orleans is known for its signature dishes. Expect ingredient exhibitors to showcase their wares in many of these famous recipes. To get a glimpse of what some suppliers will be featuring, check out the IFT booth previews starting on page 62. Returning this year are two pavilions dedicated to innovation. Chicago-based market research firm Mintel sponsors the Global New Products Pavilion, which is the place to be for the latest trends in consumer packaged food and drink flavors, ingredients and claims. Whether it’s a creative new Asian snack or the latest innovations in on-the-go packaging, Mintel’s experts can weigh in on your questions about emerging trends. Stay after the presentation to taste, touch and feel new food and drink products from around the world at Mintel’s tasting sessions, which take place repeatedly during the three days of the show. www.dairyfoods.com

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IFT Show Preview

Dairy Ingredients Complement Food Trends  Mr. B’s Bistro, a clubby, relaxed and comfortable French Quarter bistro, is famous for its Creole cuisine and this White Chocolate Brownie Dessert.

Photo courtesy of NewOrleansOnline.com.

The U.S. Ingredients Program of U.S. Dairy Export Council (USDEC), Arlington, Va., will highlight innovative applications for dairy ingredients at this year’s Food Expo. Plan to visit booth #6139 to learn how U.S. dairy ingredients can contribute to improved taste, functionality and nutrition for a variety of products targeting different consumer groups. Valuable information on innovation resources, including research labs, product and nutrition researchers and knowledgeable food scientists will be available to show how dairy ingredients are solving today’s formulation challenges. Visit the various trend stations to sample supportive prototypes. The themes are: Protein throughout the day — Emerging research suggests spacing protein intake throughout the day provides optimal benefits. A number of prototypes have been developed around this theme to address getting enough protein at different times throughout the day — from a protein-packed breakfast waffle to a chilled pasta salad made with cheese and whey protein pasta. Sodium reduction — Americans are being urged to cut back on salt and food and beverage manufacturers are looking for solutions. Permeate, a dairy ingredient, provides salty characteristics while helping formulators reduce sodium content levels in products without sacrificing taste. Healthy aging — With age, most experience a loss of muscle, or muscle wasting. Food and beverage manufacturers

can leverage the quality and value of whey protein in product innovations to reach the mature consumer interested in maintaining muscle strength to support an active lifestyle. Yogurt as an ingredient — As consumers look for ways to improve their eating habits, yogurt is being viewed in a new light as a valued dairy ingredient. Yogurt can be used as a functional ingredient in products for added flavor and nutrition. Attendees will be able to sample a refreshing, savory, yogurt-based beverage that takes its flavor cues from the Mediterranean.

Must-see Symposia Session 20 — Rethinking Protein Requirements and Recommendations: Beyond Muscle; Sunday, 10:30 a.m. to noon Session 79 — Sustainable Food Systems: Nutrition and the Environment; Sunday, 1:30 to 3:00 p.m. Session 136 — Snacking: Insight and Perspectives on Contributions to the American Diet; Monday, 10:30 a.m. to noon Session 182 — Current Trends in Texture Design of Food: Rheological and Textural Studies on Carbohydrate Technology Systems; Monday, 1:30 to 3:00 p.m. Session 220 — New Processing of Dairy Ingredients; Tuesday, 8:30 to 10:00 a.m. Session 274 — Natural Ingredient Opportunities Using Dairy Co-products; Tuesday, 1:15 to 2:45 p.m.

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Dairy Foods | May 2011

In addition, the prototypes will showcase trends related to simple labeling, satiety, the versatility and functionality of cheese, and a variety of application options using whey protein to drive the next generation of nutritious foods and beverages. For more information about the market, product and nutrition research, and application resources provided by the U.S. Ingredients program at USDEC, or to learn the latest information on dairy-related research and information, visit www.Inno vateWithDairy.com.

The Taste the Trend Pavilion is sponsored by Netherlandsbased Innova Market Insights and will focus on accelerating international trends and emerging technologies. Innova will feature a number of presentations focusing on key product development trends with insights on packaging and technology, flavors and consumer trends, complete with opportunities for new beverage concepts/tastings. Take a self-guided Trend & Solution Tour to discover the companies offering products or services related to some of the most significant issues and trends facing the food industry. Tour topics are: Ingredients for Functional Foods, New Direction for Carbs, Next-Generation Fats and Oils, Taste Modification and Weight Management and Diabetes. Printed guides for each tour will be located at the entrances to the Food Expo.  For more information on the technical program and a list of exhibitors, visit www.am-fe.ift.org.

What is eco-friendly about Evergreen Packaging cartons? U U

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Our cartons are recyclable for over 30 million households Our cartons are made with renewable materials – over 70% of the carton is made from paper using trees from responsibly managed forests Our cartons are made with renewable energy – over 50% of the energy used to make the paper in our cartons comes from biomass

Evergreen Packaging Cartons: The Smart Choice Consumers are demanding more from packaging than a cost-effective and convenient way to keep products fresh. Today a significant and growing number of consumers consider the environmental impact of the packaging in their product selection process. Over 70% of our ca carton is made from paper, derived from a renewable resource: trees. And for an in increasing number of households, cartons are recyclable.

So, consumers can enjoy milk kept fresh – and feel good about S their purchase decision. th evergreenpackaging.com

IFT Show Preview

BOOTHS Ajinomoto Food Ingredients

Amelia Bay

Ajinomoto established its name with its signature product, monosodium glutamate, and later ventured into amino acids, artificial sweeteners, savory ingredients and specialty ingredients. Ajinomoto has embraced a management philosophy focused in making significant advances in food and health on a global basis. Providing products that not only taste good, but are good for you, is Ajinomoto’’s promise. As its name implies, Ajinomoto provides the essence of taste, and it has done so without compromise for over 100 years. Please visit www. ajiusafood.com for more information.

Amelia Bay is the industry leader in the development and manufacture of tea and coffee extracts, essences and aromas. Our extraction technology isolates and captures fresh flavor and aroma compounds to produce the ultimate in brewed-quality tea and coffee ingredients for the food and beverage industry. We are the only 100% vertically integrated extraction and formulation company in North America. All products are customized to each client’s specific marketing objective. Our expert raw material selection and state-of-the-art extraction create finished products to meet exacting customer specifications.

Ajinomoto Food Ingredients www.ajiusafood.com 773-714-1436 Booth: 5516

Autocrat Coffee & Extracts Autocrat, a fourth-generation familyoperated business that roasts coffee and uses a custom state-of-the-art extraction system to manufacture coffee extracts, has enjoyed rapid growth of coffee extracts in both national and international markets. With over 100 years of tradition, Autocrat offers regular and organic coffee extracts, as well as tea extracts, that are used to flavor ice cream, iced cappuccino drinks, ready-to-drink beverages, and other dairy products. Functional foods and beverages, including coffee and tea that provide antioxidants, offer a preventive cure from inside out suggesting health benefits beyond basic nutrition. As the trend toward healthy lifestyles continues to drive consumer products, Autocrat is uniquely positioned and dedicated to producing innovative functional ingredients and applications to meet customer needs. Autocrat [email protected] 800-288-6272 www.autocrat.com Booth: 7812

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Dairy Foods | May 2011

John Harper Crandall Amelia Bay Inc. [email protected] www.ameliabay.com 770-772-6360 Booth: 5339

BUCHI Corporation For more than 50 years Buchi has been known as the market leader, inventor and innovator of lab instruments based on Evaporation and Vacuum technologies, and as the supplier of the Rotavapor® rotary evaporators worldwide. In addition, BUCHI Corporation is a proven North American provider of spray dryers for pharmaceutical and food agglomeration and microencapsulation, Kjeldahl and solvent extraction equipment for environmental and food analysis, NIR spectroscopy instruments for pharmaceutical and food Quality Control, modular flash chromatography systems, and other related laboratory equipment. BUCHI Corporation [email protected] 302-225-2465 / 877-MYBUCHI www.mybuchi.com Booth: 5300

IFT Show Preview

Concord Foods/ Oringer Division

David Michael & Co.

Oringer is a manufacturer of ingredients, flavor bases and toppings for bakery, frozen desserts and confectionary applications. We are also one of the largest private manufacturers of caramel in the United States and have developed caramels for every application. Please visit us at booth 7712 and view our new High Protein Caramel. Provides a 10% protein level combined with outstanding taste and texture. Our High Protein Caramel is highly versatile and can be used for layering, binding or as a filling; will apply easily to a variety of processes.

Visit David Michael at booth 5217 and sample our delicious CocoaMate® cookies. Baked right there at the show, these warm and indulgent treats are made with a 30% reduction in cocoa. Depending on the application, Cocoa-Mate is functionally capable of replacing up to 40% percent of the cocoa powder used in a finished product. Wash them down with a fruity flavored coconut water ice. Using coconut water as a frozen treat base offers consumers a refreshing and smooth healthy alternative, without compromising taste. Coconut water ice is hydrating, fat free and cholesterol free, as well as glutenfree, lactose-free and vegan. Using inspiration from existing coconut water lines, tropical flavors were chosen. Visitors to booth 5217 can also register for a chance to win a free trip to the David Michael 2012 Innovation Roadshow® in Philadelphia.

Concord Foods/Oringer Division [email protected] 508-580-1700 www.concordfoods.com Booth: 7712

David Michael & Co. 1-800-DM-FLAVORS www.dmflavors.com Booth: 5217

D.D. Williamson

Fortitech, Inc.

Color with Confidence! D.D. Williamson’s wide array of natural coloring, along with its sought after caramel color, helps sell 1.5 billion servings every day. DDW improves the allure of foods and beverages through visual appeal. A trusted and recognized provider of color solutions, the company operates ten manufacturing sites on five continents. D.D. Williamson IFT Booth 4429 will feature the following: new products of acid-proof, Class One (“Plain” in E.U.) caramel color; acid-proof, caramelized sugar flavor (natural); certified organic annatto extracts; and application demonstrations of “Caramel-Berry” juice drink; red sports drink; process cheese in red, yellow, orange, and purple varieties; mini fruit tarts; flour tortillas; taffy and other confections.

Essentially known as the founder and pioneer of the nutrient premix industry, Fortitech consistently leads the way in the field of fortification. For IFT 2011, the company will showcase samples demonstrating their versatility as a premix manufacturer, which include a heart healthy salsa, an energy enhancing gum and two varieties of an all-in-one stick pack – A blood orange flavor addressing weight loss and another addressing overall wellness. When added to bottled water, the stick packs create flavored, on-the-go, health promoting beverages. With the exception of the weight loss stick pack, all samples contain at least 10 individual nutrients.

D.D. Williamson 1901 Payne Street Louisville, KY 40206, USA Tel: 502-895-2438, 800-227-2635 Web: ddwilliamson.com Email: [email protected] Booth: 4429

Fortitech, Inc. [email protected] 518.372.5155 or 800.950.5156 (US & Canada) www.fortitech.com Booth: 5117

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IFT Show Preview

GEA Niro Soavi

GEA Process Engineering Inc.

