Dairy Foods October 2011

PIERRE’S ICE CREAM | FORMULATING WITH CHOCOLATE | USING RIGID PACKAGES

Innovative Ideas for Dairy Processors

October 2011

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October 2011 Vol. 112, No. 10

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

Bolder, Bigger & Better Cheese Cheesemakers are carving out a bigger and bolder position in the dairy industry. They are creating items that deliver robust flavorings, zesty spices, unusual textures and layers upon layers of taste to drive consumers back to the kitchen to prepare high-quality home-cooked meals. p. 38

Process Expo 2011 Preview On our cover: As consumers look to include more protein in their diets, they turn to cheese. Erin Price of Sargento Foods says “cheese continues to be one of America’s favorite dairy forms.” Natural cheese snacks provide the flavor variety and high protein consumers want with the calcium they need for a satisfying snack between meals, she tells Dairy Foods. Our annual cheese outlook begins on page 38, with special contributions from the Innovation Center for U.S. Dairy and the Dairy Research Institute. Cover image courtesy of the Wisconsin Milk Marketing Board.

The so-called “global food and technology show” hosted by the Food Processing Suppliers Association sets up shop Nov. 1-4 in Chicago’s McCormick Place. p. 50

The Flexibility of Rigid Packaging Package designers collaborate with dairy processors to develop rigid packaging that is cost-effective, protects foods and stands up to the rigors of handling and transportation. p. 78

Features News & Trends 10 Newsline Benchmarking for better profits; Giffords Dairy is a winner; producers fight over reforms; Dannon opens new R&D center

Products & Marketing 22 Dairy Market Trends

Ingredient Technology

Sales statistics about nondairy beverages.

Cocoa and dairy make the perfect marriage

24

Departments 8 16 19 86 88 93 97 98

New Product Review Ice cream and frozen treats for people, dogs

Editorial Supplier News People Equipment Showcase: Warehouse Automation Buyers Mart Classified Ads Index of Advertisers Inside Perspective

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32

Ingredient Technology

Wellness Watch Immune-boosting ingredients

36

Dairy Detective

REPORTS 59 Pierre’s Ice Cream Co. 76

Behind The Scenes

84 Quality on the Line

Add nutrition to snacks with dairy ingredients

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

Talking to women, not at them, is a better tactic, writes Carlos Ramirez of Alpina Foods. DAIRY FOODS Volume 112, Issue 10 (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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October 2011 Vol. 112, No. 10 www.dairyfoods.com

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From the Editor’s Desk

72 Hours in Atlanta sk 100 people why they go to a tradeshow and you can get 100 different answers, among them: to find new equipment, to find new ingredients, to find new vendors, to network, to chair committee meetings, to get educated on the latest trends. The International Dairy Show ran in Atlanta last month. I was there to look for articles, sources, ideas and to further my education on product formulation, processing techniques and current research. The International Dairy Foods Association, Washington, D.C., put on the three-day event. Here’s a (very) brief overview of what I picked up: MilkPEP CEO Vivien Godfrey said her organization will undertake fewer but bolder campaigns in 2012. The No. 1 priority is the Breakfast at Home program. She charged processors to “defend breakfast” by making sure consumers have a bottle of milk on the kitchen table in the morning. MilkPEP’s second campaign is positioning chocolate milk as a recovery beverage. Godfrey told me that the target audience is the active 18- to 24-year-old engaged in strenuous sports, like marathons, triathlons and serious body-building. MilkPEP, Washington, D.C., sees some of these athletes as fit-

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ness proselytizers who will tell their friends about refueling with the beverage. Be careful (very careful) about on-pack claims. Shoppers have specific notions about what it means for a product to be natural, real, fresh and simple. They are seemingly nonplussed by naturally occurring fats, added Vitamin D and sodium. But use the wrong packaging or messaging, and all bets are off. Shoppers rejected a spreadable butter because its package resembled one used for margarines. Heather Collins of Touchpoint Consumer Insights, Evanston, Ill., and Rachel Kyllo of Kemps, LLC, St. Paul, Minn., presented the results of focus groups in Chicago and Denver in which young adults, mothers and baby boomer women sorted a variety of dairy and non-dairy foods from “least to most” real. They highly rated whole white milk, organic 2% milk, natural cheese and Greek yogurt as “real.” Canned whipped cream, processed cheese, jarred cheeses and Parmesan cheese in a shaker were least “real.” Brick cheese in a plastic wrapper is considered less real that an irregularly sliced chunk of cheese in a deli-style wrapper. Milk processors lag in product innovations. Gary Hemphill of Beverage Marketing Corp., New York, said there is more innovation in soft drinks and fruit beverages than there is in milk-based beverages. Single-serve beverages created for immediate consumption hold promise for dairy processors. Such beverages are less price-sensitive than beverages intended to be taken home and consumed there. Convenience stores are a natural channel for single-serve, drink-right-now beverages. I sipped a variety of flavored milks in aluminum bottles from the Upstate Niagara Co-operative at the Dairy and Beverage Bar on the show floor. I liked the strawberry-chocolate flavor.

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Dairy Foods | October 2011

Schools want to work with you, not fight with you. Jessica Shelly, director of food services for the Cincinnati Public Schools, told me how she worked with Trauth Dairy, Newport, Ky., to reformulate chocolate milk into a version with fewer calories and less sugar. She got out in front of the issue, did some research of her own and was able to neutralize criticisms of the product from a vocal minority of parents. What did you learn in Atlanta? Send me a note or call me.  Jim Carper is chief editor of Dairy Foods Phone: 847-405-4009. Email: [email protected].

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NEWSLINE... Processors Improve Profits with Benchmarking airy processors can ask a lot of questions. For example: How can I know if my dairy operations are cost competitive? What areas should I focus on to improve margins and profits? How can I gain a market advantage on my competitors? These are a few questions that are likely to be answered with the use of benchmarks. Staying competitive means keeping one eye on your own company’s operational costs and the other on the costs of your peers in your industry.

D

Financial and non-financial benchmarks A business benchmark is any type of measurement used to compare some quantifiable component of a company’s activity or performance. These benchmarks can be financial such as plant cost per gallon of milk, manufacturing cost per pound of cheese, distribution cost per case, EBITDA (earnings before interest, tax, depreciation and amortization) and so on. Benchmarks can also be non-financial such as inventory out-of-stock rates, gallons processed per hour and product yields. Business benchmarks provide valuable intelligence to help an enterprise make more enlightened business decisions. Benchmarks can be used to shape an enterprise’s business strategy by setting specific and quantifiable goals and monitoring the company’s performance relative to those goals. Benchmarking is also the process of using comparable data to determine who or what is the very best and what that standard is. The key to using benchmarks is gathering relevant comparable information to determine an average or best practices standard and then comparing your information to that standard. Sounds easy, but how do you gather the benchmark information? Some practical ways of securing this information in the dairy industry include: • Active involvement in industry trade organizations where information is shared • Review of available public company information • Engaging an industry consultant that has access to comparable information • Review of information available through the U.S. Department of Agriculture To make benchmarking beneficial, the development of the standards must use information that is truly comparable. Since many dairy products are somewhat homogeneous, benchmarking for the dairy industry can be very helpful. However, comparing information from a fluid plant that primarily bottles gallons and half gallons serving large grocery chains to a fluid plant producing large half-pint quantities serving schools may not be very helpful. To benefit from a benchmarking study, the key component is to obtain the most comparable company information. Strategies and

decisions could be misdirected if the right information is not used. Companies with multiple locations producing similar products should also consider comparing benchmarks for each location. Detailed benchmarking information will produce more insightful results. Many companies know total plant costs, but it is more valuable to know unit costs for cost centers or departments within the plant and even more valuable to know unit costs for expense categories with those departments. To illustrate the levels of detail, see the following example of a fluid milk plant: Costs

Plant

Total plant costs per gallon

$.40

Bottling costs per gallon

Cost Center

Expense

$.19

Bottling wages per gallon

$.06

Bottling supplies per gallon

$.03

Bottling repairs and maintenance

$.02

Utilities

$.04

Insurance

$.01

Source: Herbein + Co.

Best practices in a milk plant An example of best practice benchmarks for a fluid milk plant using cost center levels are: Cost Center

Cost Per Gallon

Receiving

$.036

Pasteurization

.044

Bottling

.140

Cold Room

.116

Plant Subtotal

$.336

Selling

.084

Delivery

.332

Total Cost

$.752

Source: Herbein + Co.

A fluid milk plant comparing its costs per gallon to the benchmarks in the table above would identify opportunities for improvement, whether it is process redesign, cost-cutting measures or productivity reviews. Such an analysis provides management with the insight to focus in the areas more likely to produce positive results. Benchmarks can also be used as goals for managers to achieve, often tied to employee incentive plans. Continued on page 12

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Dairy Foods | October 2011

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News & Trends

Financial benchmarks can also be useful in analyzing raw product and packaging costs. In a federally regulated market, class price differences based on location are readily determinable. However, financial benchmarks for other costs of milk procurement, such as premiums paid, could also prove beneficial. Benchmarking milk shrinkage amounts and fat content in the product are often enlightening. Benchmarks for the cost of containers and ingredients would indicate if you are purchasing these items at the best price. Data for butter, cheese plants You can find costs for butter, cheese and powder plants online. The U.S. Department of Agriculture (USDA), Washington, D.C., accumulates cost data from plants in California to establish and monitor allowances within the federal order pricing system. Once the most relevant comparable data are obtained and the findings are analyzed in a benchmarking exercise, you will often realize your areas of strengths and weaknesses. Then, you determine ways to close any gap between what you and others, including competitors, are doing. For example, you may design a more efficient process to cut costs or explore ways to streamline certain processes and functions. The ultimate goal is to bring your operation up to the standard considered the best in your industry, likely to result in productivity gains and increased profitability.  By Carl Herbein, a certified public accountant and CEO and founding partner of Herbein + Co., Reading, Pa. He leads a team serving clients nationwide, including large multi-plant and small niche dairy processors.

Giffords Dairy, Babcock Hall Named Grand Champions at World Dairy Expo Babcock Hall Dairy Plant, Madison, Wis., was selected as the Cheese and Butter Grand Champion, while Gifford’s Dairy, Skowhegan, Maine, was chosen as the Grade A & Ice Cream Grand Champion in this year’s Championship Dairy Product Contest, sponsored by the Wisconsin Dairy Products Association (WDPA) and Dairy Foods magazine. The contest received a record number of 705 entries for cheese, butter, fluid milk, yogurt, cottage cheese, ice cream, sour cream, sherbet, cultured milk, sour cream dips, whipping cream, dried whey and creative/innovative products from throughout the United States. Judging was held Aug. 16 at UW-Madison’s Babcock Hall and Aug. 17-18 at the Madison Area Technical College (MATC) Culinary School, Madison, Wis. On Oct. 4, the contest’s auction was held at World Dairy Expo in Madison, Wis., where all category first-place winners were auctioned off. A portion of the proceeds went to fund the Dr. Robert Bradley Scholarship Fund, which is awarded annually to a deserving student pursuing a career in the dairy industry. Go to www.dairyfoods.com /Articles/Dairy_News to see a list of all of the first-place winners.

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Dairy Foods | October 2011

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Dairy Producers at Odds Over Proposed Policy Reform While dairy processors seem to be all in, dairy producers are not solidly behind Foundation for the Future (FFTF), a dairy reform program from National Milk Producers Federation (NMPF), Arlington, Va. On March 1, House Agriculture Committee member Collin Peterson (D-MN) and Congressman Mike Simpson (R-ID) put forward a draft legislation for a dairy policy program, based on FFTF that is designed to compensate farmers for the gap between feed costs and the milk price by providing a floor for producer margins during times of low margins to prevent an erosion of equity. On Sept. 8, the House Agriculture Livestock, Poultry and Dairy Subcommittee held a dairy policy hearing with witnesses such as the U.S. Department of Agriculture (USDA) and officials from the Farm Service Agency (FSA) and Agriculture Marketing Service (AMS). After attending the hearing, NMPF president and CEO Jerry Kozak, said “The general tone…indicates a concern that current dairy programs are not up to the task of providing a meaningful farm-level safety net. NMPF shares that concern, and that’s what has driven the creation of Foundation for the Future. We believe we have the best answer to the bottom line question of what should come next for dairy policy.” Land O’Lakes, Inc., Arden Hills, Minn., endorsed the draft legislation, stating that “this bill will help ensure that America’s dairy producers, including Land O’Lakes members, are able to thrive in the future, after some very economically challenging years,” says Pete Kappelman, chairman of the Land O’Lakes board of directors and a Wisconsin dairy producer.