GEA Niro Soavi is the global technology and market leader for high pressure pumps and homogenizers. The GEA Niro Soavi homogenizer product line provides leading technology with the widest range of machines that cover all possible application needs for the food, beverage and dairy industry. From laboratory to large-scale fully automated units, in either sanitary or aseptic execution, our homogenizers are also in compliance with 3-A standards and USDA guidelines. 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 with local, competent and professional support.

Learn more about GEA’s advanced processing solutions and process integration capabilities at the 2011 IFT Annual Meeting and Food Expo. GEA Process Engineering will exhibit to promote spray and freeze drying, particulate processing, powder transport and packaging as well as membrane filtration technology. GEA Process Engineering will also promote a wide range of feasibility- and process development-scale plants which can assist universities and corporate R&D facilities in their process, application and plant development. The range of pilot plants is available for purchase or for short-term lease.

GEA Niro Soavi [email protected] 603-606-4060 www.niro-soavi.com Booth: 5821

GEA Process Engineering Inc. 1600 O’Keefe Road, Hudson, Wisconsin, 54016, USA Office: +1 715 386 9371, Fax: +1 715 386 9376, E-mail: [email protected] Websites www.geafiltration.com / www.niroinc.com / www.barr-rosin.com Booth: 5821

Geliko LLC

GELITA AG

Geliko Kosher Gelatin

GELITA is the leading company for manufacturing and marketing collagen proteins. Coordinated from the headquarters in Eberbach, Germany, GELITA provides customers around the world with products of the highest standard, comprehensive technical expertise and sophisticated solutions. More than 20 sites and a global expert network ensure that state-of-the-art know-how is always available for customers. More than 135 years of experience in the field of collagen proteins are the basis of GELITA’s performance. A strong requirement for innovation is the driving force of the familyowned company that is continually looking for new solutions. Geliko OU kosher gelatine is available from GELITA.

Geliko, the world leader in kosher beef gelatin production offers an extended line of kosher granulated gelatin and hydrolyzed gelatin for use in foods such as marshmallows, yogurt, protein bars, beverages, gummies and more. In addition to extensive use in the food and beverage industries, kosher gelatin is also ideal for use in pharmaceutical and nutraceutical applications. Geliko’s entire line of gelatin products are certified kosher pareve by the Orthodox Union, the world’s largest and most respected kosher certification agency. Headquartered in New York City, Geliko kosher gelatin is available either directly from Geliko or through its distribution partners Gelita USA, Sioux City, Iowa and Food Industry Technologies, Miami, Florida. Geliko LLC 1751 Second Avenue New York, NY 10128 (212) 876-5620 [email protected] www.geliko.com Booth: 6546

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Dairy Foods | May 2011

GELITA AG [email protected] 888-443-5482 www.GELITA .com Booth: 6846

IFT Show Preview

ADM/Matsutani LLC

Neogen

If you are going to be in New Orleans for IFT 2011, be sure to visit ADM/Matsutani LLC’s Fibersol-2 booth. You can see the latest fiberfortified new products that have entered the market as well as sample great tasting prototypes. And while you are there, we will share more information about some very exciting new products that are now available. These products all feature the premier slow fermentation soluble dietary fiber, Fibersol®-2. Fibersol®-2 allows formulators to increase the fiber content and nutritional value of virtually any food or beverage product without affecting the taste or adding unwanted texture. Fibersol®-2 is GRAS as a maltodextrin and can be labeled “Resistant Maltodextrin”*, “Digestion Resistant Maltodextrin”, or “Soluble Corn Fiber”. It contains fewer calories than maltodextrin, with the fiber portion (90% of Fibersol-2) providing only 1.4 kcal/gram.

Neogen’s comprehensive line of rapid food safety products includes simple and accurate tests for food allergens, including milk, soy, peanut and egg residues; dairy antibiotics, including the BetaStar® receptor-based lateral flow assay for the detection of beta-lactam residuals in milk in only minutes; spoilage organisms (e.g., yeast and mold), including the Soleris® optical microbial system that rapidly detects contamination by monitoring media color changes generated by microbial growth; foodborne bacteria, including new Reveal® 2.0 E. coli O157:H7, Listeria, and Salmonella; mycotoxins; and sanitation, including the AccuPoint® 2 ATP system that combines Booth: 3810

ADM/Matsutani LLC 500 Park Blvd., Suite 1240, Itasca, IL 60143, USA 217-451-4377 www.fibersol2.com Booth: 6439

Richmond Baking Richmond Baking has over 108 years of experience providing expert baking and packaging services to companies in the food industry. With three strategically located facilities, top-of-the-line equipment and a century of experience, we thrive on making tall orders look easy. Whether we create a new formula utilizing our experienced Customer Development Team, modify an existing recipe from our research library, or utilize your formula and specifications, we’ll treat your products as carefully as we do our own. With our headquarters in Richmond, Indiana, and facilities in Georgia and Oregon, we have the size and the scope to meet the needs of virtually any food industry firm. Sue Dixon PO Box 698 Richmond, IN 47375 Phone: 262-275-5201 [email protected] Booth: 3845

Sensient Colors LLC Inspired by a limitless palette, unmatched technology and the emotional connection between people and color, Sensient ® Colors has successfully defined memorable sensory experiences for the food and beverage industries for over a century. Characterized by vibrant color solutions, Sensient defines and protects brands. By uniting advanced science and creativity with global capabilities, Sensient produces products with clean labels, safe and secure ingredients, and consistently stable color. Sensient Colors LLC is a unit of Sensient Technologies Corporation, a leading global manufacturer and marketer of colors, flavors and fragrances. Our customers include major international manufacturers representing most of the world’s best-known brands. Tom Tsimboukis Marketing Director, US Food Sensient Color Group Office: 314-658-7337 E-Mail: [email protected] Booth: 4217

www.dairyfoods.com

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Spraying Systems Co.

Spraying Systems Co. North Avenue and Schmale Road P.O. Box 7900 Wheaton, IL 60187-7901 USA 1-800-95-SPRAY www.spray.com [email protected] Booth: 4453

Visitors will experience first hand how Symrise is “making the tastes people love.” Symrise marketing and technical pros are ready to answer questions and offer important information about flavors that are part of Symrise’s taste for life® platform. • go tropicals! is a new line of tropical fruit flavors that include mango, guava, papaya, pineapple, lychee, passionfruit, pomegranate and coconut water • SymLife® Mask flavor masking solutions that effectively overcome a host of off-flavors and off-notes • SymLife® Salt addresses the medical imperative to reduce the added salt in processed foods by up to 50% while maintaining salty perceptions • SymLife® Sweet provides up to 35% reduction in sugar in beverages, confectioneries and bakery products • SymLife® Umami is a cost effective, great tasting alternative to MSG and HVP Taste is the heart of our business. Symrise Inc. 300 North Street Teterboro, NJ 07608 Tel: 201-288-3200 Web: www.symrise.com Contact: Emmanuel Laroche Email: [email protected] Booth: 5016

Tate & Lyle

TIC Gums

PUREFRUIT™ Monk Fruit Extract Consumers have asked for an all-natural, healthy, great tasting alternative to sugar. Today you can give them what they want: pure sweetness from real fruit! Introducing PUREFRUIT™ Monk Fruit Extract. From delicious dairy to bottled refreshment, PUREFRUIT™ adds all-natural, great tasting, zero-calorie sweetness—from real fruit. And PUREFRUIT™ can make a real-fruit label claim that is highly appealing to consumers: “Naturally sweetened with Monk Fruit Extract.” PUREFRUIT™ is perfect for product line extensions, revitalizations, reformulations and future product planning. With new PUREFRUIT™, your consumers can enjoy a healthy sweet taste in their favorite beverages and foods, with less sugar! To learn more about how PUREFRUIT™ can sweeten your products, your customer relationships and your sales, visit Tate & Lyle at Booth 6629.

What is Creamy? Texture has traditionally been an under leveraged aspect of food product design. Other than formulating to a target viscosity, the deliberate design of texture is nearly always absent. Product developers are handicapped by the lack of an agreed upon language to describe texture. The manner various food ingredients can be used to manipulate texture attributes is not always clear. All of this makes the food industry ripe for a new language that describes and makes texture a quantifiable part of the food design process…a Texture Revolution! To find out the attributes that constitute creamy, stop by booth #7029.

Visit Spraying Systems Co. in Booth 4453 at IFT New SV Series SprayDry ® nozzles with swirlchamber design are ideal for use in the production of dairy products. SV Series SprayDry nozzles provide comparable performance to competitive swirlchamber style nozzles but feature many important differences: • Delivery in days, not weeks • Lower cost • Special tungsten carbide material for longer wear life • Quick assembly and disassembly • Higher standard pressure ratings – hand-tight up to 10,000 psi

Tate & Lyle 1-800-526-5728 www.purefruit.com Booth: 6229

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Symrise Inc.

Dairy Foods | May 2011

TIC Gums 800-899-3953 www.ticgums.com/chat Booth: 7029

IFT Show Preview

U. S. Highbush Blueberry Council

Weber Scientific

Mini-Bars with Maxi Flavor? Blueberries! Bars are big, and they’re smaller than ever. Streamlined bars—call them thins, squares or mini-bars—chock full of real blueberries satisfy demands for health, taste, portion control. Blueberries keep bars moist, add mouthwatering flavor and make it real. Blueberries brighten gluten-free, harmonize with ancient grains, work well in savory to sweet. Blueberries’ versatile formats fit innovative blueberry bar concepts: blueberry boomer bars, blueberry beauty bars, blueberry mini-bars and jelly roll blues blueberry bars. In the Big Easy, big, easy blueberries star on restaurant menus all over town. At U. S. Highbush Blueberry Council Booth #7850, sample a blueberry mini-bar (or two), and pick up a free Blueberry Restaurant Guide. U. S. Highbush Blueberry Council 865 Woodside Way San Mateo, CA 94401 800-824-6395, 650-340-8311 650-340-8568 FAX [email protected] www.blueberry.org

Weber Scientific distributes laboratory equipment and supplies to dairy and food laboratories throughout North America. We carry hundreds of laboratory essentials plus many exclusive and hard-to-find items. New Products: EnSure™ Multi-Parameter Luminometer. One instrument for super sensitive coliform detection in seven hours (with Microsnap™), rapid allergen control, and ATP hygiene monitoring in just 15 seconds. Our innovative sterile pipet sleeve separates all particles so you draw a clean sample with your pipet every time. Featured Products: Rapid environmental Listeria swabs, Easygel™ prepared media, sponge-handle swabs, protein or glucose residue swabs for onthe-spot testing, and much more. Weber Scientific 2732 Kuser Road Hamilton, NJ 08691 800-328-8378 weberscientific.com Booth: 4806

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Liquids to Value

No Compromise.

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sneak peek a look inside…

Dippin’ Dots

REPORTS

he Paducah, Ky.-based company uses -320°F liquid nitrogen inside custom cryogenic processors to flash-freeze ice cream into tiny dots. Dippin’ Dots developed the flash-frozen beaded ice cream category, sold in theme parks, stadiums, mall-based kiosks and movie theater vending machines. New products include ice cream cakes and dairybased beverages. Contributing editor Cathy Sivak visits with the corporate team. Page 69.

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Labeling airy Foods convened a virtual roundtable of executives in the labeling field to discuss food safety, package clutter and equipment training. Page 88.