But John Pagel, owner of Pagel’s Ponderosa Dairy, Kewaunee, Wis., launched a website, www.stopsupplymanagement.com, to outline why he and other dairy farmers are opposed to the FFTF proposal. This site provides a forum for farmers, legislators and the public to share ideas, thoughts and facts about the topic. “While I applaud NMPF for starting the much-needed conversation about dairy policy reform, I am strongly opposed to the supply management portion of the FFTF proposal,” Pagel adds. “Penalizing farmers for producing too much milk when the milk price declines takes money out of our milk checks when we need it the most.” The National Dairy Producers Organization, Fresno, Calif., opposes part of FFTF, including the margin protection program and the stabilization program. In August, the group also urged “all dairy producers whose milk goes into making Class III inventoried products to voluntarily reduce their milk production by 5%.” The International Dairy Foods Association (IDFA), Washington, D.C., urges all dairy processors to ask their representatives to oppose the bill. “Most everyone now agrees that the price support program hurts dairy exports because it temporarily raises U.S. prices above international prices, yet the stabilization program operates in exactly the same way,” says Jerry Slominski, IDFA senior vice president. “National Milk [Producers Federation’s] proposal openly admits that its program will likely have this impact because it includes a provision that allows the secretary of agriculture to suspend the program if dairy prices are 20% above world prices for more than two months.” Continued on page 14

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News & Trends

Dannon Opens R&D Center at Corporate Headquarters The Dannon Co. opened a new research and development facility at its corporate headquarters in White Plains, N.Y., on Sept. 1. The $9 million facility occupies 14,000 square feet on the first floor of the headquarters. Previously, the R&D team was based in Dannon’s pilot plant at its Fort Worth, Texas, processing plant. The White Plains facility, officially called the Dannon Discovery & Innovation Center, includes equipment for manufacturing dairy foods. The move to corporate headquarters will allow the R&D team to work more closely with the marketing team, which Stewart Townsend told Dairy Foods is “a great benefit.” Townsend, the senior director of R&D, called the innovation center a scalable “state-of-the-art processing facility” where Dannon can perform the batching, pasteurizing, fermenting, cool down and packing processes and procedures involved in yogurt making. The plant, which has an Interstate Milk Shippers

14

Dairy Foods | October 2011

certificate, received milk the day after opening and began yogurt processing, Townsend said. Dannon will not be selling any product it makes here, however. Townsend said the location of the R&D center within a headquarters building is

unique within the Dannon organization. In France, Danone is located in Paris and its pilot plant is in the suburbs. The innovation center occupies what once was office space. The second floor of the headquarters is home to mar-

News & Trends

keting, finance, administration and other departments. The 40 R&D center employees consist of technicians, product developers, sensory experts and scientists. A separate section of office space is reserved for suppliers who will work on-site with Dannon employees. This arrangement will “accelerate collaboration, spur innovation and ensure integration at every stage of the development process,” according to a press release. Current research involves improving the existing portfolio of products and developing new product concepts, Michael Neuwirth, senior director of public relations, told Dairy Foods. In addition to developing new foods, Dannon will be researching processes and packaging. Dannon, with 2010 sales of approximately $1.25 billion, ranks No. 24 on the Dairy 100, Dairy Foods’ annual ranking of North American dairy foods processors. In February of this year, Dannon introduced a French-style yogurt to the U.S. market.

FSMA Requires Better Recordkeeping The Food Safety Modernization Act gives the U.S. Food and Drug Administration, Washington, D.C., increased powers to view records (except financial records) kept by dairy processors. Processors will be required to turn over records, including HACCP records, to FDA inspectors who are investigating whether foods have been adulterated or misbranded. Allen Sayler of Randolph Associates Inc., Birmingham, Ala., briefed dairy processors, suppliers and others during the webinar, “FDA’s Food Safety Modernization Act: Implications for Dairy Processors,” presented by Dairy Foods. To view an archived version, go to www. dairyfoods.com. Sayler also writes a column about food safety for the monthly magazine. Continued on page 16

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Dairy Love: A Social Media Snapshot Sara Lee has nothing on Ben & Jerry’s. It seems nobody doesn’t like the Vermontbased ice cream processor, according to a Dairy Foods analysis of Facebook “likes.” No other Facebook page had more than 1 million likes. This report is based on the leading brands of milk, cheese, ice cream and cultured dairy foods as reported in our November 2010 State of the Industry report. Rank

Page

“Likes”

1.

Ben & Jerry’s

2.

Kraft Foods

720,515

3.

Dannon Light & Fit

685,853

4.

Häagen-Dazs

646,830

5.

Shedd’s Country Crock

439,716

6.

Yoplait Light

258,024

7.

Friendly

229,063

8.

Chobani

226,688

9.

Tillamook

162,578

10.

Nestle Nesquik

145,680

3,239,812

Source: Dairy Foods, compiled by Philip Butta, editorial intern. “Likes” as of Aug. 24, 2011.

Use the sweet taste of SPLENDA® Sucralose and open the door to a vast array of ingredients and formulation expertise that provides more ways to create nutritious, delicious and profitable products. Our own independent research also helps you gain a better understanding of what consumers truly want so you are better able to develop products that are perfect for their preferences. To see all our elements in action, visit www.splendasucralose.com

© Tate & Lyle 2011

SPLENDA® and the SPLENDA® logo are trademarks of McNeil Nutritionals, LLC.

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15

News & Trends

SUPPLIER NEWS Roquette

a test kitchen, an analytical and powder lab, a human nutrition lab for culinary and animal nutrition development, an auditorium, which is used for educational seminars and courses, and a pilot lab, which is expected to be completed by the beginning of 2012. Butter Buds Food Ingredients, a division of Cumberland Packing Corp., completed the purchase of a 76,000-square-foot facility adjacent to its current facility in Racine, Wis. The space will be used for expanded production capacity, additional warehouse and office space.

On Sept. 14, Roquette America unveiled its new state-of-the-art innovation center, located in Geneva, Ill. This multi-million dollar, 3 0,000-squarefoot, LEED-certified facility acts as a collaborative tool for producers to create value-added products. It is home to

16

Dairy Foods | October 2011

Robertet Flavors selected GeoPeak Energy LLC to design, install and service a high-efficiency solar energy system at its flavors manufacturing facility in Piscataway, N.J. The roof-mounted solar panels will cover 115,000 square feet and will be operational by the end

of 2011. Fourteen percent of the manufacturing plant’s power will be provided by this system, which will reduce the site’s annual CO 2 emissions by more than 1.1 million pounds, the equivalent of planting 33,665 trees or the conservation of 1.5 million gallons of gasoline over the system’s lifetime. Cheer Pack North America moved into a 3 0,000-square-foot facility in Plymouth, Mass. The facility, located in the Plymouth Industrial Park, features office and manufacturing space, and allows for another expansion to convert films, manufacture pouches and perform injection molding. Huhtamaki acquired the assets and business of Paris Packaging, Inc., a privately held manufacturer of specialty folding cartons. Paris Packaging employs 300 people in plants located in Paris, Texas; Andalusia, Ala.; and

News & Trends

SUPPLIER NEWS Hopkinsville, Ky.; and gives Huhtamaki North America a new product platform and a stronger manufacturing presence in the South and Southeast.

tomer base with new business lines while allowing for expansion into new markets and channels. Combining Wild’s expertise with A.M. Todd’s capabilities in the natural mint market as well as specialties in flavors,

extract and organic materials allows Wild to provide the highest level of quality, innovation and consistency in the development of flavors, colors, ingredient and systems. Completion of the acquisition is scheduled for Oct. 31. Continued on page 18

Good for

Your

natural label product taste ease of formulation healthy solutions future development bottom line National Starch National Starch Food Innovation published an eight-page brochure for the North American food processing industry that demonstrates the benefits of the company’s line of texture systems for dairy foods. “P R ECI SA Optimized Texture Systems - Achieve the Perfect Texture Faster” outlines how food formulators can transform the texture profiles of many foods and build back texture and the eating experience when there is a need to reformulate. Go to www.foodinnovation.com/ precisa to download a copy. PureCircle opened a new European headquarters in London and signed a UK distribution agreement with Prinova Europe (formerly known as Premium Ingredients International). PureCircle’s UK reach will be further extended through the new distribution agreement with Prinova, which builds on the relationship the two companies have already established in the United States. Wild Flavors acquired certain assets of the A.M. Todd Group, Inc. to help facilitate enhanced growth for its cus-

Fiber is increasingly becoming the ingredient consumers are demanding. How do you give consumers the health benefits of fiber without compromising taste and texture? With PROMITOR™ Dietary Fiber! From cereal bars and ice cream, to soups and salad dressings and even flavored water, PROMITOR™ Dietary Fiber is well tolerated and formulates easily, resulting in healthier foods that taste delicious.

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our ingredients – your success ©2011 Tate & Lyle • www.tateandlyle.com

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17

News & Trends

B R I E F LY … Byrne Dairy Receives Gold Medal With a perfect score, Cornell University’s Department of Food Science, Ithaca, N.Y., named Byrne Dairy, Syracuse, N.Y., the first place winner of the 2011 New York State Fair Fluid Milk Quality Competition. Byrne Dairy’s Fresh Plant received the highest possible rating after all of the results were recorded, judged and totaled for the following categories: Flavor, Bacteria, Butterfat and Freezing Point. Dairy Research Institute, Cornell Establish Partnership The Dairy Research Institute, Rosemont, Ill., and Cornell University, Ithaca, N.Y., established a partnership with the Northeast Dairy Foods Research Center, a cooperative research and extension effort between Cornell University and the University of Vermont. The center will focus on fluid milk and dairy ingredient research, provide applications and technical support for improvements in milk powder quality and help establish the next generation of dairy ingredients. The center also will provide new learning opportunities for the industry with short course training in dairy food safety, Hazard Analysis and Critical Control Points (HACCP) and dairy processing with a particular focus on fluid milk processing, cheese making and artisan dairy production. For more information on the Dairy Research Institute, visit www.USDairy.com/dairyresearchinstitute. NDC, NFL and Top Chef Alum Kick Off Back-to-School Program The National Dairy Council (NDC), Rosemont, Ill., the National Football League (NFL) and Carla Hall, Top Chef alum and co-host of ABC’s upcoming lifestyle series, The Chew, are jump starting the new school year by motivating students to take charge of their wellbeing through Fuel Up to Play 60, an in-school nutrition and physical activity program launched by the NDC and the NFL in collaboration with the U.S. Department of Agriculture. To ensure parents make their children healthy lunches and encourage exercise throughout the school week, Fuel Up to Play 60 and Hall offer the following tips. • Don’t get hung up. Don’t get frustrated by trying to create the perfect meal for children, as long as you work toward balance. Even the occasional chocolate chip cookie works, especially when served with milk. • Create a game plan. Prepare in advance by planning out the weekly lunches and snacks. • Make good food the easy way. Food doesn’t have to be homemade to be nutritious. Reach for healthy packaged options like string cheese or yogurt. • Have fun. Making meals together can be a fun activity to teach children about the value of building a colorful and nutritious meal for themselves, and letting them co-own their own health and wellness. • Prioritize family time. Plan activities that help you and your child work toward achieving at least 60 minutes of daily physical activity – from taking a walk after dinner to playing catch or dancing in the backyard.

News & Trends

PEOPLE Agro Farma, Norwich, N.Y. Mikael Pedersen was named chief operations officer, responsible for leading global operations initiatives. Pedersen brings more than 25 years of expertise in dairy manufacturing, and can utilize his leadership and experience to develop and motivate successful management teams. Darigold, Inc., Seattle Jim Wegner was named president and CEO of Northwest Dairy Association, Seattle, and Darigold, succeeding John Underwood, who retired. Underwood will serve as special executive to the board of directors and will assist with the transition. iTi Tropicals Inc., Lawrenceville, N.J. R o b e r t o A r a g o n joined as director, business development. Aragon’s technical, commercial and managerial expertise have been instrumental in the

expansion of diverse food and beverage industries in the United States, European Union, Asia, Australia, South America, Caribbean, and more. His expertise spans agriculture, financing, project development, management, international trade and liaison with private and public sectors.

agribusiness and dairy industry manager for the food and beverage vertical market management. In this role, Garcia is responsible for the development and penetration of the edible oil, agribusiness and dairy industries promoting industry specific solutions. Intelligrated, Cincinnati

QCS Purchasing, LLC, Lisle, Ill. Vince Glaviano will serve as director of supply management. He most recently worked as Glaviano supply chain manager for Appetizers And, Inc., a division of H.J. Heinz, where he oversaw the purchasing, logistics, planning and inventory of finished goods and raw materials. Siemens Industry Inc., Buffalo Grove, Ill. Pablo Garcia was named edible oils,

Greg Cronin was named executive vice president, responsible for leveraging the company’s software capabilities and assisting in the ongoing development of the company’s software strategy. He will also take an active role in sales and marketing activities for Intelligrated’s software portfolio. Virginia Dare, Brooklyn, N.Y. Adayit (Deedee) Kalo joined as a flavor chemist, responsible for creating new flavors for beverage, dairy, sweet goods, pharmaceutical and oral care product applications. Continued on page 20

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Sustainability Awards Highlight Excellence Across Dairy Supply Chain The Innovation Center for U.S. Dairy, in affiliation with the Dairy Research Institute, announces the U.S. Dairy Sustainability Awards, a new program that recognizes dairy farms, businesses and collaborative partnerships for efforts that deliver outstanding economic, environmental and/or social benefit, thus helping to advance sustainability of the dairy industry. The awards are divided into three categories: dairy farm, dairy processing/manufacturing and energy conservation/generation. Nominations are being accepted at www.USDairy.com/Sustainability/Awards through Dec. 1. There is no fee to enter. Winners of the U.S. Dairy Sustainability Awards will be announced in February 2012. In addition, honorees will share their stories and passion for sustainability on a national scale in forums and venues, and will be featured on www.USDairy.com/Sustainability. All nominations will be evaluated based on the program’s or project’s results as measured by triple bottom-line success — economic, environmental and social. Judges also will assess the potential for adoption of the idea by other dairy farms and businesses, demonstrated learning, innovation and improvement and scalability. Judging will be completed by an independent panel, including Jim Carper, chief editor of Dairy Foods magazine, representing the full spectrum of the dairy supply chain, as well as academia, government, media, business and non-governmental organizations. The distinguished panel of judges will be announced in October. For more information or to nominate, go to www.USDairy.com/Sustainability/ Awards. 