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Curt Jones, founder of Dippin’ Dots, added beverages, frozen yogurt and ice cream cakes to his company’s menu.

Equipment Showcase Caps and closures. Page 96 Maintenance equipment. Page 100

Back to the Future Dippin’ Dots taps entrepreneurial roots with product launches, brand initiatives and new distribution.

Silgan

 Cathy Sivak Contributing Editor

fast forward what’s coming in June…  Fage USA  Henry Randolph’s “Quality on the Line”  Sustainable Packaging  Filtration  USDEC’s Tom Suber on exports

he early entrepreneurial mentality that proclaimed Dippin’ Dots “The Ice Cream of the Future” is back. Product innovation, consumer-focused branding initiatives and expanding distribution position the Paducah, Ky.-based specialty ice cream processor for a return to growth and profitability.

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“All of the ingredients are being put together right now for that to happen. I’m as excited now as I have ever been about our potential,” says Curt Jones, founder and president. The company’s namesake core product, Dippin’ Dots, is a flash-frozen beaded ice cream widely available at theme parks, stadiums and other major entertainment Continued on page 70 www.dairyfoods.com

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Corporate Profile  The Dippin’ Dots management team gathers at the counter of the Metropolis, Ill., corporate-run scoop shop (left to right): Michael Barrette, v.p. of sales; Rick Noble, director of operations; Stan Jones, director of research and development; Steve Heisner, director of administration; Curt Jones, founder and president; Mike Milner, controller; and Dana Knudsen, director of marketing and graphic design.

venue concessions as well as mall-based kiosks, events and movie theater vending machines. Jones pioneered the processing concept in 1987 when his love of homemade ice cream and a work project studying encapsulation methods for cultures dovetailed into an extracurricular experiment: use of liquid nitrogen to flash-freeze homemade ice cream mix. The resulting ice cream beads provide minimal ice crystal formation with maximum cold, creamy mouthfeel.

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Dairy Foods | May 2011

Within a year, Jones left his career as a microbiologist to launch Dippin’ Dots from a 24-foot by 24-foot garage on the Jones family farm and a Lexington, Ky., storefront. Created in -320°F liquid nitrogen, Dippin’ Dots require special handling compared to conventional ice cream. Products are stored, delivered and merchandised in custom freezers that maintain the ice cream’s free-flowing nature with -40°F temperatures. As Dippin’ Dots developed a track record with initial accounts including Nashville’s Opryland, its distribution and processing capabilities grew steadily, moving to rented space in Paducah, then to a custom-built facility opened in 1995. A $7.5 million invest-

Corporate Profile ment in a two-phase processing, freezer and distribution operation expansion grew facilities to 120,000 square feet by 2006. Separate assembly of kiosk and merchandising equipment in an adjacent 18,000-square-foot building supplies franchisees and accounts. Gains of the late ’90s to early-2000s gains found Dippin’ Dots on numerous business publication rankings of fastest-growing companies and franchise opportunities and consistently recognized by accounts as a top vendor. The business structure was formalized, and in 2005, added outside leadership that allowed Jones to step out of the day-to-day-operations. Then a series of potentially insurmountable challenges hit simultaneously: record-high dairy pricing along with transportation and liquid nitrogen price spikes; loss of a costly, drawn-out legal battle related to processing patents; and subsequent banking challenges. “We’d been knocked so far back down, we had to treat it as a start-up again,” Jones says of his return as president in 2009. “I’m not planning on stepping out again any time soon.” Mall traffic declines and resulting Dippin’ Dots franchise closures combined with plummeting theme park attendance further strained sales performance. “People do spend more money on small treats during a recession; it just didn’t work with our product. We got hit as a luxury item,” Jones says. The company’s 2007 sales of $40 million were un-profitable, a first since the company was launched. Sales declined to roughly $30 million by 2010. But Dippin’ Dots is focused firmly on the future, developing new products, using social media and targeted marketing to build the brand, and expanding distribution into new channels. Combined

with the turnaround of previously slumping theme park sales in the latter part of 2010 and positive franchisee sales reports, Dippin’ Dots has potential for a “nice little increase” of up to 10% for 2011, Jones says. “And from there, the picture gets better.” Dots developments The core beaded Dippin’ Dots ice cream line has developed to encompass more than 40 varieties. Inclusion-laden Cookies ’n Cream with Oreos is the current top seller. Other popular flavors include banana split, chocolate chip cookie dough, chocolate and vanilla. New product additions are created as niches of basic market trends, and designed to maximize capacity and add sales growth without pulling sales from the core Dippin’ Dots business, says Stan Jones, director of research and development. A college pal and long-time colleague of Curt Jones, Stan Jones is unrelated but part of the business since its inception. A vanilla frozen yogurt version of Dippin’ Dots is slated to roll out this summer via participating franchisees as a better-for-you smoothie line addition to the shakes and sundaes initially introduced in 2007. The vanilla yogurt dots include live and active cultures, and are sweetened with all-natural, plant-derived Truvia. Yogurt dots also open up the breakfast daypart for Dippin’ Dots products. “You add blueberries and granola, it’s a breakfast item when you wouldn’t ordinarily be selling ice cream before 11 a.m. at the earliest,” Stan Jones says. The technology behind flash-frozen beaded ice cream is also creating a whole new take on coffee. Dippin’ Dots Coffee, first Continued on page 72

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Corporate Profile introduced to the trade in 2009, extends the brand to a new segment with flash frozen espresso. The line features frozen edible espresso dots as well as Forty Below Joe “no-ice-needed” frappé in caramel, mocha and vanilla flavors. The versatile espresso and frappé dots can also be heated to create espresso or coffee-based drinks with fresh-pressed taste. A hot beverage cart test is in place at Universal Studios in California. Several theme parks are testing spoonable coffee dots and cold coffee drinks in stand-alone carts and kiosks featuring graphics aimed to let consumers know Dippin’ Dots is “more than just ice cream,” says Michael Barrette, v.p. of sales and franchising. The company is also introducing Fruit Twisters, the working name of an all-natural ‘just add beverage’ beaded product line. The product creates frozen-style beverages without ice and blenders, and will be tested in the beverage segment with support from major theme park customers in Texas and Florida. Managing calorie, fat and sugar content as well as taste led to development of low-fat and non-fat Dippin’ Dots products. The brand also uses Truvia sweetener to create a sugar-free chocolate dairy dessert and a sour blue raspberry ice. While developing formulations for alternative sweeteners is always tricky, for Dippin’ Dots, the change in the freeze point was a positive. “We don’t have to keep it as cold,” Stan Jones says. To support potential school foodservice distribution, Dippin’ Dots is also developing a low-fat, low-calorie, Truvia-sweetened product that surpasses federal lunch guidelines as a better-for-you item. “If it passes muster with the grownups, we like our chance

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that we’re going to get trial,” Barrette says. Products designed specifically for conventional frozen product distribution rather than specialty handling offer definite growth opportunities. Dippin’ Dot Ice Cream Cakes, dot-infused ice cream cakes introduced in 2010 with the help of a copacker, are now created on a new processing line at the Paducah facility. Customers include a 165-store chain in the Northeast and a 90-store chain in the Southeast, with new distribution through a frozen foods home delivery company. The cakes are also available through participating franchisees. A second retail freezer product, Dots ’n Cream, is a half-gallon conventional ice cream product infused with dots. Available in select Midwestern retail outlets and in participating franchisee locations, the product rolled out in 2006, was re-introduced with new flavors and packaging in 2008 and expanded to club stores in 2009. A 6-ounce single-serve is in development.

Corporate Profile Branding initiatives The Dippin’ Dots marketing expansions beyond leisure and entertainment venues are a direct response to consumer demand. “One of the top comments we get from consumers is ‘Where can I find Dippin’ Dots?’ Our fans want greater distribution,” says Dana Knudsen, director of marketing and graphic design. Dippin’ Dots conducts product-based marketing aimed at its core demographic teens and tweens ages 8-18, and secondarily to mothers with younger children. A growing base is comprised of older people who have tried the product and liked it, or to consumers who have grown up with the brand. Brand initiatives, including promotions, marketing programs, packaging design and graphic design of all POP and marketing materials are handled in-house; social media outreach teams Dippin’ Dots with an agency.

Hollywood product integration includes trademarks and products found in “Fat Albert,” “Kicking & Screaming” and “Cheaper by the Dozen.” Segments produced for Food TV, The Travel Channel, The Oprah Winfrey Show and the Food Network have also showcased the brand. Corporate programs are integrated with POP marketing and “charged through social media,” Knudsen says. Launched in 2007, the Dippin’ Dots Facebook page is now 3.8 million fans strong. Queries such as, “What would you do with a million dots? A billion?” generate thousands of fervent fan comments. The ability to customize social media programs allows Dippin’ Dots to tailor marketing for individual customers and channels. Fan interaction has helped name Dippin’ Dots menu items and likewise determined the final flavor in the set offered by a large regional water park account. Social media programs likewise support the company’s web site and Forty Below Zero Club, an emailbased consumer fan club that creates geo-targeted email blasts. A rebuild of the Dippin’ Dots website provides additional consumer-brand engagement and allows timelier and more costefficient direct content updates. Site upgrades unveiled in midFebruary feature a more intuitive online ordering system and allow consumers to order an array of products in the same shipment. “We have seen an increase in the number of products people are ordering as well as the total amount of the average order,” Knudsen says. Broad corporate marketing initiatives provide brand notoriety with consumers and supports national, regional and local accounts with additional POP messaging. Examples include a recent proContinued on page 74

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Corporate Profile motion featuring rising country duo the JaneDear Girls; sweepstakes prizes included a $250 Visa gift card, a $250-value Dippin’ Dots party pack and a copy of the duo’s new self-titled CD. Similar contests pair Dippin’ Dots with movies such as “Despicable Me” and video games such as de Blob 2. Curt Jones chose the company’s Paducah location as a way to provide opportunities in the largely rural, economically-distressed region; he is a native of Pulaski County, Ill., about 35 miles away, and notes roughly half of the company’s 170 employees commute from Illinois. “I’ve been very proud that we’ve been able to create jobs in this area.” Jones says. The Dippin’ Dots Foundation – run by an 11-member board that includes Curt Jones, his wife Kay, daughter Tracey and father Milford – additionally supports the community with scholarships to students attending Curt Jones’ alma maters as well as to Dippin’ Dots employees and their families. Stand and deliver More than 20 years of exposure has led consumers to virtually expect Dippin’ Dots at theme parks, water parks, museums, professional sports stadiums and minor league sports venues. Direct accounts sales include 1,500-plus entertainment venue locations and comprise the majority of Dippin’ Dots sales, with 165 Dippin’ Dots franchise operations a “robust minority,” Barrette says. Beyond domestic sales, Dippin’ Dots currently distributes to nine countries and has licensed manufacturers in Korea and Canada. Free-flowing Dippin’ Dots products provide serving efficiencies critical to concessions with time strictures such as sporting event intermissions. “Everyone comes out of their seat at the same time. We can serve 12 customers a

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minute. If you are pouring soft serve or something else, it takes much longer,” Barrette says. “The quality of the taste is the reason we get the repeats. We have a great track record with the velocity of the repeats.” At the end of the first quarter, Dippin’ Dots overall business was up nearly 9%, with sales up almost double at business partners including Universal Studios in Orlando, Barrette reports. “We’re not out of the recession. But the business is growing in today’s environment. We’re reaching out to other outlets to meet the demands,” Barrette says. “The brand is going to start flexing its muscle, but in an intelligent way. Chasing every customer everywhere, we’re not that kind of brand.” Dippin’ Dots account managers work closely with customers on a national, regional and local account level to support the brand and drive sales growth. Along with products, Dippin’ Dots supplies 10-foot by 10-foot mall kiosks, 4-foot by 6-foot mobile fiberglass carts and various other sales units equipped with freezer technology to hold product at -20 to -40˚F. Units also feature graphics designed in-house to showcase the brand and its products. “Kiosk building is really one of the important elements that allowed us to expand and has put us in almost every theme park in America. We bring the complete package,” Curt Jones says. While a franchise kiosk can display more than a dozen flavors and create menu items, in a theme park environment, limited offerings are tied to speed of service. “The slowest part is the decision process,” Barrette says. As part of its business development efforts, Dippin’ Dots has worked with its larger theme park customers to establish 30 Sundae Shops over the last two years, including a shop at Cedar Point, Sandusky, Ohio, one of the largest U.S. theme parks. Described as a “mini satellite store” by Barrette, the shops offer traditional Dippin’ Dots in a cup as well as menu items made with dots such as floats, sundaes and milkshakes and now edible coffee, frappe drinks and dots-based frozen-style drinks. The kiosks are a familiar mall fixture, but economic trends have created a new franchise push for mobile concession-style event presence rather than a fixed location. The 4-foot by 6-foot carts equipped with a freezer and a canopy or umbrella are expected to increase presence at medium-sized fairs and events. Freestanding stores as opposed to mall kiosk locations appeared promising in the early 2000s, but the concept remains in the development phase as Dippin’ Dots learns best practices with corporate-operated stores in Nashville, Metropolis, Ill., and a Paducah mall location. The retail drug store channel is the latest foray for Dippin’ Dots core products. Nearly 100 Walgreens drug store locations are showcasing Dippin’ Dots in countertop and floor-based specialty freezers at checkouts in Nashville, Memphis and Alabama. “There’s a lot more room that we can grow and not hurt our brand,” says Curt Jones. “We’ve stabilized our core product again; it’s starting to grow. My goal is to grow the business to a $200 or $300 million a year company. I can’t say that’s going to happen in five or six years, but at some point. We’re setting the basis for that now.” 

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Plant P lant C Close-up lose-up

 Ice cream mix dots are formed inside cyrogenic processor units at the Dippin’ Dots plant in Paducah, Ky. Photos by Vito Palmisano

Dots on Demand Futuristic flash-freeze processing creates Dippin’ Dots ice cream and more in Paducah, Ky.  Cathy Sivak Contributing Editor

rocessing floor fog, stainless steel frost and the occasional freezer snow flurry underscore the frigid ice cream processing temperatures found at the Dippin’ Dots facility in Paducah, Ky. The company uses -320°F liquid nitrogen inside custom cryogenic processors to flash-freeze ice cream into tiny dots. The concept was pioneered in the late 1980s by Curt Jones, founder and president. His love of homemade ice cream and his microbiology career dovetailed to create ice cream with minimal ice crystal formation for maximum creamy mouthfeel. Early processing in a 400-square-foot garage on the founder’s family farm soon expanded to a rented, 2,000-square-foot space

P

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in a former liquor store in Paducah. In 1995, the company opened its custom-designed 20,000-square-foot Dippin’ Dots facility and 6,000-square-foot kiosk/equipment assembly operation on a 17-acre light industrial tract on Paducah’s outskirts. A series of processing, warehouse and freezer expansions have since grown processing operations to 120,000 square feet and kiosk operations to 18,000 square feet. Capacity and efficiency of the plant’s cryogenic processors, called CP units in-house, have likewise evolved. The company’s original CP unit made 4 gallons of ice cream dots per hour. The fifth-generation CP units now create 60,000 gallons per week – the equivalent of 3 billion tiny frozen dots.

Plant Close-up

 At -180°F out of the processor, Dippin’ Dots create frost and a cold fog as a line worker fills bulk gallon bags. Inclusions are poured into the manual hopper (left). The pre-pack Dippin’ Dots line’s cyrogenic processor unit is shown above.

Bulk gallon bags and single-serve packages are held in -40 to -50°F freezer space, then are shipped around the world in -100°F totes and cooler boxes. Customers store the product in Dippin’ Dots-provided freezers that hold product at -40°F prior to serving to consumers in venues, including malls, theme parks and movie theaters. Maintaining even, deep-freeze handling is critical to prevent clumping of the free-flowing frozen pellets. “The product itself is a built-in quality control feature,” says Rick Noble, Dippin’ Dots director of operations. The facility produces more than 40 varieties of Dippin’ Dots in ice cream, sherbet and flavored ice varieties as well as coffee product versions of dots. In May, frozen yogurt dots will roll out from the plant for franchisee and foodservice account launches. In March, a filling line already in place to create Dots ’n Cream retail ice cream half-gallon cartons began creating Dippin’ Dots Ice Cream Cakes. Both products are designed for merchandising in standard freezer cases.

“We’re continually trying to improve our process, improve our products and improve the range of markets that our products can go into. That’s all part of our long-term goals,” says Stan Jones, the company’s director of research and development. The two Jones, unrelated, are college pals and long-time collaborators. Stan Jones created the CP units and headed the Paducah facility’s original design-build as well as subsequent expansions. Proximity to southeast Illinois draws facility employees from both sides of the state line. The plant currently has 135 full-time employees, and adds flexibility during peak production periods with temporary workers. One full shift is dedicated to production five days a week, with a second shift for maintenance and sanitation. Mix mode Creation of the unique beaded ice cream creation starts with a traditional frozen dessert approach. The Dippin’ Dots facility purchases plain and chocolate 10% butterfat ice cream mix from cooperative Prairie Farms. The plant’s single receiving bay accepts an average of four loads of mix totaling 20,000 gallons per week, and handles double that volume during peak production periods. The mix for Dippin’ Dots is treated as raw product, and is subject to in-house lab tests, including standard plate count, coliform, temperature and viscosity, explains Glen Thompson, quality assurance manager. Federal and state-level inspections and certifications along with third-party and in-house audits ensure Dippin’ Dots processing Continued on page 78 www.dairyfoods.com

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Plant Close-up

AT A GLANCE Dippin’ Dots, Paducah, Ky. Year plant built: 1995 Description of additions/renovations: Original 17,000-gallon capacity “pit” freezer chilled with liquid nitrogen replaced with traditional above-ground freezer (1997); new silos, pumps, HTST pasteurizers, bulk cryogenic processors, freezer expansion (2004); freezer, warehouse, shipping expansion (2006); pre-pack filler line added (2007), espresso press (2009). Size: 126,000 square feet on 17-acre tract, including 18,000-square-foot kiosk/equipment assembly shop. Number of employees: 170 total, 135 production Products: Dippin’ Dots ice cream, sherbet, yogurt, cake and coffee. Total processing: 60,000 gallons of ice cream dots per week. Milk receiving: One bay, average four loads Prairie Farms ice cream mix per week (20,000 gallons a week, doubles during peak production); four silos-three 20,000 gallon, one 6,000 gallon. Pasteurization: One HTST pasteurizer, 6,000-gallon per hour; three pasteurized mix silos, 20,000 gallons each. Production lines/types: Five custom cryogenic processors (CP); four bulk lines fill 26,000 1-gallon bags per day. Pre-pack line fills 6,000 3-ounce pouch packages per day, 8,000-pack capacity; alternate size capability. Finished product freezer: 380,000-gallon capacity, -40 to -50°F; 17,000 square feet. Kiosk production: 18,000-square-foot shop for construction of kiosks, carts, stands and other point-of-purchase sales equipment. Dry storage capacity: 20,000-square-foot dry storage warehouse for ingredients, packaging, other dry good. Unique equipment: Fifth-generation custom cryogenic processor units use liquid nitrogen to flash freeze ice cream mix droplets.

capabilities and ongoing HACCP certification. A rabbi visits the facility’s production six times a year for kosher certification. In addition, the company’s suppliers document HACCP programs and ingredient allergen potential. Samples are additionally taken prior to pasteurization, at the flavoring tanks and from finished product as part of the internal audits that follow quality assurance checklists at each phase of the process, Thompson says. Once accepted, mix is held in receiving in three 20,000-gallon silos and the plant’s original 6,000-gallon silo. Mix is pumped

 Flavor vat operators synch mix levels and pump speeds with production pace to keep proportions on-target for multi-flavor products.

from receiving silos to the HTST pasteurizer on the processing floor. It is pasteurized at 175°F for 28 seconds at 6,000 gallons per hour, and then pumped into one of three 20,000-gallon silos dedicated to pasteurized storage. The base ice cream mix for Dippin’ Dots is then pumped to a dozen 200- and 100-gallon flavor vats. Bulk flavors are measured from drums and poured manually into the vats in a 23-28 minute process. Careful timing and creative batching allows the plant to create up to seven different varieties per production shift. For instance, vats for chocolate in the morning shift to chocolate mint in the afternoon. Multi-flavor Dippin’ Dots products require simultaneous use of multiple flavor vats – Banana Split uses four vats to combine banana, chocolate, strawberry and vanilla dots in one package. Vat operators carefully synch mix levels and pump speeds with production pace to keep required flavor proportions. Flavor vat mix levels are monitored with a “good old-fashioned measuring stick for less glitches” than automated systems, says Robert Reams, vat operator. Drops to dots The individual mix flavors are pumped through clear tubing to the CP units where mix is transformed to Dippin’ Dots. The CP unit pan sprays the flavored mix out in tiny droplets. Gravity pulls droplets into the tank of -320°F liquid nitrogen. The near-instant transformation from fluid mix to bb pellet-sized ice cream beads minimizes ice crystal formation, the “secret” behind the creamy mouthfeel of Dippin’ Dots products. The flash-frozen beads sink in the CP vat’s liquid nitrogen. Augers move the free-flowing, -180°F ice cream beads to the filler. Continued on page 80

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Dairy Foods | May 2011

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Plant Close-up  The pre-pack dots line averages 6,000 3-ounce packs per day for merchandising via vending machine, single-serve freezers and school systems.