New Products & Marketing

DAIRY MARKET TRENDS

Non-Dairy Beverage Sales Soak up the Competition  Marina Mayer Executive Editor

he saying goes, what goes up must come down. The same can be said however for what goes down must come back up. Such is the case for non-dairy beverage sales, which continue to display rising figures, even though some brands saw sales drop.

T

Bottled water sales rise to the top The $7.8 billion bottled water category, for instance, isn’t showing any signs of hitting the ground. The category increased 2%. According to Chicago-based SymphonyIRI Group, for the quarter ended Aug. 7, 2011, private label ranked No. 1 in the convenience/PET still water segment with $1 billion in sales. Meanwhile, vitaminwater Zero, produced by Glacéau, Whitestone, N.Y., experienced a 159.6% jump in sales, partially due to its “uncapped” campaign, which pairs vitaminwater with music, action sports and fashion. RTD iced coffee, tea creates ‘buzz’ The ready-to-drink cappuccino/iced coffee segment displayed some up-and-down results, similar to the highs and lows felt after a good swig of caffeine. Overall though, sales increased 5.5% and units increased 8.3% for the period. As for individual brands, sales of Illy Issimo, produced by Italy-based Ilko Coffee International Srl, jumped 485.2% for its 100% Arabica coffee selection, while Seattle’s Best, Seattle, rose 383.4% in sales for its Vanilla Latte, Iced Mocha and Iced Latte options in a can. On the other hand, Cinnabon, Seattle, experienced an 89.1% decline in sales, while PomX iced coffee, produced by Los Angeles-based Pom Wonderful, LLC, underwent a 60.8% drop in sales. The canned and bottled tea sector, a $2.4 billion category, showcased mixed results as well. On the upside, AriZona Arnold Palmer Half & Half, created by AriZona Beverage Co., Cincinnati, in partnership with golf professional Arnold Palmer, saw a 50.4% increase in sales. AriZona Arnold Palmer is a blend of traditional black tea and lemonade. Other positive marks go to Lipton Brisk Tea, an iced tea soft drink that’s produced by Unilever-owned Lipton in conjunction with PepsiCo. Lipton Brisk Tea raked in a 27.1% increase in sales and comes in eight flavors. Meanwhile, Lipton Diet pulled in a 4.3% rise in sales. The traditional Lipton brand didn’t fare as well in sales, seeing a 15.5% drop in sales, whereas Lipton Pureleaf dropped 8.5%. 22

Dairy Foods | October 2011

Top 10 Brands of Refrigerated Juices/Drinks % change vs. yago

Unit Sales (millions)

% change vs. yago

Brands

Dollar Sales (millions)

1

Orange Juice

$2,747.3

+0.8

908.9

-1.9

2

Fruit Drink

$737.4

+6.7

383.7

+5.1

3

Lemonade

$390.4

+10.1

198.7

+4.9

4

Juice & Drink Smoothies

$383.3

+16.6

113.9

+13.4

5

Blended Fruit

$290.0

-9.4

97.1

-8.0

6

Grapefruit

$78.7

+1.6

24.6

+1.2

7

Cider

$64.2

+1.6

19.2

+0.6

8

Apple

$52.8

+3.2

21.0

+3.6

9

All Other

$50.9

+8.5

9.5

+12.7

10 Vegetable Juice/Cocktail

$40.1

+9.6

9.5

+9.0

For the latest 52 weeks ending August 7, 2011 Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Walmart)

Juice rules Refrigerated juices and drinks are extremely popular non-dairy beverages. Orange juice, for example, is the highest grossing sector, raking in $2.7 billion in sales thanks to Coca-Cola’s Minute Maid brand, which saw sales balloon 444%. Juice and drink smoothies placed fourth (see table) with a 16.6% rise in sales. Odwalla Superfood, produced by Odwalla Inc., Half Moon Bay, Calif., saw a 148.9% jump in sales, while Naked Well Being, a line of better-for-you smoothies produced by Naked Juice Co., Monrovia, Calif., underwent a 114.4% climb in sales. Despite a pattern of sales increases, the blended fruit division, which snagged the No. 5 slot, experienced a 9.4% dive in sales. Odwalla kicked off the downward spiral with a 32.5% plummet in sales. Meanwhile, Fruit2Day (produced by WhiteWave, LLC, Broomfield, Colo.), Minute Maid and Dole (both from Dole Food Co., Thousand Oaks, Calif.,) saw sales decline 15.9%, 14.1% and 12.6%, respectively. On the other hand, sales for Welch’s Healthy Start, a no-sugaradded, 100% juice line by Welch’s, Concord, Mass., soared 1,630.9%. Dairy processors can study the data to help them decide what beverages they should be bottling. 

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New Products & Marketing

NEW PRODUCT REVIEW

In early August, Straus Family amily Creamery, Petaluma, Calif., introduced a slow-cultured, tured, locally made organic sour cream to San Francisco Bay-area grocery stores. The artisanal sour cream comes in two varieties — full fat and light — and is packaged in 16-ounce containers. And 16 is the magic number for this product because that’s how many hours it is cultured in small batches without any additives. The result is a naturally thick-textured sour cream with a clean, rich flavor. “I wanted to create a pure, simple sour cream that tastes great,” says Albert Straus, president. “It all starts with the milk. Although making sour cream without gums or stabilizers takes time, it’s worth the effort. It’s more art than science to let the unique flavor of our milk come through with just the right balance of sweet and tangy.”

Made with organic milk from strictly grass-fed cows, the process is a slow and vigilant one, which produces delicate ccheese curds with a light tartness nestled in the natural creaminess of carefully handled milk. The glass jars maintain the h cottage cheese’s integrity, meaning none co of the leaching that occurs with plastic o containers happens in the new glass jar co and the shelf life of the cheese is extendan ed, especially compared to plastic packed aging, according to the company. The ag transparent glass container, along with tr eye-catching graphics and the Traders ey Point Creamery signature cow adorning P the lid help the product sell itself. Until recently, locally made cottage cheese from Traders Point Creamery, Zionsville, Ind., was only sold through the company store and nearby retailers. It is now available through select Midwest-area Whole Foods Markets thanks to an extended shelf life that the company has been able to achieve after converting from plastic to glass packaging. The company was awarded a 2011 Clear Choice Award from the Glass Packaging Institute, Alexandria, Va., for this packaging conversion.

Promised Land Dairy, Floresville, Texas, is known for its Jersey cows milk products, in p particular Midnight

NOTEWORTHY I NTROD UCTION S From cocktails cockt to dessert, the bacon trend is making consumers go hog wild. In ma response, Future Food Brands, Carrollton, Texas, is rolling out Salads of the Sea Smokey Bacon Crab Dip. Cream cheese is the base for Di this unique version of surf-and-turf.

24

Dairy Foods | October 2011

Land O’Lakes, Minneapolis, introduces Land O Lakes Cinnamon Sugar Butter Spread. This new spreadable butter er combines the kick of cinnamon on with the sweetness of sugar and nd no artificial ingredients.

New Products & Marketing

Chocolate Milk and Old Fashioned ned Egg Nog. So the company commbined the two for a special holiday treat: limited-edition Promised Land Chocolate Egg Nog. “We just could not pass up the opportunity to blend our two top-selling items to see if we could make a new treat for the holidays,” says Gordon Kuenemann, general sales manager. “Some people that find eggnog flavors overwhelming or premium, rich chocolate to be too intense will find this to be an absolutely perfect blend of these two all-natural flavors.” In September, Carlinville, Ill.-based Prairie Farms Dairy sent students back to school with new fat-free, lower-sugar milk varieties in four kid-friendly flavors: Chocolate, Cookies’N Cream, Strawberry and Vanilla. The proprietary recipes do not include high-fructose corn syrup or artificial sweeteners and are based on fat-free milk that does not contain any artificial growth hormones. The school milk line also includes fatfree and 1% milkfat white varieties. Since the Healthy, Hunger-Free Kids Act was signed into law in December, Prairie Farms has worked aggressively to improve the formulations used for flavored milk sold in schools. “Our customers asked and we delivered,” says Rebecca Leinenbach, sales program director. “The new formulation is a direct result of ongoing conversations with school foodservice professionals about the stricter standards for school meals that will take effect in the 20122013 school year.” Available a year ahead of schedule, the new fat-free chocolate milk contains 130 calories per 8-ounce serving and 11

grams of added sugar, compared to the previous 1% milkfat variety with 170 calories and va 116 grams of added sugar. Packaging for fruit- and P yogurt-based smoothies continues to evolve as manufacturers try to deliver the freshest product to consumers, yet with a shelf life that allows for efficient distribution. That’s what Dole Packaged Foods LLC, Westlake Village, Calif., hopes it achieved with the new Dole Fruit Smoothie n Shaker product, where the packaging is integral to the cconsumption of the product. The userfriendly, functional and attractive high-end single-serve container solves a convenience hurdle that limited home consumption of hand-blended smoothie-type products. The product contains both frozen fruit and yogurt. A special proprietary process eliminates the need for a blender, which is one of the biggest complaints consumers have about making smoothies at home, according to the company. Simply unscrew the cap, add juice to the fill line, re-apply the cap and shake for about 30-45 seconds. The result is a perfectly blended smoothie, just like from the local smoothie shop. Each low-fat smoothie contains real yogurt with live and active cultures, including probiotics, as well as prebiotic fiber. Read more about this packaging on page 82. 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.

I N T E R N AT I O N A L Yogurt has long been associated with healthful eating and weight management. In Mexico, that image has been reinforced by the launch of Svelty Figura Yogurtt Gelatin. This low-fat, low-calorie product from Nestlé S.A., Vevey, Switzerland, is a hybrid of yogurt and gelatin with a satiety position. Sweetened with sucralose, each 95-gram cup contains 50 calories, making it a smart choice for consumers watching their waistlines. The inclusion of yogurt provides substance, while the lightness of gelatin removes the guilt. Mediterranean ccuisine continues to drive innovation in all food categories, in all corners of the world. Polo ish dairy Polmlek is Olsztyn Sp. z o.o. O introduces Warmia in C a p r e s i Tz a t z i k i Cream Cheese. UnC llike the traditional spread or dip, this version comes in slice form and is designed for use in sandwiches or as a bagel topper. Edelweiss, a German dairy located in tthe Bavarian region and a subsidiary of France-based Bongrain S.A., B is rolling out a limited-edition yogurt spread under its Brunch brand. New Mona Lisa Spread with Blossom Honey relies on a unique honey variety that lends a sweet, delicate flavor to a normally tart bread spread.

Contributed by Krista Faron, director of innovation and insights, Mintel Research Consultancy, Global New Products Database (GNPD). For more information call 312-9320400 or visit www.gnpd.com. Continued on page 26 www.dairyfoods.com

25

New Products & Marketing

NEW PRODUCT REVIEW: FOCUS ON ICE CREAM Ice cream marketers are showing us that yes, we love ice cream in the summer…but the right flavor complements winter quite well, too. It also makes for a great late-night snack, regardless of what the temperature is outside. Oklahoma City-based Sonic, America’s Drive-In, celebrated summer with a line of Sundae Shakes. Available in three 100% sippable flavor adventures — Strawberry Dream, Turtle and Classic Hot Fudge — the shakes resemble the classic spoonable desserts. They all start with vanilla ice cream. Strawberry Dream contains real strawberries — not red syrup — and is finished with whipped topping, more real strawberries and a cherry. Turtle is adorned with chocolate syrup and nuts and finished with whipped topping, caramel, more nuts and a cherry. Finally, Classic Hot Fudge is loaded with hot fudge, whipped topping and more hot fudge.

The flavor from these New England innovators that has as raised some eyebrows ws and has made Saturday ay Night Live (SNL) fans ans laugh, just hit freezer zer cases last month. New limited-batch Schweddy ddy Balls is an ode to a classic ssic SNL sketch from 1998.. The ice cream flavor features es Fair Trade vanilla ice cream with a hint of rum and is loaded with fudge-covered rum balls and milk chocolate malt balls. (Go to www.benjerry.com and click on the Schweddy icon.) Ben & Jerry’s formulators further show their admiration of late night comedy with Late Night Snack: a salty-sweet combination where vanilla ice cream carries a salted caramel swirl and fudge-covered potato chip clusters. Inspired by “Late Night with Jimmy Fallon,” the flavor is a tasty triumph to Jimmy’s satisfying wit. It also gives back by using two Fair Trade ingredients: cocoa and vanilla.

As the temperatures drop, Smith Dairy Products Co., Orrville, Ohio, expects consumers to warm up to new w Ruggles Hot Chocolate Premium Ice Cream. Described ass creamy chocolate ice cream swirled with marshmallow and d chocolate chunks, the company will be marketing this innoovation as a winter flavor rather than a holiday flavor, with h shipments beginningg mid-November and d ending sometime in n February. Ice cream marketer Ben Ic n & Jerry’s, Waterbury, Vt., aw wholly owned subsidiary of Unilever, Englewood Cliffs, N.J., once again Cli shows Americans that sho anything goes with ice any cream, including adultcrea only liquor flavors. During the summer, the company rolled out Bonnaroo Buzz. Named after the legendary Bonnaroo music festival in Tennessee, and developed with a nod to that locale featuring a whisky-caramel swirl (the whiskey is cooked out), this coffee and malt ice cream includes English toffee pieces. 26

Dairy Foods | October 2011

Speaking of giving back, our furry friends who give us unconditional love deserve a frozen treat, too. Nestlé Dreyer’s Ice Cream Co., Oakland, Calif., a part of Nestlé USA, Glendale, Calif., introduces Frosty Paws Bites, a bitesized version of the similarly named single-serve cups of doggie ice cream. Made with high-quality protein, vitamins and minerals and no sugar, dogs can fetch either an original (vanilla) or peanut butter-flavored bit that is enrobed in a vanilla yogurt coating. For more on ice cream, visit www.dairyfoods.com and type “ice cream” into the search box. 

Ingredient Technology Photo courtesy of Wisconsin Milk Marketing Board

From milk chocolate to chocolate milk, cocoa and dairy make the perfect marriage.  Donna Berry Product Development Editor

hocolate milk is one consumer favorite in the midst of an identity crisis. Long a staple of most children’s school lunch, chocolate milk has been banned from many districts, despite the knowledge that many kids won’t drink white milk as an alternative and thus are not receiving essential nutrients. On a different playing field, chocolate milk is being embraced by sports enthusiasts as an economical recovery drink, as the formulation provides a balanced ratio of protein to carbohydrates, making chocolate milk a great way to recover after weight training and power exercise. And then there’s the heart-health link, with studies showing that consuming chocolate and cocoa flavanols can reduce one’s risk of heart disease and stroke. (But don’t consume too much because chocolate and cocoa can pack on the calories and contribute to unnecessary weight gain, which has the opposite effect on heart health.) Interestingly, a recent analysis conducted by researchers from the University of Cambridge in England and presented at the European Society of Cardiology Congress, Aug. 27-31, in Paris confirmed that a number of studies show that eating chocolate has a positive influence on human health. Researchers analyzed results from seven studies involving more than 100,000 participants with and

C

without existing heart disease. For each study, they compared the people with the highest chocolate consumption against those with the lowest consumption. Five studies reported that higher levels of chocolate consumption were linked to a lower risk of heart disease. Further, the highest levels of chocolate consumption were associated with a 37% reduction in cardiovascular disease and a 29% reduction in stroke compared with lowest levels. The studies did not distinguish between dark or milk chocolate, and included consumption of chocolate bars, drinks, biscuits and desserts. The potential health benefits of cocoa-containing products are beginning to expand beyond heart health. According to a study published in the American Journal of Clinical Nutrition (January 2011), for the first time, cocoa flavanols have been shown to exert a positive effect on select gut bacteria in humans. This new study now suggests that cocoa flavanols may also exert a prebiotic effect, much like soluble fiber. And a study in the December 2009 volume of Journal of Proteome Research suggests that daily consumption of 40 grams of dark chocolate significantly changed a person’s metabolism, as well as changed the metabolism of the gut microflora. The implications of the study are that subtle changes in dietary habits, such as eating dark chocolate, can benefit both host and microflora metabolism with potential long-term health benefits. Continued on page 30

28

Dairy Foods | October 2011

PRODUCT DEVELOPMENT Dairy product innovators have come to rely on ADM Cocoa for consistency and quality. But what really sets us apart are the added extras you can’t get anywhere else. Like product development. Come to us with an idea, we’ll help you transform it into a high-performance 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

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Ingredient Technology

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 content claims must ensure that the chocolate ingredients being flagged in product formulations contain a high percentage of cocoa flavanols. All of this research presents opportunities for dairy processors to explore the addition of cocoa to products other than school milk. Not that they should give up on chocolate school milk. In fact, the contrary is true. Fluid milk processors should be

exploring lower-fat, lower-calorie flavored milk options for school. For example, Prairie Farms Dairy, Carlinville, Ill., not only reformulated its school chocolate milk to be fat-free with lower-sugar, the company also added a chocolate variant: Cookies’N Cream. (See New Product Review on page 25.) Ingredient innovations Regardless of the delivery vehicle and how the product is marketed, many dairy processors manufacture some chocolate dairy foods. In recent months, a number of ingredient suppliers introduced innovative chocolate ingredients that address various issues in the marketplace — from price sensitivities to allergens to sugar content. For example, one supplier launched a tailor-made cocoa replacement solution using a high-quality carob powder ingredient. This solution allows dairy foods manufacturers to make significant cost savings in the total recipe cost, as the low-cost ingredient possesses a familiar cocoa-like flavor and color, and can be used as a partial cocoa replacement in various applications, including mousse, ice cream and dairy-based beverages. By adjusting the temperature and roasting conditions during the production of the carob powder, the company can modify the color to range from light to dark brown, and the flavor from sweet to having a strong, unsweetened taste profile. Another supplier offers a cocoa extender that can replace up to 30% of the cocoa powder used in ice cream, yogurt, beverages, puddings and toppings. It can replace both Dutch and 30

Dairy Foods | October 2011

Brewed Cocoa Beverage Honest Tea, the nation’s top-selling organic bottled tea company, which is based in Bethesda, Md., and is part of The CocaCola Co., Atlanta, introduced Honest CocoaNova, a line of lowcalorie brewed cocoa beverages. Though the beverage contains no dairy, it is a product that a dairy could manufacture, right alongside chocolate milk and iced tea. Honest CocoaNova is described as a brewed cacao infusion that contains antioxidants and theobromine, a caffeine-like substance naturally found in dark chocolate. The main ingredient in the drink is certifiedorganic, Fair Trade-certified cocoa beans, which are roasted and ground into a natural cocoa powder. This powder is then brewed through a patentpending process to create Honest CocoaNova. Each 10-fluid-ounce bottle contains approximately 50 milligrams of theobromine. “Everyone has tasted cocoa, but Honest CocoaNova is cocoa as you’ve never known it. It has a rich, satisfying flavor with only 50 calories per bottle,” says Seth Goldman, president of Honest Tea. “We’ve been working on this concept since 2006 and can’t wait to see how consumers respond.” 

natural cocoa and comes in natural and artificial forms. (Keep in mind that use of such cocoa replacements disqualifies the food product from being associated with cocoa flavanol-related health benefits.) Recognizing that a large percentage of the U.S. population has food allergies or sensitivities, one supplier introduced a line of organic chocolate ingredients that are made in a dedicated facility that does not process any major allergens, including dairy, peanuts, tree nuts, eggs, soy, wheat or other known sources of gluten such as barley, rye, oats and triticale. Produced by a family-owned cocoa processer in the rainforests of South America, these single-origin, premium-organic chocolate ingredients range from chocolate chips and wafers to covertures and cocoa powder. These products are also free of soy lecithin, a common emulsifier used in the majority of chocolate products. All of these chocolate ingredients are available as Fair Trade — a growing area of demand. Another area of increased interest, which complements the lowering of sugar contents in school chocolate milk, is using alternative, low- and no-calorie sweeteners with cocoa. One supplier replaced all of the sugar in a line of chocolate ingredients with an all-natural sweetener solution comprised of dietary fibers, the natural sugar alcohol erythritol and a stevia-based sweetener. The chocolate can be used in multiple applications, including molding, enrobing and inclusions for ice cream. The no-sugar-added chocolate contains no artificial sweeteners and does not produce a laxative effect when consumed, according to the company. From reducing costs to lowering sugar to keeping chocolate milk in schools, dairy processors have many chocolate and cocoa ingredients from which to choose to meet their formulation and marketing needs. 

Ingredient Technology

WELLNESS WATCH Photo courtesy of Danisco

Donna Berry

Milk and other dairy foods enhanced with immune-boosting ingredients appeal to consumers who want to give their bodies a little extra protection to ward off colds, infections and serious diseases.  Donna Berry Product Development Editor

oms have long warned their kids that if they play in the rain, they might catch a cold. The reality is moms just don’t want to clean up muddy messes, but telling a child that would only serve as an invitation to splash and slosh. The truth is you cannot catch a cold from being wet and chilled for an extended period of time, but a soggy state can lower one’s resistance to infection, and quite possibly a cold virus can be contracted. The good news is that normally healthy individuals with uncompromised immune systems can boost their shield of armor through nutrient-dense foods, in particular dairy foods, which are inherently loaded with nutrients that improve overall well-being. They also function as an ideal carrier for immune-boosting ingredients. Such enhanced foods appeal to consumers of all ages, in particular parents who want to build their kids’ autoimmune systems and mature adults who experience a reduction in their ability to ward off infection. According to the 2011 Functional Foods/Foods for Health Consumer Trending Survey conducted by the International Food Information Council (IFIC), Washington, D.C., a majority of

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Americans believe they have some control over their health and that food and nutrition play the most important role in maintaining and improving their overall health. Additionally, most (87%) consumers agree with the concept of functional foods, which are described as foods and beverages that may provide benefits beyond basic nutrition. Since 1998, when the first IFIC study was conducted, there has been a significant increase in consumer awareness of such functional foods, and consumers continue to be interested in learning more about these beneficial foods. In fact, a majority of Americans are interested in foods and beverages that can provide a host of health benefits, including boosting immunity. In this year’s survey, 79% of the 1,000 adults who participated in the web-based survey this spring agree that some foods or beverages can boost their immunity. Immune health Indeed, immune health is one of the fastest-growing health concerns among Americans, according to the 2011 HealthFocus International U.S. Trend Report. “In fact, the report shows that Continued on page 34

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Dairy Foods | October 2011

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Ingredient Technology

three of the Top 10 food benefits of interest to Americans are related to immune function,” says Barbara Davis, vice president, HealthFocus International, St. Petersburg, Fla. “These three benefits are: helps reduce risk of cancer, supports the immune system and helps build resistance to common diseases.” Davis does say, however, that even though consumers might be finding these benefits increasingly appealing, food and beverage marketers are proceeding very cautiously with making such immunity-related claims. This is likely a result of more and more regulatory agencies challenging claims here and abroad. “What we are seeing this year is more activity in making content claims — what is and is not in a product,” she says. “Examples include ‘contains antioxidants’ and ‘enhanced with omega-3 fatty acids.’” Supporting HealthFocus’ data, Ipsos Marketing, Consumer Goods Sector, New York, says that the top benefits parents want their children to receive from eating healthy foods relate to heart health, reduced risk of disease, brain development and immunity. “Manufacturers are feeling the pressure from all angles to market healthier food to children,” says Lauren Demar, CEO of Ipsos. “Parents are demanding nutritious and functional foods to serve their children while new regulations are restricting marketing efforts for less healthy food options. At the same time, manufacturers need to appeal to children by offering great-tasting food with ‘kid appeal,’ as children still influence food purchases in many countries.” Demar adds, “It is a whole new world for marketers, but we are already seeing them step up to the challenge. Today we see healthy options for kids in a wide range of categories, including beverages (juice boxes fortified with calcium), dairy (milk with omega-3 fatty acids), cereal (gluten-free options) and snacks (fruit chews containing vitamin C).” Ingredients for immunity There are a number of well-recognized immune-boosting ingredients and others where the science is still emerging. Many of the following ingredients are readily added to milk-based beverages, as well as other dairy foods, in particular yogurt. Aloe vera — Best known as a topical ointment, aloe vera can also be consumed alone or added to formulations. It has been shown to increase resistance of an organism to adverse influences such as infection or stress, as well as function as a natural anti-inflammatory and promote healthy cell growth. Beta-carotene — Produced by plants and converted by the body into vitamin A, beta-carotene harbors potent antioxidant properties. It also has been shown to stimulate and enhance many immune system processes. Colostrum — The first milk produced by female cows and given to newborn calves, colostrum contains active antibodies, which are natural immune-boosting substances. Echinacea — Commonly referred to as the purple cornflower, this botanical is recognized as a remedy for reducing symptoms associated with the common cold. Grape seed extract — The proanthocyanidins found in grape seed extract have been shown to be 20 to 50 times greater than betacarotene or vitamins C and E at scavenging free radicals. Further, studies have shown that grape seed extract helps promote the structural strength of blood vessels, which in turn helps promote healthy blood pressure levels, heart health and a proper inflammation response, all factors that contribute to immune response. Green tea extract — Green tea is loaded with epigallocatechin gallate (EGCG), a powerful antioxidant that has been shown to 34

Dairy Foods | October 2011

Most Important Benefit Children Receive from Eating Healthy Foods - According to Parents in 24 Countries Healthy Heart

23%

Reduced Risk of Disease Later in Life

18%

Better Brain Development

18%

Better Immunity

18%

Avoiding/Reducing Obesity

8%

Strong Teeth and Bones

7%

Reduced Risk of Attention Deficit Disorder Good Digestion Healthy Looking Skin

4% 3% 2% Source: Ipsos Marketing, New York, 2011

affect migration of immune cells to sites of inflammation and have a positive effect on chronic inflammatory disease. Omega-3 fatty acids — The family of fatty acids referred to as omega-3s has been shown to boost immunity by producing white blood cells that destroy dangerous bacteria. Other studies have shown that omega-3s help the body to not overreact to an infection. They also have anti-inflammatory properties, which suggest that they can help slow down the effects of autoimmune diseases. Prebiotics — Prebiotics are substances that promote the growth and activity of beneficial bacteria in the gastrointestinal tract, which in turn enhances immune response. Probiotic cultures — Select clinically proven probiotic strains have been shown to support the immune system, assisting the body in fighting disease caused by bacteria and viruses. Soluble fiber — Soluble fiber has been shown to have an antiinflammatory effect on the body, which helps strengthen the immune system and helps the body recover faster from infection. Vitamin C — Shown to increase the production of infectionfighting white blood cells and antibodies and increase levels of interferon, the antibody that coats cell surfaces, vitamin C is said to prevent the entry of disease. Vitamin D — Known as the sunshine vitamin, vitamin D is critical to replenishing the lining of the gut and maintaining the integrity of the mucosa. This contributes to a healthy digestive system, which in turn leads to improved immune response. Vitamin E — This powerhouse fat-soluble vitamin enhances the production of antibodies that ward off infection and may also reverse some of the decline in immune response commonly seen in aging. Zinc — Best known as the pill to pop when you feel the sniffles coming on, research on zinc shows that not only does it bolster the immune system to fight colds; it can also help stave off other common infections. 