Frigid temperatures inside the CP unit create frost on the exterior of the filler line and can freeze the stainless steel feed to the filler nozzle. Preventative action includes a heat gun mounted to blow into the filler; it is activated when the equipment begins to squeak from the cold. Inclusions such as crushed cookies for Dippin’ Dots No. 1 flavor, Cookies ‘n Cream with Oreo, are added via a manually fed hopper on the bulk filler. The company uses 4 tons of Oreo inclusions each week. Line workers use pedal releases to drop dots and inclusions from the filler into plastic gallon bags. Bulk bags are weighed, then manually heat sealed and boxed six-gallon bags to a carton. Experimentation with filling line efficiencies to reduce manual handling has yielded unsatisfactory results, says Noble. “It’s a process that is difficult to automate due to the extremely low temperatures.” The cartons are placed on a conveyor and travel at an incline off the processor floor to palletizing; products are then moved to the freezer via forklift. The bulk CP units are also used to create flash-frozen espresso dots for the company’s Dippin’ Dots Coffee line, launched in 2009. An industrial-sized espresso machine extracts espresso from Brazilian and Guatemalan Arabica coffee beans. The espresso is then immediately converted into dots. The Dippin’ Dots Forty Below Joe Edible Coffee features the frozen espresso dots as well as frappé in caramel, mocha and vanilla flavors. The versatile espresso dots can also be heated to create espresso or coffee-based drinks with fresh-pressed taste. Dots on the go In space adjacent to the bulk CP units, the plant creates pre-packaged dot products for merchandising via vending machine, singleserve freezers and school systems.

The pre-pack Dippin’ Dots line averages 6,000 3-ounce packs per day. Capacity is 8,000 packs per day, but is deliberately slowed to prevent equipment failure. “The use of nitrogen and ultra-cold temperatures tends to wear parts,” Thompson says. A CP unit forms the dots, which are then routed to the filler. The line can also fill 50 gram, 2.5- and 7-ounce packs as required. A new inclusion feeder for the prepack line to be online by the end of May will phase out the current multistep process for inclusion-laden varieties. Without the feeder, bulk gallon bags of pre-mixed Cookies ‘n Cream with Oreo dots are transferred from the adjacent bulk filler to the pre-pack line via wheeled dry ice tote, then poured into a manual feed hopper on the pre-pack unit’s filler. A puff of air opens the pre-formed pouches, and dots automatically drop in. Pouches are sealed and hand packed 50 to a carton. The boxes are then transferred to the conveyor system, which whisks product to palletizing and then to freezer storage. Cake creations The Paducah facility added ice cream cakes to its line-up in March. The newest and most labor-intensive addition to the plant’s processing capabilities, the cake line utilizes expertise and equipment already in place for the company’s retail halfgallon Dots ‘n Cream ice cream line. However, the new product has required additional staffing, as 34 line workers are involved in the assembly line-style cake creation from start to finish. An East Coast co-packer established Dippin’ Dots cake distribution through select retail chains. Initially, Paducah cake production will be dedicated to a frozen food home delivery service partnership. Unlike the special freezer accommodations required for dots, both Dots ‘n Cream and the cake lines can be held in standard ice cream cases. Pre-made dots are added to ice cream mix via an inclusion hopper to create one of two cake varieties, Cookies ‘n Cream or Rainbow. The dot-infused ice cream pours out of the filler at soft-serve consistency into 6-inch round plastic cake molds at a rate of five per minute, about half of potential capacity. A line worker uses food-grade cardboard to smooth the dotinfused ice cream at the bottom of the plastic cake mold, then uses the cardboard to create a bottom seal. “The actual temperature of the dots when introduced to the ice cream mix immediately begins to freeze the cakes from the inside,” Noble says. Continued on page 82

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Dairy Foods | May 2011

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Plant Close-up  The newest addition to Paducah processing capabilities is the Dippin’ Dots Cake line, decorated assemblystyle. An existing filler line is used to create the ice cream cakes (inset).

Cake molds are then transferred to a conveyor for a trip through the -200°F freezer tunnel. The rapid internal freezing combined with the tunnel creates an ice cream cake with creamier-then-regular ice cream texture, Noble says. The day’s run of Rainbow Confetti Cake hard freezes in the tunnel at a rate of 17 minutes, 50 seconds per cake. The ready-todecorate “blanks” are held in dry ice-filled shipping containers to await decorative touches. Line workers remove cakes from plastic molds for the decorating process; the food-grade cardboard acts as a holder. Employee-operated mechanical icing equipment smoothes butter cream frosting on cake exteriors. Cakes are inspected for frosting gaps and touched up as necessary. The cake is then passed to a “dollop” machine, where an employee guides application of decorative frosting around the cake top’s edge. The next worker sprinkles a colorful mixture of Rainbow flavor Dippin’ Dots onto the cake top. Next, “stringers” of blue and red frosting are hand-applied to the cake top by two more line workers. Cakes are then placed in pre-formed bakery-style cake boxes, run through the metal detector and date coded. Cake boxes are shrink-wrapped, packed eight to a shipping carton, and sent via conveyor for palletizing, freezer storage and distribution. Freeze for all The ultra-cold 380,000-gallon-capacity storage freezer is kept at between -40 and -50°F. A two-door entry system leads from palletizing and distribution areas to a staging area. Once inside the insulating pocket, a second set of doors permits full entry into the freezer, where palletized products are stored on racks and forklifts leave tracks in the snow generated by the occasional updraft. The freezer uses a pallet racking system to optimize storage space, much more accessible than the facility’s original pit 82

Dairy Foods | May 2011

freezer. The non-mechanical freezer pit harnessed the liquid nitrogen gases from the CP units; product pallets were lowered and lifted with a crane. When the pit’s capacity began to be strained and product retrieval impractical, the pit replaced with a 90,000-gallon capacity freezer. Freezer space has since expanded, first to 180,000-gallon capacity, then to the current 380,000-gallon capacity. Dippin’ Dots products are shipped via commercial carrier in customdesigned, pallet-ready shipping containers. Each holds 360 dot gallons at -100°F with a four-day supply of dry ice in a bunker compartment. Dry ice is also used in one-way lined freezer cartons. The plant uses an average of 45,000 gallons of liquid nitrogen per week and an additional 20,000 pounds of dry ice. Use of liquid nitrogen and dry ice requires close attention. In addition to the cold, oxygen displacement is a real hazard. “Keeping airflow moving is a top priority. A return air system and exhaust fans keep air flowing. We also have oxygen monitors to warn us if oxygen levels drop below the required level,” Noble says. Employee safety is also ensured with a well-organized safety program. Department-specific safety meetings are held weekly for all employees, and include GMP training for all employees; new production staffers also receive GMP safety training. The facility ships domestically and worldwide to countries, including Mexico, Canada, Australia, the Philippines and Kuwait. Upon delivery, Dippin’ Dots products are stored in company-supplied freezers to maintain -40˚F below temperatures. The exception is the standard freezer temperatures products, Dots n’ Cream ice cream and Dippin’ Dots Cake. The production team continues to examine the process for ways to increase efficiency and reduce shrink, “really, the same thing that every business looks at. We just have a little bit more unique process,” Stan Jones says. For instance, clean-up was streamlined by the 2004 addition of CP unit clean-in-place (CIP) capabilities, believed to be a first for processing equipment with screw conveyors, Stan Jones says. “We went from having to physically break down the equipment to clean it to having clean-in-place technology.” Capturing cold generated by the sinking gases from the liquid nitrogen continues to be a priority, perhaps with a large nitrogen tunnel, says Curt Jones. “It’s still something we think about. We’ve got that capability if we ever want to revisit that idea. It worked.” 

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Plant Close-up

Behind the Scenes A photo gallery of Dippin’ Dots, Paducah, Ky. Photos by Vito Palmisano

 Dippin' Dots opened its processing facility in 1995; a series of processing, warehouse and freezer expansions has since grown processing operations to 120,000 square feet and kiosk operations to 18,000 square feet on the 17-acre site.

 Curt Jones, Dippin' Dots founder and president, shows off the kiosks, carts and other concession equipment created in-house to provide specialty freezers, brand consistency and turnkey operations.

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Dairy Foods | May 2011

Plant Close-up

BEHIND SCENES the

For more photos, visit www.dairyfoods.com/behindthescenes. Or, take a picture of the mobile tag with your smart phone to go online now. Get the free mobile app at http://gettag.mobi.

 Left: Mechanized “dollop” ability sped up the decorative process over initial manual application. Below left: Dippin’ Dots treats its ice cream mix as raw product. Cathy Sivak, contributing editor, gets a look at the HTST pasteurizer. Below: The 380,000-gallon-capacity storage freezer is kept between -40 and -50°F to keep ice cream dots freeflowing.

www.dairyfoods.com

85

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Labeling Technology

Labels Provide Info, Safety Hail the hard-working label. It imparts nutrition data and other product attributes to shoppers, while providing tamper-evidence. he talk in the dairy processing world is about “sustainability,” “food safety” and “nutrition.” These terms resonate with the general public. Marketers use packaging and labeling to convey these concepts to shoppers. A new, voluntary U.S. Department of Agriculture initiative identifies bio-based products (those whose main ingredients are renewable plant or animal materials). The USDA says the purpose is to more clearly identify bio-based products and to promote their use. Clear Lam Packaging, Inc., Elk Grove Village, Ill., received a biobased label for its renewable thermoformed produce packaging made from more than 93% plant-based bioplastics derived from Ingeo PLA (polylactic acid), along with ingredients. Marketers can put a USDA-certified bio-based label on their packaging. Clear Lam submitted additional packaging for the BioPreferred program, including packages for dairy foods such as yogurt and cottage cheese. Consumer packaged goods (CPG) marketers are including nutrition information (including calories per serving and fiber content) more prominently on their packaging, while grocery retailers are using shelf talkers to convey this information. Food marketers are taking advantages of new technologies, such as smart phones, to add quick-response codes to packages. This is a way to engage the shopper and to provide additional information about the brand. This spring, Dairy Foods chief editor Jim Carper convened a virtual roundtable of executives in the labeling field and asked about food safety, package clutter and training. Following is an edited transcript of emailed responses.

T

Dairy Foods: How has the increase in food safety-related product recalls over the last three years impacted the services you offer or the engineering and design of your equipment?

Meet the Panel Jim Dwyer, president and CEO, The RB Dwyer Group, Melville, N.Y. Don Earl, owner, Overnight Labels, Deer Park, N.Y. Drew Faust and John O’Donnell, sales, EPI Labelers, New Freedom, Pa. Ron Giordano, chairman and CEO, H.S.Crocker Co., Huntley, Ill. Stacy Santos, marketing manager, Dion Label Printing, Westfield, Mass.

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Dairy Foods | May 2011

 A print-and-apply labeler from EPI Labelers, New Freedom, Pa.

Jim Dwyer: Every label that we print incorporates nutritional information. In addition, many of our customers like the benefits of a decorative sleeve and tamper-evident band. This all-in-one combination label allows the CPG to bring out a product that looks great and also is secure. It also eliminates the need for two components, making this a more environmental friendly package. Our tamper-evident bands and preforms — frequently used on ice cream and cultured products — also provide that extra amount of security that consumers are looking for. John O’Donnell: We have seen an uptick in customers requesting application of [our] barcode labels to packages using a printContinued on page 90

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Labeling Technology and-apply labeler to apply tracking labels to the front or back of packages. Drew Faust: The print-apply system has led us to engineer more printer applicators for an ever-expanding array of applications, ranging from master cartons to individual packages. Dairy Foods: What steps has your company taken in reaction to the new Food Safety Modernization Act?

Photo courtesy of Videojet Technologies

Ron Giordano: We are coordinating with our auditing team to ensure that these new measures are being addressed.

 On the bottling lines at Ultra Dairy in New York, a laser coder and small-character ink jet printers can run up to 16 hours per day, five days per week. Each printer stores generic templates to allow line operators to access preset formats and coding-space sizes. The operators can then modify these templates to include required information.