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Ingredient Technology

DAIRY DETECTIVE

Dairy Ingredients Add Nutrition to Snacks e are a snacking nation. Almost 87% of U.S. consumers snack between meals. In 2009, domestic consumers spent more than $93 billion for foods eaten during a snack occasion. Given the increase in snacking, controversy now rages as to whether snacking abets or abates the obesity crisis in our country. Snacks, including calorie-laden beverages, now comprise almost 25% of our daily caloric intake according to 2007-2008 NHANES data. At the 2011 IFT annual meeting in New Orleans, Rick Mattes of Purdue University, West Lafayette, Ind., explained that the data is contradictory as to whether snacking is positively or inversely associated with body mass index. Harvey Anderson from the University of Toronto in Canada noted that the composition and resulting physiological effect of between-meals snacks are important. Both Mattes and Anderson agreed that there is no clear definition of a “snack,” and that the lines between meals and snacks are blurred. Anderson and colleagues conclude that increased frequency of eating is not associated with body weight and/or other parameters of obesity, and may in fact be beneficial in this regard. At the 2010 Dairy Ingredient Symposium in San Francisco, Dan Benardot of the Department of Nutrition at Georgia State University, Atlanta, highlighted several important points on energy balance. “Muscle catabolism (breakdown) does occur with inadequate fuel, as an adaptation to the poor fuel delivery. Infrequent eating and large meals result in higher fat storage, even if total caloric intake is the same. Insulin, blood sugar and leptin (an appetite-suppressing hormone) are best controlled with frequent small feedings that dynamically match energy requirements.” Nancy Auestad, vice president of regulatory affairs, Dairy Management Inc., Rosemont, Ill., said at the 2011 IFT sym-

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Dairy Foods | October 2011

posium: “Given the nutrient and caloric contributions of snacks to the American diet, there is a clear opportunity and challenge for food manufacturers to create more nutrient dense snacks.” When we snack A study by the Innovation Center for U.S. Dairy found that the world of snacking occasions is almost evenly split between consumers seeking “nutritious” solutions (51%), and those trolling for “fun munching” options (49%). Looking at retail sales of UPC-coded foods considered to be snack foods reveals that five categories are basic dairy foods — ice cream (3.1% of retail snack dollars), frozen novelties (2.5%), milk (1.3%), yogurt (0.9%) and cheese (0.9%). There are also opportunities to formulate dairy ingredients into several snack categories — candy and gum (7.3%), salty snacks (3.9%), cookies (2.3%), crackers (1.8%) and bars (0.9%.) The greatest compound annual growth rate from 2004-2009 has been seen in yogurt (5.9%) and salty snacks (5.3%). Adding more naturally nutritious dairy ingredients allows snack manufacturers to play on both the “healthy” and “fun” sides of the snacking occasion. Dairy ingredients contain a variety of nutrients — including protein, calcium and other dairy minerals — that boost the nutritional content of snacks. Research has shown that diets higher in protein can promote satiety. And while snacks contribute 25% of total energy, they only contribute 14% of daily protein intake. An excellent way to boost the protein content of snacks is by fortifying them with concentrated whey and milk protein ingredients. For those looking for crunchy dairy treats, extruded versions of whey protein concentrate, whey protein hydrolysate and milk protein concentrate are now available. These crisp inclusions are frequently used in nutrition bars such as the new Eat-Smart

Sharon Gerdes

Chocolate Peanut Caramel Crunch Bars, produced by iSatori, Golden, Colo. Several companies are now producing freeze-dried yogurt, including Watershed Foods, Gridley, Ill., and Nurture Inc., Devon, Pa., which produces Happy Melts organic freeze-dried yogurt snacks for babies and toddlers. Yogurt powder is also a popular coating for snack items. Cheese crisps are a crunchy new way for the dairy industry to capture market share in the salty snack category. Kitchen Table Bakers, Syosset, N.Y., won three 2011 Silver Sofi awards from the National Association for the Specialty Food Trade, New York, for crackers made entirely of cheese. Real cheese and cheese powder also add flavor and nutrition to a wide variety of iconic snack crackers, including Pepperidge Farm Cheddar Goldfish (made by Pepperidge Farm Inc., Norwalk, Conn.), Sunshine Cheez-It (manufactured by Kellogg North America Co., Battle Creek, Mich.) and Frito-Lay Cheetos (owned by PepsiCo’s Frito-Lay North America, Dallas). At the IFT Expo, the U.S. Dairy Export Council featured Cheesy Crunchers, made with reduced-sodium cheese, butter, whey protein concentrate, whey protein crisps, cheese powder and whey permeate. Whey permeate can be added to a wide variety of bakery and snack products to boost flavor and reduce sodium content. The formula for Cheesy Crunchers and a new monograph on whey permeate for sodium reduction can be found at www.InnovateWithDairy.com. These versatile crunchers are a great example of the power of dairy to create snacks that are fun, tasty and nutrient dense.  Food industry consultant Sharon Gerdes works with the U.S. Manufacturing & Ingredient Marketing program at the U.S. Dairy Export Council to promote the use of dairy ingredients in food and beverage formulations.

Danisco USA Inc. Four New Century Parkway New Century, KS 66031 www.danisco.com

Cheese Outlook 2011

Bolder Bigger Better

As the economy turns down, the cheese category responds with a slew of new products that bring big and bold flavor and texture back into the kitchen and into home-cooked meals.  Marina Mayer Executive Editor t used to be that consumers would go out to eat to obtain the cheese-flavored spark in their meal. Whether it be spicy shredded Mozzarella over a salad or a fresh slice of cheese on a burger, more and more consumers were heading to restaurants to curb that zesty cheese craving. But as the economy took a nosedive, it provided opportunities for the cheese market to carve out a bigger and bolder position in the dairy industry. That’s why many of today’s cheese producers are creating items that deliver robust flavorings, zesty spices, unusual textures and layers upon layers of taste — all factors in helping consumers return to the kitchen to prepare those high-quality home-cooked meals. “Cheese continues to be one of America’s favorite dairy forms,” says Erin Price, marketing director, consumer products division for Sargento Foods Inc. “The natural cheese snacks category in particular has been growing. It provides the flavor variety and high protein consumers want with the calcium they need for a satisfying snack between meals.” As a result, the Plymouth, Wis.-based processor launched Sargento Natural Blends, a new line of natural snack-andsliced cheese options, available in Cheddar-Mozzarella and

I

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Dairy Foods | October 2011

Provolone-Mozzarella cheese sticks, Cheddar-Mozzarella, Provolone-Mozzarella and Colby-Pepper Jack deli-style slices and ChefStyle Shredded Pepper Jack and Shredded Extra Sharp Cheddar cheeses.

New Flavors and Blends on the Cheeseboard Light Spinach & Artichoke Spreadable Cheese by Alouette Cheese USA Salsa Asiago by Sartori Cheese Marionberry (with cranberries and hazelnuts) by Rising Sun Farms Shredded Pepper Jack by Sargento Premium Reserve Cheddar by Cabot Creamery Cooperative

Cheese Outlook 2011

“Consumers enjoy sharp and aged cheeses as well as cheeses that combine two or more varieties, such as sharp and mild cheddars, pepper jack with jalapeños and habaneros and Colby-pepper jack,” says Price. To meet consumers’ growing demand for robust flavors, Cabot Creamery Cooperative, Montpelier, Vt., developed a new item for the dairy case called Premium Reserve Cheddar, which has a sharper age profile than the company’s Seriously Sharp Cheddar. “This item is designed to give the dairy consumer even more options for bold, sharp, aged cheddar cheese,” says Amy Levine, director of marketing/sales services. “The overall economic atmosphere will continue to drive the category,” she says. “Consumers who began to go out and spend more at restaurants will likely come back to cooking at home, reversing trends in recent months showing the cheddar category declining. However, when eating at home, consumers do want to still have high quality and not give up flavor and texture.” Cabot Creamery also launched a renaming of its Sharp Cheddar to be Smooth Sharp, which better defines the taste and texture profile of the cheese, Levine adds. Most consumers don’t want to give up that rich-tasting experience, but also don’t want to feel guilty about “indulging” in a creamy-textured cheese. That’s why in May, Alouette Cheese USA, LLC, New Holland, Pa., introduced All Natural New Light Spinach & Artichoke Spreadable Cheese. “As one of our best-selling spreadable cheeses, we reformulated the traditional spinach and artichoke to meet the consumer demand for a delicious, creamy cheese with half the fat and 30% less the calories,” says Cristina Anton Villa, director of marketing new products. “The new Light has the same creamy texture and superb taste of Alouette, but offers consumers a healthy alternative.” Last year, Alouette, a division of France’s Bongrain, unveiled Extra Creamy Brie, a triple crème soft-ripened cheese that comes in a 5-ounce carton featuring parchment paper (to maintain freshness) and a protective wooden tray (for presentation). ‘Chef-ing’ it up style For some processors, their goal is to develop European-inspired flavors that promote mass appeal and marry herbs and spices with cheese, says Chad Vincent, chief marketing officer for Sartori Cheese, Plymouth, Wis. In response, this year, Sartori released a new line of products that are “innovative takes on traditional products,” Vincent says. The Espresso BellaVitano, for example, is a sweet, sugary, creamy, butter blend of BellaVitano flavors mixed with lightly sweetened, slightly smoky roasted Italian-style espresso coffee flavors. The Salsa Asiago is hand-rubbed with a proprietary mix of exotic sun-dried tomatoes, onion, garlic and ancho peppers. Extra-Aged Fontina is aged twice as long as usual, Vincent says, to produce a rich, deep, creamy fruitiness. And, Mediterranean Fontina features a creamy base of Fontina cheese hand-rubbed with garlic, thyme, Aleppo pepper and olive oil.

 In response to consumer demands, processors have developed spicier cheeses. Sargento makes a Pepper Jack and Cabot Creamery a habanero Cheddar. “Cheeses like Asiago and Fontina are becoming on-trend as table cheeses,” Vincent says. “Sartori classic Asiago and Fontina are a perfect balance of nutty, savory and creaminess, which lend themselves well to baking on bread or in sauces. Cheese types treated with spices, herbs and liqueurs are gaining more notoriety and being used in cooking. A well-designed flavored cheese should have a ‘next tier flavor’ that one would not achieve with the cheese or complementary flavor alone but is achieved after curing together. This finished flavor can be very unique and great in cooking dishes with exciting new flavor profiles.” Specialty cheeses that wow the senses and give an additional sense of value to the consumer are also some of the emerging trends, according to Sarah Zaborowski, vice president sales and marketing for Columbia Cheese, Long Island City, N.Y., an importer of European-style cheese. “From Switzerland, we represent a cheese, Scharfe Maxx, that though based on tradition results finally in a very unique cheese. It’s a traditional 15-pound wheel but receives an intense wash with brine made of herb, wine and spices. It ages and is washed for six months and the rind becomes especially pungent. But it’s a cream-added cheese, so although the rind looks rosy and standard, inside the paste remains incredibly smooth, and the recipe creates an unusual sweetness that plays against the sometimes garlic or ramp-like intensity coming in from the rind,” she adds. This cheese landed in the United States in May, and is ideal for a cheese platter or to be used by chefs for creative pizzas and gratins. Continued on page 40 www.dairyfoods.com

39

Cheese Outlook 2011

The Power of Protein By communicating the protein content of cheese to consumers, processors can position their products as meatless alternatives. By Miriam Erickson Brown We all want to be liked, but some of us don’t have to try very hard. Take cheese, for example; in recent research, consumers told us they chose cheese because they like the way it tastes. But, I think consumers might choose cheese even more often if they knew what a great source of protein it is, especially since

Columbia Cheese also represents a U.S. farm-made cheese from New York called Hudson Red. “It’s an adorable plump disc that is soft and washed-rind,” Zaborowski says. “Because it’s only about an inch tall, it ripens quickly from the b. linens, the bacteria responsible for the color and strong aroma of the cheese. It does have intensity to it and is incredible to roll a bite around in the mouth, as the paste is so unctuous and indulgent.”