Dwyer: The Food Safety Modernization Act does not directly impact shrink labels because the labels do not come in direct contact with food. However, we do business with many CPGs and they have certain requirements for our facilities. Our facilities have adopted food-safety policies and procedures that incorporate good manufacturing processes so that our facilities pass their inspections. Dairy Foods: There is a movement among packaged goods companies to add nutritional data to the front of their packages. Other CPGs are adding mobile tags (QR or quick-response codes) elsewhere on the package. How do you advise customers to avoid package clutter?

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Labeling Technology  A shrink-sleeve label on a beverage container from Overnight Labels, Deer Park, N.Y.

Stacy Santos: Requests for QR codes are increasing. A QR code can be printed on various substrates, so it does not matter whether it’s printed on a film, foil or tag material. The one thing that must happen, as with all barcodes, is that the QR code must be on a white background to yield the best scan results. Since QR codes can carry information both horizontally and vertically, a QR code is able to encode the same amount of data in approximately one-tenth the space of a traditional barcode. Most label designs that we see in the dairy industry are one to three colors. However, recently, we are seeing a shift to more companies using shrink sleeves in their packaging and four-color process labels. There hasn’t been a problem incorporating QR codes into the label because they can be so small. There is most always white space available on current dairy label designs. A food manufacturer does not have to give up something (product benefits, etc.) in return for a QR code. QR codes can be in four color, not just black and white. If you research “QR codes color,” you will see some fascinating, colorful codes and some embedded images, such as a company logo, giving them a cool design effect.

nutritional information on a label and applying it to either the front or back of a package that is produced on vertical or horizontal form/fill/seal equipment. This creates the flexibility to apply a label rather than printing the information on the film, allowing the information to easily be changed without creating unusable packaging film that has been printed with outdated information. Additionally, we have several customers that get labels pre-printed with their multicolored logo and we add the variable information to it, giving them total flexibility. Simply put, it adds flexibility and reduces waste. Don Earl: If it’s a beverage or some other product that comes in a container, they may be able to use shrink sleeves. Shrink sleeves conform to the whole container and give more real estate for additional reporting information required by the USDA or FDA. A sleeve gives you 360-degree graphics and potential tamper evidence, much more than a pressure-sensitive (PS) label does.

Faust: We can offer the customer the option of applying pre-printed labels or printing variable

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Labeling Technology When a PS label is required, we can supply the customer with a peel-back label. This structure allows us to print on the front of the label, and then print on a portion of the adhesive side, increasing the real estate of a typical label. These labels are generally made out of a film material and offer beautiful graphic appeal and durability. Dwyer: Our shrink labels offer a 360-degree image area. Therefore, there is enough room for graphics, nutritional information and anything else they might want the consumer to know about their product. Designing graphics for shrink labels enables the CPGs plenty of room for data. Dairy Foods: How do you ensure adequate operator and maintenance personnel training as your equipment or systems continue to advance, both mechanically and electronically? Faust: We have always worked very hard to keep the operators and maintenance personnel front and center as our equipment continues to advance. We believe that our equipment should be easy to use as well as maintain. We also take what are sometimes painstaking steps to design simplicity into the equipment from the beginning of the design phase. The end result is a system that is easy to learn. Therefore, training is simplified and more than adequate. If technology is used correctly, it does not add complexity. In fact, it can be used to your advantage and remove complexity. O’Donnell: We have always stayed true to the opinion that, for operators, any mechanical adjustment or HMI adjustment should remain easy to understand. We also lock out any function in the HMI or PLC that is not critical to the day-to-day operation of the equipment. The adjustment of variable information within the PLC or HMI can be accessed using a security code that is typically given to one senior member of the maintenance staff. As for maintenance training, we employ the techniques learned through the PMMI Certified Training program that all of our techs have been schooled in. Giordano: Our continuous training programs as specified in our standard operating procedure program are being updated, and training is ongoing throughout the year. It is a never-ending program that keeps all personnel in the plant attending training all year.   A U.S. Department of Agriculture initiative identifies bio-based products (those whose main ingredients are renewable plant or animal materials). Producers of qualifying materials can promote the eco-friendliness of the packaging with this label.

Codes on Caps, Sleeves Keep Track of SKUs Byrne Dairy’s Ultra Dairy unit produces aseptic milk and dairy products in a 40,000-square-foot facility in East Syracuse, N.Y. Clear, crisp codes are important to Ultra Dairy because the codes are used to meet government and customer requirements for supply chain traceability. In addition, some of Ultra Dairy’s customers require barcodes that are scanned for inventory purposes. Finally, end consumers rely on clear expiration dates to ensure they are purchasing and consuming a fresh product. “It is critical for us that the codes on every package are clear, legible and reliable,” says Eric Greiner, ESL sales manager for Ultra Dairy. “If our  On one bottling line, Ultra customers receive a case with Dairy codes caps on finished a barcode they can’t scan or a products with a small product with a code they can’t character ink jet printer and on another line the printer is read, they’ll send it back.” set up to code sleeves that For coding on its bottling are wrapped around bottles. line, Ultra Dairy uses a smallPhoto courtesy of Videojet character ink-jet printer. On Technologies one line, Ultra Dairy codes caps on finished products, and on another line, codes sleeves that are wrapped around bottles. The inkjet printers, laser coders and print-and-apply labelers are from Videojet Technologies Inc., Wood Dale, Ill. The fluid cartridges also include a microchip that verifies whether the correct fluid has been installed. This is extremely helpful for Ultra Dairy because the company must use different inks for the bottle caps and the sleeves, as the sleeves require an ink with a faster drying time. The microchip ensures the fluids for each substrate cannot be mixed up or incorrectly installed. – Contributed by Sascha Benke, director of vertical marketing, food, Videojet Technologies Inc. Read more about this installation at http://tinyurl.com/4xbqzg7 in the Case Studies section of DairyFoods.com.

EXTRAS Dion Label Printing .............................................. www.dionlabel.com EPI Labelers ....................................................... www.epilabelers.com H.S.Crocker Co. .................................................. www.hscrocker.com Overnight Labels ...................................... www.overnightlabels.com. The RB Dwyer Group........................... www.therbdwyergroup.com

www.dairyfoods.com

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Logistics & Distribution Beyond the Filler

Overlooked Resources in Dairy Logistics hat are your largest distribution, fleet operations, logistics and management challenges? Could it be scarcity of qualified drivers, internal competition for adequate capital investment dollars, regulatory compliance, finished-product storage capacity, inadequate or outdated management and operating technology or environmental mandates? In its March 2011 newsletter, Great Dane Trailers wrote that “by the end of 2013, a major fast-food chain will require all temperature-controlled carriers to have the capability to monitor reefer units from a remote location and electronically send temp data for the life of the shipment to a centralized website.” Do you currently have the capability to comply with such requirements? Many managers and executives in fluid dairy and ice cream distribution, logistics management and operations may not be familiar with the vast range of resources available from today’s thirdparty logistics (3PLs) providers. There are two basic types of 3PL providers; asset-based and non-asset-based. I generally consider non-asset-based as providers of technology plus management and operations services and resources. Asset-based providers also offer capital asset investments, which they might also operate for you.

W

If processing long-life products is a growth opportunity, you may need to design and implement new operations capabilities to grow your distant-market-distribution along with finished-product warehousing resources. Consider a third-party logistics (3PL) provider. Between the two types, they can offer customized combinations of services, equipment, technology and facilities designed for virtually any or all of your current distribution and logistics issues and challenges. The greatest mistake or shortcoming for many processors taking their first look at possible 3PL solutions is tunnel vision. That is to say they take a very narrow and pre-determined focus on a single problem or solution rather than a broader “imagine the possible” view. While a simple substitution of a dedicated contract carrier to replace current in-house transportation to a distant market may 94

Dairy Foods | May 2011

Don Wilson

be the solution needed today, that is merely a response to a specific situation. However, if processing/packaging of long-life products is seen as a new growth opportunity and is expected to continue expanding, you may need to design and implement new operations capabilities for profitably growing your distant-market-distribution along with finished-product warehousing resources. A hypothetical example For the purposes of our discussion, let’s look at a dairy or ice cream company aiming to conserve both internal working and investment capital while meeting the capital and customer demands of continuing new growth. New long-life processing and packaging technology has enabled the company to greatly expand production and reach into distant new markets. Taking advantage of those new market opportunities will require additional long-haul transport fleet equipment, along with refrigerated or deep-frozen product storage, load-out facilities and direct-store delivery in those distant markets. In short, this will require additional investments in capital equipment and physical facilities, additional labor and management staff, and technology and systems investments. Working with an asset-based 3PL, the ice cream processor developed two possible alternatives for consideration. 1. The 3PL would purchase, manage and operate the state-ofthe-art processing plant’s finished-product storage and distribution facility along with providing, operating and managing the long-haul transport fleet equipment needed to supply the distant markets. This will free up capital for the processor to invest in, manage and operate distant-market storage and customer delivery capabilities. 2. The 3PL would finance, operate and distribute in those distant markets while “wearing” the company’s logo and signage as its representative. The dairy processor would transport its products to those markets themselves. From those two fairly complicated alternatives, a dozen additional refinements or additional tweaks can probably be designed. The first scenario would free up a substantial amount of the company’s investment and operating capital. The second would avoid (or reduce) the company’s additional capital investment needs for these new and distant markets. This rather simplistic example provides at least a hint at what is possible in a 3PL provider relationship. I believe it just scratches the surface of the “possible” and hope that it excites your imagination to the point that you seek out and explore the possible with 3PL partners.  Don Wilson is president of the Wilson Group, Waxahachie, Texas.

W HY H O L A C D I C E R S

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TO P C H O I C E for increased PIZZA TOPPING

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New Product Showcase

Caps & Closures Silgan IPEC’s product portfolio includes a range of 38 millimeter dairy closures consisting of a virtually leak-proof ISO (screw-on), consumer-friendly ISS (screw on or snap-on/screw-off), industry staple lightweight ITT (tamper tail), classic 5-lead ICD (screw-on) and easy-toapply ISC (snap on/off), all used for gallon, half-gallon and single-service HDPE and PET applications. Silgan IPEC 724-658-3004 www.ipec.com

Silgan IPEC

Portola Packaging introduced SteriShield liner-less plug closure technology for aseptic beverage packages, including juices, isotonics, dairy, energy drinks, milk, vitamin waters, drinkable yogurt, teas and more. These closures are compression molded using a proprietary resin blend, which includes high-density polyethylene. The end result is a lightweight closure that does stress crack, backoff, etc. during the sterilization and/or distribution process. Additionally, the structure can withstand an aseptic sterilization environment of up to 140°F. Steri-Shield plug closures can be made in a variety of sizes ranging from 38-43 millimeters, with or without a tamperevident band. Portola Packaging, Inc. Portola 630-701-9443 www.portpack.com

SIG Combibloc Inc. SIG Combibloc is expanding its product range by adding a new screw cap — the combiCap. The new closure mechanism weighs just 1.85 grams (0.065 ounces). Less weight means fewer raw materials are used, which is good news for the environment. SIG Combibloc Inc. 610-546-4200 www.siggroup.com Tetra Pak unveiled a series of new closures designed to meet the diverse needs of the global beverage market — DreamCap, LightCap and HeliCap. DreamCap, an ergonomically designed closure made especially for on-the-go consumption, is aesthetically pleasing, easy to drink from, highly portable, simple to dispose of and safe. The cap’s high neck and over-the-edge design offer easy and comfortable access to the carton spout, allowing improved control of liquid flow. Meanwhile, LightCap was designed to keep plastic use and cost to a minimum, making it particularly suited for larger-sized closures, whereas HeliCap combines one-step easy opening with distinctive tamper evidence. Tetra Pak Inc. 847-955-6000 Tetra Pak Inc. www.tetrapak.com 96

Dairy Foods | May 2011

Elopak Inc. Elo-Cap US closure from Elopak has a special pull-ring membrane that meets advanced consumer safety requirements for fresh milk and juice. It features a bore seal for leak-free re-closure, consumerfriendly grip and seven standard colors. Elo-Cap US uses about 15% less plastic than previous caps, reducing cost and environmental impact. The Pure-Twist cap for long shelf life or aseptic products has an anti-drip lip and an integrated cutter that creates an opening the moment the cap is unscrewed. Elopak, Inc. 248-446-5449 www.elopak.com

No Contamination

H.S. Crocker Co.

H.S. Crocker’s unique two-piece lid handles and seals like the lids customers buy today, and run on equipment with no adjustments. It also offers new opportunities and ideas to bring to customers. Pick any design or shape that fits product needs for when the lid is peeled back, leaving only the custom design. H.S. Crocker Co. Inc. 847-669-3600 www.hscrocker.com

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World Dairy Expo

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Dairy Product Contest Enter the only North American judging contest to include all dairy products Contest Dates August 1, 2011 August 8-11 August 16-18

Rexam Rexam’s new stock 70 millimeter dualdispensing closure is ideal for spooning and shaking out product. Designed for parmesan cheese, it can also be used for salad crunches, condiments, powders and products that require larger dispensing openings. Its 2-piece design is created for custom-colored top and base. The closure is designed for one hand operation, featuring stay-open hinges that lock the lids away from the product flow. Rexam 812-868-2228 www.rexam.com Continued on page 98 dfx05114Contest-third.indd 1

Contest entry forms due Contest entries shipped Judging days

Contest Auction Tuesday October 4, 2011 World Dairy Expo, Madison, WI For more information on how to enter this contest, visit www.wdpa.net or call 608-836-3336.

More contest information to follow in next month’s issue.

97 www.dairyfoods.com 4/18/11 10:00 A

New Product Showcase Closure Systems

Closure Systems International is a leading supplier of aseptic closures, earning a global reputation for excellent sealing, consumer safety and highly efficient application performance. CSI’s closure portfolio includes one- and two-piece designs to meet the varying needs of dairy customers using HDPE and/or PET bottles. Its two-piece lined caps, such as SP38D-ML, and its family of one-piece, lightweight Asepti-Lok closures ensure secure hermetic sealing and re-sealing, critical for on-the-go packages. CSI’s closure systems

solutions help customers maximize profits by increasing the marketability of their brands and optimizing their total cost of operations. Closure Systems International 800-311-2740 www.csiclosures.com Spiralkote Flexible Spiralkote Packaging supplies a wide range of bottlecapping foils, both reelfed and die-cut lids, under the Capsteril brand. Suitable for a wide range of bottles and containers, Capsteril is usable in sterilization, pasteurization, extended shelf-life and ultra high-temperature processes. Spiralkote also supplies Capsteril with gamma radiation treatment in airtight packaging for aseptic applications. Capsteril is supplied globally to both multi-national and local producers and meets the highest quality and hygiene demands. Spiralkote Flexible Packaging 407-859-7780 www.spiralkote.com

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.

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New Product Showcase

Maintenance and Cleaning Supplies Cintas offers a line of rental apparel for women. The retailinspired garments are designed by women, for women, and incorporate fashion with functionality. A rental apparel program allows working women to save money on buying expensive work clothing, as well as saving time from doing laundry every week. Cintas 513-754-3566 www.cintas.com Envirocid Plus is a zero-phosphorus, low nitrate-acid CIP cleaner. Ecolab says its patent-pending acid CIP cleaner provides a zero-phosphorus and reduced-nitrates solution (by 65-75%) to help meet a company’s compliance and sustainability goals without giving up performance. Ecolab 800-392-3392 www.ecolab.com The Optimax system from Hydrite Chemical Co. is designed to control, dispense and record liquid chemical products. Dispense applications include portable containers, tank batching, product transfers, CIP and COP tanks, membrane cleaning and form washers. A digital display provides a visual readout of the dispensing status. The base Hydrite Chemical Co. unit with solenoids supports up to 10 products and records chemical usage in up to 60 areas. The dispenser provides a method of controlling and dispensing liquid products using a scale and reliable air-actuated pumps, which is ideal for container filling. Hydrite Chemical Co. 262-792-8741 www.hydrite.com Enduro Power is a high-performing, foam-based cleaning solution from Diversey, designed specifically for dairy and food manufacturing operations. The product is said to improve penetration of dirt and soil, reducing the need for reapplication because its lightweight formulation helps chemicals adhere to the surDiversey Inc.

dftv 100

Dairy Foods | May 2011

face as much as four times longer than other cleaners. Diversey Inc. 800-233-1000 www.diversey.com/enduropower Custom-configured lifts from Southworth Products Corp. can be designed into most production lines. These platforms are also appropriate for stock picking from higher shelves, such as the vertically stacked compartments of storage carSouthworth Products Corp. ousels. Southworth designs stable scissors lifts in stationary or movable configurations and in a multitude of platform sizes and lifting ranges. Options include custom controls; soft start/stop; indexed lifting and lowering, slide-out sections that increase platform size, fold-down safety gates and handrails, and custom deck treatments (non-skid, anti-static, etc.) Southworth Products Corp. 207-878-0700 www.SouthworthProducts.com Biowater Technology specializes in dairy wastewater treatment systems. The company says its systems optimize treatment configurations to help a customer’s CIP and COP systems work more efficiently and make sure compliance is achieved. The company assists customers in determining the best-suited solution when it comes to life-cycle benefit associated with primary treatment in combination with biological/secondary treatment of food waste streams. Sludge hauling costs, chemical usage and overall cost to operate the plant are said to be substantially reduced. Biowater Technology 401-305-3622 www.biowatertechnology.com TankJet tank-cleaning products from Spraying Systems Co. clean dryers and tanks up to 100 feet (30 meters) in diameter. Options include high-impact tank cleaners for removing stubborn residues from conical and box-shaped spray dryers, and storage and mixing tanks. Dozens of mediumand low-impact tank cleaning nozzles and spray balls are also available for cleaning tanks, vessels and totes. Spraying Systems Co. 800-957-7729 www.tankjet.com

Spraying Systems Co.

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

Buyers Mart

PLANT EQUIPMENT Hanna Instruments’ new HI 903 Volumetric Karl Fisher Titrator combines an ultra high-precision titrant delivery system with optically regulated magnetic stirring, sophisticated endpoint determination, dynamic dosing and background drift correction algorithms. It comes equipped with a solvent handling system to reduce cell conditioning time and can be connected directly to any laboratory balance via serial interface. The software and menus appear on a large color LCD display, making it simple to view results, choose from included methods or develop a custom method for almost any application or sample type. Hanna Instruments Inc. 800/426-6287 www.hannainst.com

HK Instrument

R & D INGREDIENTS

a less variable product and improve efficiencies upstream. HK Instrument Systems 412-653-7717 www.hkinstruments.com Intelligrated

Omega

PRS-TMM12 series transducers from Omega Engineering are designed for use in sanitary or hygienic clean-in-place applications in the food, dairy, beverage and biopharmaceutical industries. These transducers are manufactured with 316L stainless-steel housings that meet the dimensional and finish requirements of 3-A Standard 74-03 and ASME BPE-2007, and are welded and processed to provide a clean, smooth 32-microinch or better surface finish in wetted areas. Omega Engineering Inc. 203-359-1660 www.omega.com HK Instrument Systems’ HK-1 is a microwave-based measuring system that measures total solids during ultra filtration and other filtration processes. By continuously monitoring the total solids of raw milk or whey, the producer can have better control over the total solids, eliminate hand samples, completely automate UF methods, produce 102

Dairy Foods | May 2011

Mangosteen juice concentrate and puree from iTi Tropicals comes from mangosteen fruit, which is processed under GMPs and concentrated by an evaporator. Frozen mangosteen concentrate 30 brix is packed in 44-pound pails and 441-pound drums, whereas the puree is packed in 40-pound pails and 441-pound drums. Both mangosteen solutions are sourced from Thailand and free of any additives or preservatives. iTi Tropicals 609-987-0550 www.ititropicals.com

Intelligrated introduced the PLC-controlled Alvey robotic palletizer, which improves line integration, response time and overall productivity while reducing operator and maintenance training. PLC-based robotic controls are an alternative to the traditional proprietary robot controller, enabling customers to deploy new Alvey robotic palletizing solutions while maintaining standard familiar control platform. With minimal training, plant floor personnel can support these Intelligrated robotic applications without being “robotic experts.” Intelligrated 877-315-3400 www.intelligrated.com Westfalia

Westfalia Technologies introduces Savanna.NET warehouse management software version 2.3. Key fea-

At IFT 2011, June 11-14 in New Orleans, D.D. Williamson will showcase a wide array of new natural coloring, including acid-proof class one caramel color and caramelized sugar flavor and certified-organic annatto extracts. Attendees can also swing by booth 4429 and taste-test a “chocoberry” juice drink, a red sports drink, processed cheese in red, yellow, orange and purple varieties, mini fruit tarts, taffy and other confections. D.D. Williamson Colors LLC 800-227-2635 www.ddwilliamson.com SternVitamin introduced SternVit E 50% SD, a fat-soluble vitamin that prevents oil film from forming on the surface when drinks are fortified. SternVit E 50% SD consists of at least 50% vitamin E acetate with special carriers and flow aids, and as a single ingredient, is suitable for all beverages that are to be fortified with micronutrients, including drinks for athletes, Ace energy drinks, juices, milk, flavored milk drinks, yogurt, milk powder and more. SternVitamin GmbH & Co. KG + 49 (0) 41 02 / 202-007 www.sternvitamin.de

tures include real-time 3D visualization of the warehouse; a dashboard for tracking key statistics of warehouse operations; streamlined user rights-management interfaces; and improvements to the order picking module for integrating third-party picking solutions (i.e.; high-speed layer picking and mixed

Buyers Mart

layer picking). Savanna 2.3’s 3D visualization allows users to view the warehouse from any angle, including walking through it. Individual items/SKUs and warehouse zones can be identified and filtered. Westfalia Technologies Inc. 800-673-2522 www.westfaliausa.com RMT Robotics introduced its newest robotic gantry-based case, layer and crate picking solutions. Specifically designed to meet high-volume, high-SKU distribution demands, this picking system offers a scalable and profitable alternative to manual or semi-automated case picking for beverage distribution operations. Key features include automated handling to reduce the need for human resources, a compact design of the storage space to ensure higher processing rates per square foot, error-free picking results in lower return rates and increased customer satisfaction and precise information on the location of all products as well as the ability to isolate SKUs in the event of a problem or recall. Plus, the modular design allows for smaller initial installations that can be easily expanded in volume or product variety. RMT Robotics, a Cimcorp Oy company 905-643-9700 www.rmtrobotics.com Martin Borthers