54% of consumers are trying to get more protein in their diets and eat less meat (one in four adults have cut back on meat consumption for health reasons). Research shows that one-fourth of meat reducers are already consuming more dairy, mainly because they know dairy gives them healthy bones. The rest of those meat reducers are consuming the same amount of dairy. (I have to pause here and note that opportunities like this rarely come around for dairy). Continued on page 42

Meanwhile, companies like Rising Sun Farms are meeting global demand by providing a flavor experience like no other. For instance, the Phoenix, Ore., producer released the Party Cheese Torta line, which blends soft cheeses with layers of fresh herbs, spices and other delicacies. These gluten-free, all-natural cheese options are designed as elegant appetizers, spreads for chicken and meat entrees and toppings for pasta dishes. They come in

Pesto Dried Tomato (layers of fine cheeses topped with pesto sauce and crowned with minced dried tomatoes), Gorgonzola (blended with pure cream cheese, Northwest pears and a cranberry nut topping), Marionberry (a fusion of marionberries, cranberries and roasted hazelnuts) and Key Lime (key lime, apricots and cranberries fused with cream cheese). “Retail specialty cheeses can side-step this trend by promoting a fulfilling, atContinued on page 46

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Dairy Foods | October 2011

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© 2011 Donaldson Company, Inc. Minneapolis, MN. All rights reserved.

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Tel 800-543-3634 Fax 952.885.4791 processfi[email protected]

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Cheese Outlook 2011

Consumers do not currently see dairy products as a top source of protein. The top menu choices for meatless meal proteins are tofu, eggs and lentils. No wonder the greatest challenges for someone reducing meat in his or her diet are lack of variety, cravings and poor nutrition. Dairy’s relevance in an environment like this is mindblowing. Cheese not only tastes great, but also is a good source of high-quality protein. Think about what an effect we could have by collaborating as an industry to convey more protein messaging for cheese, cottage cheese, milk and yogurt, giving us an advantage in a marketplace that is placing increasing value on protein and multiple nutrient content. In fact, 47% of consumers find the message “good source of protein” very important on product labels. The Innovation Center for U.S. Dairy, which is funded by the dairy checkoff, created and tested protein messages across multiple dairy categories, including cheese. All this cool stuff can be accessed on www.USDairy.com/hw. Take a look at a couple of the top-rated cheese messages (when combining purchase motivation and believability scores): • Cheese is more than just calcium; it also provides protein your body needs to help stay healthy. • Cheese helps curb hunger with a diet higher in protein. Cheese is a good source of high-quality protein. • Your body uses protein all day long. Try cheese, a good source of protein, to help you get your protein throughout the day. According to my colleague Gwen Bargetzi, marketing director at Hilmar Ingredients and a member of the Innovation Center for U.S. Dairy Health and Wellness Committee, “this particular nutri-

42

Dairy Foods | October 2011

ent has never been as top of mind for the average consumer or offered as much potential for dairy as it does today. Highlighting dairy protein and its functional and health benefits will help grab the attention of consumers. To fully leverage this trend and show that dairy is irreplaceable in our diet, better awareness of dairy products’ inherent high-quality protein is a must.” You don’t have to use our exact lingo — we know the marketing brains will want to make them their own, based on their company’s strategies — but these messages serve as a great foundation. The point is, by communicating the protein nutrition and the variety of other benefits of dairy to consumers, our products become a simple meatless solution in both the nutrition and taste categories. At the risk of sounding cheesy, bring it on.  Miriam Erickson Brown is the Health and Wellness committee chair for Innovation Center for U.S. Dairy, Rosemont, Ill, and the president/CEO of Anderson Erickson Dairy, Des Moines, Iowa.

 Columbia Cheese imports 15-pound wheels of Scharfe Maxx from Switzerland. The wheel receives a wash with brine made of herb, wine and spices that makes the rind pungent.

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GEA Westfalia Separator Division

Cheese Outlook 2011

Protein: An Emerging Opportunity Despite increasing competition, the industry can capitalize on dairy’s equity beyond calcium and bone health to meet evolving consumer needs. By Barb O’Brien The dairy industry’s long investment in nutrition and consumer research is paying dividends. Dairy is being recognized for its unique nutrient package and health benefits among the nutrition community. When it comes to the consumer audience, an incredible opportunity exists for the industry to promote its current and future product offerings. That’s why the time is now to promote dairy’s multiple nutrients and the physical and emotional benefits these products bring consumers of all ages. The dairy industry has long leveraged its superior nutrient package, but in the past decade, non-dairy products have been starting to take ownership in this space. Dairy alternatives, juice, water and other snack foods are taking aim at dairy by leveraging a similar nutrient story. In fact, nearly half of adults now believe that dairy milk and dairy alternatives are equally nutritious, according to Emerging Diets Research, 2010, conducted by Dairy Management Inc. Today’s consumer environment presents a great opportunity for dairy, with its strong focus on health and wellness. Dairy’s story can help to win the health and wellness battle — it has a superior nutrient package, science supports its value and research shows consumers believe in its benefits.

Despite increasing competition, the industry can capitalize on dairy’s equity beyond calcium and bone health to meet evolving consumer needs. In fact, protein is taking center stage as a nutrient of importance, with more than half of consumers looking to include more protein in their diet (which shows slight growth over previous years), according to research findings from the NPD Group’s Dieting Monitoring Service, 2008. Consumers have high unaided awareness of the benefits of protein, in general (the only nutrient they show more knowledge of is calcium). They perceive protein as a way to help with the following: • Build and maintain muscle • Recovery of muscle after exercise • Achieve sustained energy • Suppress hunger • Slow muscle loss with aging • Provide an alternate protein source for those seeking meatless meals This presents an emerging opportunity for dairy Continued on page 46

COME TO THE EXPERTS WHEN YOU’RE TALKING SEPARATORS... GREAT LAKES SEPARATORS, INC. Over 57 Years of Combined Experience • Separators • Clarifiers • Centrifuges • Surplus Westfalia Parts • Installation & Start Up • Unbeatable Prices! Call Dave Lambert at (920) 863-3306 or Dick Lambert at (920) 825-7468

If you’ve been looking for a company that offers a full line of aseptic valves, you can stop looking now. We’re Rieger, a world-class manufacturer of hygienic and aseptic valves. For over 100 years, we’ve been delivering bestin-class valve solutions for food, chemical and pharmaceutical companies around the world. And now, we’re happy to announce we’re making our innovative products available here in North America. This includes our industry-leading line of aseptic valves, customizable to work with your existing equipment. Ready to learn more? Contact Flow Products of Kenosha, Wisconsin at (262) 657-5566 today.

GREAT LAKES SEPARATORS, INC. E1921 County Road J • Kewaunee, WI 54216 Fax: (920) 863-6485 • Email: [email protected] 44

Dairy Foods | October 2011

Flow Products, Inc.

262-657-5566 • 5732 95th Ave., Ste. 800 • Kenosha, WI 53144 www.flowproducts.us • info@flowproducts.us

S U C C E S S

S T O R I E S

HOW A VEMAG CHEESE

FORMER

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

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

Leading the food industry in processing and packaging solutions.

Cheese Outlook 2011

home gourmet experience,” says Karen McJilton, Eastern regional sales manager. “As frequency of restaurant dining declines, consumer spending increases for more economical, palate-pleasing options in the home. The value of spending minimally on a little taste of luxury at home continues to hold appeal.” The Party Cheese Torta line comes in a 20-ounce wreath-shaped package equipped with a belly band. Now that more and more Americans are spending their dollars at the grocery store, stocking up on items used to create at-home meals, consumers can also whip up taste, texture and flavor thanks to the ever-expanding assortment of specialty cheeses. 

9KVJ6QVCN2TQFWEV+PURGEVKQP6JG$GPGƂVU#TG%NGCT From Every Angle & Every Stage Of The Packaging Quality Process HI-Speed Checkweighing

Safeline X-ray Inspection

Safeline Metal Detection

CI-Vision Vision Inspection

Visit us at Process Expo in Booth # 202 SAFELINE

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Visit www.mt.com/pius-processexpo2011 %CNN r'OCKNRKOCTMGVKPI"OVEQO

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Dairy Foods | October 2011

to leverage its total nutrient package with emphasis on protein content as a way to help stand ahead of the competition. But, the industry will need to help consumers connect protein and dairy first. Although research from NHANES 2003-2006 (ages 2-plus years) shows dairy already provides nearly 20% of consumers’ protein consumption per day (with milk leading and cheese a close second), today’s consumers give dairy credit for calcium and little else. While dairy proteins are top-quality, fewer than one in five adults list protein as a nutrient present in cheese. The percentage is even less for milk and yogurt, as indicated in the 2009 NRF Benchmark Quantitative study. Raising the profile of dairy’s protein benefits is especially important given the health-driven meat-reducing trend. The first step is to reframe dairy’s story in the marketplace by communicating the presence of multiple nutrients. Research shows that today’s meat-reducing consumers do not recognize the multiple nutrient benefits of dairy as a key driver in choosing more dairy products. To help motivate all consumers to choose more dairy, linking nutrients to specific benefits creates a powerful opportunity. The dairy industry can couple nutrition science in the benefit areas mentioned above to better ladder to how dairy can help fulfill these needs. The Innovation Center for U.S. Dairy, which is funded by the dairy checkoff, created and tested protein messages in multiple benefit areas across multiple dairy categories. These messages offer brands foundational statements that can be customized based on business goals and marketing strategies. By using core messages as a base, brands will contribute to building awareness of dairy’s important protein benefits and further amplify dairy as a food group rich in nutrients to meet many health and wellness needs. The industry can access a library of protein messages as well as consumer insight research to help guide marketing and communications of dairy protein at www.USDairy.com/hw.  Barb O’Brien is the president of the Innovation Center for U.S. Dairy, Rosemont, Ill.

Maxiren® Delvo-Tec®

The best ingredients made for your US cheese. Maxiren® - a winning solution in cheese production: Maxiren® provides optimal milk coagulation, maximum cheese yield and consistent cheese ripening. Delvo-Tec® - proven to produce high quality cheese: Bulk set cultures and media deliver full flavor, consistent texture and high quality cheese. [email protected] | www.dsm.com

Cheese Outlook 2011

Tapping Into the Artisan Cheese Opportunity Dairy research centers provide short courses and hands-on training, spurring new companies and new products for cheesemakers. By Bill Graves The opportunity is as ripe as the rich aroma from a block of handcrafted artisan cheese. With their oftentimes unusual names, smooth textures and unique flavors, artisan cheese has grown in popularity. Varieties from feta to Gouda to Asiago have become a must on any savvy host’s appetizer platter. Today, across the United States, almost 1 billion pounds of specialty cheese is produced annually. Cheesemakers everywhere are tapping into this growing market and consumers’ love affair with these unique cheeses. Many, new to the cheesemaking process, are learning the ropes of specialty cheesemaking at the universityaffiliated National Dairy Foods Research Centers located around the country. The National Dairy Foods Research Center program is a dairy checkoff-funded initiative supported by the Dairy Research Institute, Rosemont, Ill., established by America’s dairy farmers who have a commitment to product, nutrition and sustainability research. The program provides the dairy industry with product and ingredient research and technical resources to help increase sales and demand for dairy. There are five research centers across the country that annually offer 13 artisan/specialty/farmstead cheese courses with more than 350 attendees. The centers are located in California (Cal Poly State University and University of California-Davis), the Midwest (University of Minnesota-St. Paul, South Dakota State University-Brookings and Iowa State University-Ames, Utah State University and University of Wisconsin-Madison) and the Southeast (North Carolina State University and Mississippi State University). Research center short courses, training spur growth The dairy centers’ significant efforts to promote the making of artisan cheese through short courses and training are making an impact on the bottom line. In Wisconsin alone, specialty cheese production has more than doubled in the last decade to more than 500 million pounds. Dairy center technical training and short courses have helped artisan/specialty cheese companies develop domestically produced, high-quality specialty cheeses for this growing market. Consumer interest and demand for new and complex flavors also has helped artisan cheesemaking grow exponentially, according to Dave McCoy, vice president of product research for the Dairy Research Institute. “The Dairy Research Institute is in step with growing consumer interest and the potential this means to cheesemakers,” he says. “We are committed to providing the valuable resources and ongoing training needed to be competitive.”

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Dairy Foods | October 2011

From 2005 to 2010, specialty cheese growth in Wisconsin jumped 26%, based on Chicago-based SymphonyIRI data, equivalent to a 35% increase in dollar sales. Specialty cheese represents 21% of Wisconsin’s yearly total 2.61 billion-pound overall cheese production. The Master Cheese Maker Program at the Wisconsin Center for Dairy Research (WCDR) at University of WisconsinMadison, has been a major driver of specialty cheese growth. Seventy-three percent of winners at the U.S. National Cheese Champion contest at WCDR and almost 45% of the winners at the World Cheese Champion Cheese contest attended short course training. On the other side of the country, the Dairy Products Technology Center at California Polytechnic State University, San Luis Obispo, Calif., offers a basic cheesemaking short course to artisan and farmstead cheesemakers. The center’s annual artisan/ farmstead cheese course includes hands-on cheesemaking, where attendees make five varieties of cheese in the center’s pilot plant cheesemaking facility. Interest has definitely spiraled upward, according to Phillip Tong, director of the dairy research center at Cal Poly and a contributing columnist for Dairy Foods. “It is great to see so many of the dairy processors from this course now making and selling high-quality cheeses throughout the country,” he says. “Of the 60-plus cheesemakers that showcased their cheeses at the American Cheese Society Meeting in Seattle last year, nearly half of them had taken our course at Cal Poly.” Artisan cheese food safety training In addition, the dairy centers will be offering artisan cheesefocused food safety short courses and training. The Innovation Center for U.S. Dairy’s Food Safety Operating Committee is partnering with the dairy centers to develop a dairy food safety training program for small dairy processors, including specialty artisanal/farmstead operations, on the processes needed to ensure the highest dairy food safety in their unique operations. With more consumers interested in the unique and broad range of flavors offered in the artisan cheese market, the dairy centers will continue to provide cutting edge technical insight and knowledge to help increase artisan/specialty cheese growth for the industry. To learn more about these short courses, visit www.usdairy.com/ DairyResearchInstitute/Pages/Up comingEvents.aspx.  Bill Graves is the senior vice president of product research for Dairy Research Institute, Rosemont, Ill.

There’s only one Alberger brand salt. ®

© 2009 Cargill, Incorporated

It’s the shape that makes it great. Alberger® brand salt, exclusively from Cargill, is created from a process that starts with a hollow pyramid shape to form multi-faceted crystals. These unique crystals with a large surface area and low bulk density provide superior adherence, blendability and solubility compared to regular cube-shaped granulated salt. The rapid solubility also gives Alberger® salt its flavor burst when used in topical applications. To find out what else we can bring to the table, call 1-888-385-SALT or visit cargillsalt.com. collaborate

www.cargillsalt.com

>

create

>

succeed™

Process Expo Show Preview

The Global Food, Technology Show Dairy plant managers can find equipment and new techniques for food and beverage processing. here else can dairy processors find the latest in trends, packaging equipment and technology than Process Expo 2011, otherwise known as “the global food and technology show.” Hosted by the Food Processing Suppliers Association (FPSA), McLean, Va., Process Expo 2011 takes place Nov. 1-4 in Chicago’s McCormick Place. This 100% food-focused event attracts more than 10,000 attendees from the world’s leading food companies who are looking for solutions that will help them more rapidly, efficiently, safely and successfully create and bring food products to market, says the expo organizer. The educational program features three main areas of interest. Designed to address critical issues in the food and beverage industry, the educational sessions provide a wide array of manufacturing solutions for participants from some of the industry’s top experts. Sessions start each day of the show and are free.

W

Process Expo Addresses Key Dairy Industry Issues By Pete Herb Process Expo may not have the word “dairy” in its name, but the premiere 100% food-focused tradeshow is packed with opportunities for dairy processors. Food safety has always been a critical concern in the dairy industry and it is punctuated by heightened consumer awareness of recalls and contamination issues. Dairy processors want to ensure that they are delivering top quality products to their consumers that are safe for consumption. One of the many free educational opportunities is a presentation on the key aspects of the Food Safety Modernization Act (FSMA), the likely implementation steps and how food processors can start to prepare for compliance. Hailed as the most significant public health legislation in more than 60 years, the FSMA will likely impact every food processor worldwide. Another presentation will discuss how brand protection and food safety go hand-

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Dairy Foods | October 2011

in-hand. Technology can help manufacturers improve compliance and lead the marketplace while reducing costs. Technology also helps manufacturers and consumers successfully navigate the new regulations while building increased product value. Processing efficiencies is another topic that is foremost in the minds of dairy processors. They need to keep their production lines up and running and ensure that their processes are repeatable day-after-day. If lines are down, they aren’t making saleable product and profitability suffers. They need processing equipment that is reliable and keeps their lines running for many years with minimal maintenance. Process Expo exhibitors will showcase the latest improvements in equipment design to boost performance and reduce maintenance. One educational session will provide insights to help processors better manage their maintenance operations, ensure the safety and quality of their products and satisfy the requirements of third-party audits. Another presentation will address how having the right mixing technology can improve uptime, product consistency, re-

duce functional ingredient amounts and cut down on product losses. Since the show covers the entire food and beverage industry, dairy processors will not only have the opportunity to see the latest technologies in their specific industry, but also observe processing solutions in other industries that may solve a problem in their plant. For example, the cheese industry has a need to handle curd efficiently without damaging the product. Manufacturers have had success with pumps that have long been used in tomato and orange juice pulp concentrate processing. Industry Councils, the foundation of FPSA, play a major role in shaping Process Expo and will have dedicated space on this year’s show floor. The Council Pavilion, booth 5412, will provide a social setting for attendees to talk to representatives from different councils to discuss how they operate and how suppliers and processors in their particular industry can better collaborate. Dairy Council Day is Nov. 4. Pete Herb is chairman of the FPSA Dairy Council and president of Fristam Pumps USA.

Process Expo Show Preview

“This is by far the most comprehensive educational program we’ve ever offered at Process Expo,” says David Seckman, president and CEO of FPSA. “We are grateful for the support of our food processor educational sub-committee that chose the submissions that will best appeal to Process Expo attendees. We are confident that the strength of this program gives food processors yet one more reason to come to Chicago this fall to a show that is on track to double in size as compared to the 2010 show. By combining this high-level educational content with the unmatched technical expertise that attendees will find on the show floor, Process Expo has become an integral resource for the food and beverage processing industry and a must-attend event.”

Attendees can also visit the Siemens Exhibitor Spotlight Theater, which will deliver a series of short technical workshops throughout the day on the show floor, covering a wide variety of topics. Visitors can listen to experts discuss manufacturing solutions. Dedicated entirely to Process Expo’s attendees from Latin America is Seminario de Innovaciones, which runs throughout the day on Oct. 31. These sessions are presented in Spanish and sponsored by the show’s international partners—Canainca, Canilec, Comecarne and Chilealimentos. FPSA also launched a Spanish language version of its website to inform Latin American food processing professionals about the benefits of participating in Process Expo. While still in development, the Spanish language educational sessions will feature topics such as food safety and sanitation, employee training and maintaining standards for food and beverages being exported into the United States. In addition, FPSA councils will develop industryspecific sessions for dairy and beverage, as well as meat/poultry/ seafood, bakery, and fruit and vegetables.  For exhibitor and attendee information, travel arrangements, airfare discounts, registration links and more, go to www.myprocessexpo.com.

Exhibit Hours Tuesday, Nov. 1 Wednesday, Nov. 2 Thursday, Nov. 3 Friday, Nov. 4

9 a.m. – 5 p.m. 9 a.m. – 5 p.m. 9 a.m. – 5 p.m. 9 a.m. – 2 p.m.

Admix Admix provides solutions to your toughest mixing challenges with a focus on adding powders into liquids. They have been recognized as a leader for high performance, high efficiency sanitary mixing systems and for their commitment to innovation and high quality. Admix offers a broad range of products for inline mixing and milling, powder induction, as well as in-tank batch processing and will be introducing two new products at the ProcessExpo. Stop by and visit Booth #423 and see What’s New! Admix 800-466-2369 www.admix.com Booth: 423

Exhibit show hours are subject to change.

www.dairyfoods.com

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Show Preview

BOOTHS Ampco Pumps Ampco Pumps has experienced great success with our ZP1/ZP2 positive displacement pumps and we’re pleased to introduce our newest innovation – the ZP3! This pump offers in-line cleanability without further modifications, front-loading seals, 100% parts interchangeability of ZP2-style gear cases, and an option to upgrade ZP2-style pumps to a ZP3 pump. All of our ZP pumps include a stainless steel gear case, 17-4 shafts, and helical gears. We’re excited to demonstrate how you can save time, money, training resources and inventory expense by switching or upgrading to a ZP3 pump. Stop by and see us in Chicago at Process Expo in booth #3614.

Anderson Instrument is unique in the world of process instrumentation manufactures as we only manufacturer application specific sanitary instrumentation for use in the Food, Beverage and Pharmaceutical processing industries. Our products offerings range from chart recorders and controllers, sanitary flow meters, and a broad range of sanitary sensors including pressure, temperature, level and analytical transmitters. Recently introduced, we are highlighting the industries first fully modular sanitary pressure transmitter. Series MPF (Modular Pressure Food) is component based and broadly field configurable thus reducing cost of ownership, reduce down time and lower critical spare inventory. Please stop by our booth for a demonstration on how the MPF can save your facility time and money.

Ampco Pumps 414-643-1852 www.ampcopumps.com Booth: 3614

Anderson Instruments Company, Inc. [email protected] 800-833-0081 www.andinst.com Booth: 2156

Donaldson Company, Inc.

FOSS North America

THINK PURITY. THINK DONALDSON. Donaldson’s innovative filter designs meet your purity requirements while minimizing operating expenses and reducing downtime. We deliver energy efficiency and reliable performance to customers around the globe. • Filtration solutions from pre-filtration to final, and from low to high capacity • Service items and replacement filter elements for many brands of filter housings for shipment within 24 hours

FOSS offers a complete range of dedicated solutions providing new opportunities to optimize your dairy production - from improving quality and safety of raw material, through to milk standardization, and verification of end products. For process control, FOSS offers in-line analysis solutions that have helped producers obtain tighter production control and increased profitability. ProFoss™ is an in-line process analysis solution that monitors multiple quality parameters such as moisture, total solids and fat in dairy products. ProcesScan™ is an on-line analyzer that provides a total solution to monitor and control the process line in real-time. Learn more at Process Expo or visit us www.foss.us/dairy.

Donaldson Company, Inc. Compressed Air and Process Filtration on 800-543-3634 [email protected] www.donaldson.com Booth: 1615

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Anderson Instrument Company, Inc.

Dairy Foods | October 2011

FOSS North America 8091 Wallace Road Eden Prairie, MN 55344 952-974-9892 952-974-9823 www.foss.us Booth: 3615

Show Preview

framarx/waxstar

GEA Niro Soavi

framarx/waxstar is a family owned and run waxed paper company founded in 1966. We specialize in converting waxed and coated papers for product interleaving, primarily in the meat industry. At framarx/waxstar we emphasize quality, stress customer service and are always willing to put in RUSH priority, customized printing, a unique size, or special packaging. We know that by avoiding rejections or problems with paper in the field, we are saving our customers and ourselves valuable time and money. With most of our customers, we enjoy long-term relationships. They have come to expect us to come through for them on a routine basis. High quality is expected, and we are proud to be a part of their quality product. We are confident that we have what you are looking for in a paper source.

GEA Niro Soavi is the global technology and market leader for high pressure pumps and homogenizers. Established in 1947 and part of the GEA Group – one of the leading engineering companies worldwide –GEA Niro Soavi maintains its leadership position through product innovation, reliability and local presence in order to satisfy customer expectations. Our international sales and service network allows GEA Niro Soavi to be close to customers regardless of where they are, with local, competent and professional support.

framarx/waxstar Lawrence Czaszwicz, President 3224 Butler Ave. South Chicago Heights, IL 60411 800-336-3936 [email protected] www.framarx.com Booth: 5617

GEA Niro Soavi [email protected] 603-606-4065 www.nirosoavi.com Booth: 3403

GEA Tuchenhagen North America

GEA Westfalia Separator

GEA Tuchenhagen is a global leader in the manufacturing of a wide range of sanitary flow components for the dairy industry. Products include mixproof, single-seat, divert, modulating, butterfly, pressure relief and sample valves; valve control technology; inline instrumentation; cleaning devices; vessel protection and cleaning systems; and the revolutionizing mixproof 24/7 PMO Valve and 24/7 PMO Tank Valve. Additional services offered by GEA Tuchenhagen include concept design engineering, manifold prefabrication, preventive maintenance and customer training. Stop by booth #3403 to see our latest innovations.

Founded in Germany over a century ago, GEA Westfalia Separator offers a full range of products in the dynamic filtration and separation categories, including high performance separators, clarifiers, decanters and membrane filtration systems. Our equipment can be found in small and large dairy processing facilities. A new separator design was recently introduced. It features an integrated direct drive system that is installed directly underneath the bowl in the separator’s frame. Further, our engineers work with customers to design complete processing lines for many dairy products. Besides separators, the company manufacturers butter churns, pasteurizers and milk standardization equipment.

GEA Tuchenhagen North America 90 Evergreen Drive, Portland, ME 04103 207-797-9500 www.tuchenhagen.us Booth: 3403

GEA Westfalia Separator [email protected] 800-722-6622 http://us.westfalia-separator.com/marketsapplications/ dairy-technology.html Booth: 3403

www.dairyfoods.com

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Show Preview

KARL SCHNELL

Mettler Toledo

Latest control technology for filling machines Vacuum filling machines of the KARL SCHNELL company have always been the technical forerunner in the area of the industrial filling technology. This applies also to the new generation of the KS Vacuum Filler P10 Type 5 8 8. They set themselves apart through precise gram portioning, filling free from air bubbles and maximum filling capacity. In the development process, the technicians at KARL SCHNELL make easy visualisation and intuitive operation a top priority. The core of the new KS control is the modern industrial PC which takes over all automation tasks. The new KS Vacuum Filler P10 thus sets new standards in terms of operation, ergonomics and connectivity.

METTLER TOLEDO invites you to a total 360° Product Inspection experience with a chance to see how our solutions can look at your inspection challenges from every angle. Take advantage of this opportunity to view our innovative, award winning in-line checkweighing, metal detection, X-ray and vision inspection solutions all in one place. Visit us in booth 202 and learn how our solutions can increase efficiency, reduce manufacturing costs and improve the competitiveness of your business. You could win $25,000 on our iPad PrizePad! METTLER TOLEDO 6005 Benjamin Road Tampa, FL 33634 www.mt.com/pi 813-889-9500 Booth: 202

John Mauthe KARL SCHNELL Inc. USA (920)982-9974 [email protected] www.karlschnell.com Booth: 5019

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Nelson-Jameson, Inc.