Martin Brothers remanufactured its Crepaco S420 ingredient feeder with inverter-controlled A/C motors for a quiet, cool, clean and entirely adjustable operation. The touch-screen operator’s panel replaces the switches, buttons and knobs. Plus, the panel now contains controls for the start/ stop/speed of motors, alarm page for overheating protection of drives and motors, hour meter for preventive maintenance schedule, spare parts listing and current date/time. Martin Brothers, Inc. 800-652-2532 www.teammartinbrothers.com

Buchi

gives clear results, with one line of detection specifically for ceftiofur. The test can be used with Neogen’s AccuScan III reader for accurate record keeping and data analysis. Neogen Corp. 517-372-9200 www.neogen.com Polypack

Buchi introduces the NIRMaster, the newest addition to its portfolio of NIRSolutions. This instrument is the first stand-alone FT-NIR spectrometer that has been specifically designed with hygiene in mind for the food and feed industries. The NIRMaster is available in food-grade polymer and stainlesssteel housings (both in protection class IP54 and IP65). Further, its unique polarization interferometer provides the instrument with high sensitivity, ensuring accurate and reliable results, as well as a level of robustness not typically found in instruments with other interferometer designs. Plus, its internal laser reference eliminates the need for frequent, expensive instrument standardizations, saving users time and money. Buchi Corp. 302-652-3000 www.mybuchi.com Bosch Packaging introduces its intelligent transport system (ITS), a product infeed unit for horizontal flow wrappers. ITS balances out product flow irregularities, creates defined spaces and synchronizes product and film speeds. The system also ensures careful product transport of sensitive and non-accumulable food and confectionery products. It achieves output levels of up to 1,400 products per minute, and is powered by linear motors, in which more than 30 rotors are moved independently. Bosch Packaging Technology Inc. 715-246-6511 www.boschpackaging.com Neogen’s newly validated BetaStar Plus test (AOAC-RI 021107) detects dairy antibiotic residues in the beta-lactam group (penicillin, ampicillin, amoxicillin, cephapirin, ceftiofur and cloxacillin), at or below FDA regulatory levels. BetaStar Plus is an extremely simple dipstick test that requires only minimal training and equipment to produce consistently accurate results. It is also one of the fastest dairy antibiotic residue tests available, and can be used on the farm, tanker or in the laboratory. In just five minutes, BetaStar Plus

Polypack built a new wrap-around case packer to complement its existing line of shrink-wrap equipment. When compared to traditional RSC cases, the new case packer offers up to 30% savings on corrugate and uses die-cut corrugate blanks and forms by first loading the product onto the blanks. The end result is a tightly packed case that offers superior support for thin chipboard cases. The new case packer also features multi-layer packaging capability, servo-controlled gantry product loading system, automatic changeover adjustments and processes up to 20 cases per minute. Polypack Inc. 727-578-5000 www.polypack.com The BLX-F2 automatic bag loader from Sealed Air’s Cryovac brings an optimized level of versatility and efficiency to automated bag loading. The high-speed system offers configurable options using roll or boxed taped bags for an expanded variety of product sizes, shapes and weights. Ideal for cheddar and Italian cheeses, the system allows processors to program their infeed for both in-line and perpendicular product separation and staging, depending on the application. The new loader also handles a wide range of product weights, from 8 ounces to 12 pounds, and requires minimal time for changeovers. Plus, it operates at speeds up to 45 cycles per minute depending on product length, and the touch-screen operator interface can be programmed to save up to 99 different product settings. Sealed Air Corp., Cryovac Food Packaging Systems 800-845-3456 www.cryovac.com www.dairyfoods.com

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

AUCTION

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105

EQUIPMENT FOR SALE

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106

Dairy Foods | May 2011

3/7/11 10:17 AM

EQUIPMENT FOR SALE

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107

EMPLOYMENT

HIRING Milk Processing Plant Manager Join our progressive & expanding company on the cutting edge of technology. This position will oversee the efficient operation and function of Kreider Farms Milk Processing Plant in Manheim, Pennsylvania. Applicant Requirements: • BS degree in Food/Dairy Science or related Field. • Five years Dairy/Food Mfg experience • Five years Management experience • Computer skills in Word & Excel

Job Skills Requirements: • Strong organizational ability • Good communication skills • Problem solving • Ability to manage people

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SERVICES

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

108

Dairy Foods | May 2011

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Ad Index

Company Name ADM Cocoa Admix, Inc. Ajinomoto Food Ingredients LLC. Amelia Bay, Inc. Ampco Pumps Co. Autocrat Premium Coffee & Syrup Bentley Instruments BUCHI Corp. Clear Seas Research Concord Foods Inc. Corn Products Specialty Ingredients Cryovac DD Williamson Dairy House Danisco USA Inc. David Michael & Co. Delkor Systems, Inc. Evergreen Packaging FC Stone Flavorchem Fortitech, Inc. FPSA Fristam Pumps, Inc. GEA Niro Soavi NA GEA Process Engineering, Inc. GEA Tuchenhagen North America Gelita USA Gram Equipment Great Lakes Separators H.S. Crocker Company, Inc.

Page No. 29 16 41 9 70 45 90 32 13 71 43 3 48 25 31 27 BC 61 92 21 49 55 4 68 IFC 89 52 73 90 54

Company Name

Page No.

International Dairy Foods Association iTi Tropicals Matsutani ADM MilkPEP Mintel International Neogen Paul Mueller Company Pecan Deluxe Candy Company Polypack, Inc. Powder Solutions Relco Richmond Baking Robert Reiser & Co. S&D Coffee Sensient Food Colors Siemens Energy & Automation Spraying Systems Co. SPX Flow Technology Segment Sudmo North America, Inc. Symrise Tate & Lyle Tetra Pak, Inc. Thirs-Tea Corp. TIC Gums Tindall Packaging, Inc. United International Industries U.S. Highbush Blueberry Council Weber Scientific Wisconsin Dairy Products Association

7, 91 12, 50 14, 15 35 109 81 6 72 18 97 6 37 95 39 57 101 79 IBC 75 51 17, 19 83 24 53 99 92 33 11 97

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

109

Inside Perspective

Meeting the Challenge of Sodium Reduction t seems that hardly a week goes by without another food company announcing its commitment to sodium reduction, or another group proposing voluntary targets for food producers. The debate on whether sodium was an issue or not ended last year with the Institute of Medicine’s report, “Strategies to Reduce Sodium Intake in the United States.” The message was reinforced in the revised 2010 Dietary Guidelines for Americans with an increased focus on a recommended daily allowance of 2,300 milligrams sodium for most adults and a new, reduced daily allowance of 1,500 milligrams for a significant portion of the population such as children and at-risk adults. However, this now raises two important questions. Firstly, what’s the route forward to achieving an overall 33% reduction in dietary sodium (from the current 3,436 milligrams daily average)? Secondly, in the quest to limit sodium consumption, how do we avoid creating shortfalls in other positive nutrients such as calcium and protein?

I

Protein, calcium and sodium Consider this. Dairy products deliver approximately 11% of the sodium in the U.S. diet, with much of that (8%) coming from cheese. Even a simple glass of pure 2% milk contains 130 milligrams of sodium. So if you follow the three-servings-ofdairy-a-day rule, you’ll likely consume at least 390 milligrams of sodium, or 17% of your daily guidance. However, dairy products are also very important sources of calcium (21% of dietary calcium comes from cheese), protein and other valuable nutrients. Hitting 2,300 milligrams sodium a day (let alone 1,500 milligrams a day) by relying on reduced consumption and avoidance while avoiding any shortfalls is not going to work for most consumers. Even minimally processed products such as cheddar cheese or cottage cheese have added salt as part of their traditional make process, which cannot be easily 110

Dairy Foods | May 2011

removed or reduced without sacrificing quality. Sodium plays a complex role in cheese and is more than just salt added for taste. In natural cheese, salt is vital for curd formation and curing. Even relatively small reductions in sodium change the environment for the micro-flora, which results in change to taste and texture that goes much further than simply being less salty. In process cheese, sodium salts play a critical role in delivering not just the flavor, but also the creamy melt characteristic. It is possible to exchange some of the sodium salts with other salts, such as potassium. Yet this creates another set of challenges with unwanted taste changes in the form of increased bitterness. Reductions can be made, but even slight decreases of 10% are not always straightforward and can alienate loyal consumers. Looking beyond reduction Despite these challenges, Kraft Foods, Northfield, Ill., has been actively working on sodium reduction for more than two decades and in 2010, we announced further plans to reduce sodium across our U.S. portfolio by an average of 10% by 2012. That’s equivalent to 750 million teaspoons of salt. In cheese, for example, we reduced the sodium in Kraft Velveeta by 10% in 2010. However, to reach the recommended consumption levels, we need to look beyond sodium reduction in existing products. The industry has three other parallel paths: 1) introduce reduced-sodium alternatives to existing products; 2) innovate with new products that offer great taste but are naturally low in sodium; and 3) invest in new technology to better manage how we use sodium in our products. Within Kraft cheese, we are making progress on offering reduced-sodium versions of products. The challenge is the balance between a meaningful reduction in sodium while still delighting the consumer with taste. As part of this strategy, Kraft Foods now offers reduced sodium (30%

Nigel Kirtley

lower) versions of both Breakstone’s and Knudsen cottage cheeses as well as other cheese varieties, such as Swiss, which are lower sodium. Innovating with new products that are naturally low in sodium also needs to be part of the solution. It is also the hardest and riskiest strategy, which has to be rooted in a broader business rationale and not just lower sodium. One recent example from Kraft is the launch of Athenos Greek yogurt, which has only 100 milligrams of sodium and 0 grams fat per serving while still delivering great taste and texture with 23 grams of high-quality protein. In March, the Dairy Innovation Center of Dairy Management Inc., Rosemont, Ill., published a paper on the sodium content of various retail cheeses in the United States. It is a unique and substantial piece of scientific work based on real marketplace data. One of the interesting findings was the relatively wide range in sodium content (as measured analytically) across cheeses. Even within one cheese type, such as cheddar, there was significant variation (470-730 milligrams per 100 grams) and even still within individual brands there was variation. Perhaps that should not be a surprise as cheese is made directly from milk, a natural material, which itself varies. Many of our manufacturing processes are based on long-established traditional methods with the focus for a cheesemaker on amount of added salt rather than final sodium content, which is more difficult to measure. As an industry, improving our control of sodium has to go in parallel with any steps in reductions. The sodium challenge is tough, and to tackle it we need to use all our options; it’s just not going to be business as usual.  Nigel Kirtley is vice president R&D at Kraft Foods Cheese and Dairy, Northfield, Ill. Dairy Foods seeks essays from dairy processors. Contact [email protected].

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