Paul Mueller Company

Nelson-Jameson, Inc. has been a trusted source of food processing supplies since 1947. Our Buyers Guide for the Food Industry features thousands of items used daily in food plants and includes hard-to-find specialty items. Products include safety & personnel, production & material handling, sanitation & janitorial, processing & flow control, laboratory & QA/ QC, bulk packaging and ingredients. The catalog also features a wide assortment of color-coded and metal detectable items to keep your product safe. Headquarters in Marshfield, Wisconsin, warehouses in California, Idaho and Pennsylvania. Request your FREE copy of our Buyers Guide today and visit our new website www.nelsonjameson. com. We’ll see you in Chicago at Process Expo! Nelson-Jameson, Inc. 2400 East Fifth Street P.O. Box 647 Marshfield, Wisconsin 54449 800-826-8302, Fax 715-387-8746 www.nelsonjameson.com [email protected] Booth: 4619

Established in 1940, Paul Mueller Company has been building a reputation as an outstanding manufacturer of stainless steel tanks and industrial processing equipment that make the customer’s process smoother, faster, and more reliable. Mueller® has evolved into a global process solution provider, offering manufactured equipment and components, integrated process systems, and expanded-scope construction. Our philosophy is simple: we are committed to meeting and exceeding our customers’ expectations of value by providing high quality equipment, excellent service, and complete process solutions. Mueller products are used in over 100 countries worldwide on dairy farms and in a wide variety of industrial applications, including food, dairy, and beverage processing; pharmaceutical, biotechnological, and chemical processing; water distillation; heat transfer; HVAC; heat recovery; process cooling; refrigeration, and thermal energy storage.

Dairy Foods | August 2011

Paul Mueller Company 1600 West Phelps Street • Springfield, Missouri 65802 1-800-MUELLER (683-5537) • (417) 575-9000 • Fax: (417) 575-9669 www.muel.com • E-mail: [email protected] or [email protected] Booth: 1612

Show Preview

Reiser

Seiberling Associates, Inc.

Vemag Cheese Shredder and Portioner from Reiser Reiser and Vemag have designed a variety of cheese shredding and portioning systems for all types of applications and production requirements. This solution is ideal for dispensing precise portions of shredded cheese onto pizza and prepared meals. The system combines a Vemag Portioner with a Cheese Shred Depositor attachment. Cheese blocks and scraps are loaded into the Vemag’s hopper, where they are then shredded and portioned directly onto conveyed product. The shredded cheese is perfectly portioned and is deposited cleanly and evenly with no mess. Depositing consistent portions onto moving lines is easily accomplished. Reiser 725 Dedham Street Canton, MA 02021 781-821-1290 Fax: 781-821- 1316 [email protected] www.reiser.com http://www.reiser.com/cheese/cheese.php Booth: 2602

Seiberling is an Engineering and Technical Consulting Company providing process, clean-inplace (CIP) and steam-in-place (SIP) design and control system integration services to the Food, Dairy, Pharmaceutical and Biotech industries. Seiberling Associates, Inc. was founded in 1976 and has built long-term relationships with clients by developing innovative, automated and cost effective hygienic engineering solutions. The extensive hygienic and automation processing experience and educational background of our staff enables Seiberling to understand the needs of our clients and their project partners, so we can tailor our services to achieve the unique goals of each individual project.

Separators Inc.

SPX Flow Technology

Centrifuge Service, Equipment, and Parts Your “One Stop” Source…Great Service…Great Value Separators Inc. is North America’s leading centrifuge service provider specializing in the remanufacturing of Alfa Laval, Tetra Pak and Westfalia centrifuge equipment. Separators Inc. offers a full complement of startup, maintenance and repair services and stocks over 4,000 parts with 24/7 availability. Industries served include: dairy, beverage, rendering, edible oils, pharmaceutical, biofuels and industrial fluids.

SPX’s Flow Technology segment designs, manufactures and markets engineered solutions and products used to process, blend, meter and transport fluids. Our leading brands have global operations which serve the food & beverage, power and energy and industrial markets. Recognized for its leading brands and turnkey systems capability, the Flow Technology segment offers a complete line of sanitary valves, pumps, scrape heat exchangers, homogenizers, mixers, dryers and evaporators for today’s modern processing facilities. It’s hard to find a more comprehensive portfolio of processing equipment anywhere else. SPX Flow Technology will be exhibiting Anhydro, APV, Bran+Luebbe, Gerstenberg Schröder, Johnson Pump and Waukesha Cherry-Burrell brands.

800-233-9022 [email protected] www.separatorsinc.com Booth: 3714

Seiberling Associates, Inc. Wisconsin-Ohio-California 608-313-1235 Email: [email protected] www.seiberling.com Booth: 1014

SPX Flow Technology [email protected] 262-728-1900 800-252-5200 www.spxft.com Booth: 1002

Categories · Processing Equipment & Supplies · Aseptic Processing Equipment · Butter Processing Equipment · Cheese Making Equipment · Heat Exchangers · Homogenizers · Mixers · Processing Systems · Pumps & Valves

www.dairyfoods.com

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Südmo North America, Inc.

Tetra Pak

Pentair Südmo’s 365it Complete is the first PMO mix proof valve that does not require a full port leakage chamber while meeting 3-A Sanitary Standard 85-02, which includes cleaning via valve seat lifting for use in dairy plants. The 365it Complete PMO reached the latest 3-A 85-02 acceptance following third party verification confirming the valve meets and exceeds all 3-A Sanitary Standards for mix proof valve requirements and can be used in PMO dairy applications. By combining the 365it Complete PMO with the IntelliTop® 2.0 you can now have maximum efficiency and safety in a smaller footprint.

Tetra Pak provides solutions to enable our customers in the dairy, beverage, prepared food and cosmetic industries to achieve cost-effective and continuous processing of quality products. Our topquality processing equipment, integrated systems, project management, engineering services, spare parts and maintenance programs make Tetra Pak the preferred choice among processors.

On average the 365it Complete PMO . Weighs 45% less . Loses 30% less CIP during seat lifting . Reduces height by 18% . Uses 20% less air

Tetra Pak 800-806-9675 Fax: 847/955-6500 www.tetrapakprocessing.com [email protected] Booth: 1814

Südmo North America, Inc. 815-639-0322 [email protected] www.sudmona.com Booth: 3419

Urschel Laboratories, Inc.

MasoSine

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sneak peek a look inside…

Pierre’s Ice Cream

REPORTS

focus on innovative new products helps this Cleveland-based ice cream processor gain shelf space in groceries nationwide. A brand new plant helps it achieve manufacturing efficiencies for its own brands and for its co-packing business. Page 70.

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Rigid Packaging Roundtable n this Dairy Foods exclusive Q&A discussion, we find that rigid packaging designers are exceedingly flexible. They collaborate with dairy processors to develop packaging that is cost-effective, protects foods and stands up to the rigors of handling and transportation. Page 78.

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Quality on the Line enry Randolph reviews the quality assurance tests every processor needs to know. Page 84.

H

By developing new products, CEO Shelley Roth is leading Pierre’s Ice Cream Co. to markets far from its Cleveland headquarters.

Warehouse Automation N

Photos by Vito Palmisano

Extending Its Reach

ew products to help dairy processors keep track of their foods. Page 86.

New products like antioxidant fruit sherbets and probiotic frozen yogurts are putting Cleveland-based Pierre’s Ice Cream Co. into supermarket freezers nationwide and even overseas.  Jim Carper Chief Editor

fast forward what’s coming in November…  State of the Industry  Exporter of the Year  International Whey Conference

Highlights

or as much as ice cream is depicted as a “fun” food, the actual selling of it is anything but. The business of ice cream is hard work. The competitive landscape in the United States is dominated by two multinational conglomerates. Unilever, based in Rotterdam, Netherlands, sells Breyers and Ben & Jerry’s, while Nestlé, Vevey, Switzerland, owns Dreyer’s, Edy’s and Häagen-Dazs. Private-label brands as a whole are No. 1 and outsell the top branded product by a margin of twoto-one, according to Chicago-based SymphonyIRI Group. To compete in this world, small, privately held dairy processors need to develop innovative new products, be creative in their marketing, manufacture efficiently

F

Continued on page 60 www.dairyfoods.com

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Corporate Profile

 Pierre’s merchandiser Jermaine Nevels assists customer Tracy Boyd (in cap), the frozen food manager of Dave’s Markets stores in Cleveland. and be responsive to all of their customers (retailers, private-label accounts and consumers). Pierre’s Ice Cream Co., Cleveland, has followed that approach to success with its ice creams, sherbets, sorbets, frozen yogurts and novelties. Pierre’s, headed by CEO Shelley Roth, produces more than 235 products and flavors in various formats. That’s a far cry from the original three flavors (French vanilla, Swiss chocolate and strawberry) sold in pints by Alexander “Pierre” Basset, who founded the company in the 1930s. The ice cream market as a whole has been slow. Sales at supermarkets, drugstores and mass merchants (excluding Walmart) increased a scant 1% to $4.01 billion in the 52 weeks ended Aug. 7, according to SymphonyIRI Group. Pierre’s Ice Cream eked out a small increase in dollar sales during that peri60

Dairy Foods | October 2011

od, along with its Pierre-branded frozen yogurt, sherbet and sorbet products. Unit sales of ¡Hola Fruta! fruit sherbet, however, were particularly robust, increasing more than 20%. Product development Though based in Cleveland, Pierre’s is not a regional ice cream processor. New products, like ¡Hola Fruta! and Yovation frozen yogurt, extend Pierre’s reach nationally. Roth is directing the company’s growth throughout the United States and internationally. Asked about her strengths as a leader, Roth answers with the words “recipes,” “creativity” and being “a good listener.” Roth keeps an eye on culinary trends and figures a way to apply them to dairy foods. She wanted to make an antioxidant product, so Pierre’s tried one with ice cream. The trouble was that it didn’t taste

very good. Roth suggested an antioxidant sherbet, and ¡Hola Fruta! was born. Yovation, a probiotic frozen yogurt, and Slender, a line of reduced-fat ice creams sweetened with sucralose, are two other products developed in response to market trends and consumer demands. The company also specializes in the manufacture of private-label lines. Pierre’s does not have a formal, written process for developing new foods and flavors. Instead, Roth says, “We like to have fun with it. Inspiration and ideas can come from anywhere: fans, customers, employees.” Case in point: Smooth Churned Ray’s Root Beer Float, named for Ray Kralik, the company’s lead flavor man. The 38-year veteran of the company suggested the flavor. After just three months on the shelf, Root Beer Float became one of the company’s most successful flavors of 2011. Kralik

Hundreds of Products, Flavors Pierre’s Ice Cream Co. manufactures more than 235 products and flavors. Ice creams fall into Premium (the top of the line), Homestyle (a mid-priced line) and Royal (a value line). Products are certified kosher by the Orthodox Union (and the sorbet is pareve, meaning it can be consumed with both meat and dairy meals). Among the brands and products are: • Pierre’s Premium Ice Cream • Pierre’s Frozen Yogurt • Pierre’s Homestyle • Pierre’s Slender No Sugar Added Reduced Fat Ice Cream • Pierre’s Smooth Churned Light Ice Cream • Pierre’s Pure Fruit Sherbet • Pierre’s Sorbet • ¡Hola Fruta! Pure Fruit Sherbet • Yovation Probiotic Frozen Yogurt • Pierre’s Frosted Smoothies • Pierre’s Frosted Chocolate Malt • Super Scoop Pierre’s also sells a variety of frozen novelties (sticks, sandwiches and slideups, made by a third party) for retail and bulk sale. Select flavors are available in 3-gallon bulk cans for foodservice customers. 

himself became a bit of a local celebrity, with a profile in The Cleveland Plain Dealer newspaper and interviews with local radio and television stations. For its in-store launch, a retail customer asked Kralik to serve samples of the flavor. This year alone, Pierre’s added six Yovation flavors: black cherries & chocolate chunks, butter pecan, cappuccino, chocolate, Moose Tracks and vanilla (it also makes a vanilla-pomegranate-blueberry flavor). It changed the format to pints from quarts in 2010. ¡Hola Fruta! added a seventh flavor — black cherry lemon — to its line of pints. The diversity of product, as well as offering new and innovative flavors, sets Pierre’s apart from other ice cream makers, Roth says. “¡Hola Fruta! and Yovation Probiotic Frozen Yogurt are great examples. ¡Hola Continued on page 62 www.dairyfoods.com

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Corporate Profile Fruta! really took sherbet to a whole new level and developed a loyal fan following as it opened new markets to us. Fans write to us from all over the country, from California all the way to Florida looking for ¡Hola Fruta!,” Roth says. “Yovation is a better-for-you product (it features a probiotic culture) and has less fat and fewer calories than regular ice cream. It also offers frozen yogurt lovers more than the everyday vanillas, chocolates and strawberries,” she added. “Regularly creating and introducing new products and flavors is what keeps people coming back to your freezer door wondering what they’ll see next. Our customers not only welcome new Pierre’s flavors to their store shelves, but trust us to work with them in creating new flavors for their own private labels knowing our reputation for unique, great-tasting and premium-quality products. Someone who purchases a container of Pierre’s ice cream or a pint of ¡Hola Fruta! or Yovation, or partners with us to create a product for their own private label, chooses Pierre’s because of that reputation for quality,” she says. The new $9.2 million plant, which opened this summer (see related article on page 70), helps Pierre’s in serving private-label and foodservice accounts. “With the added capacity in our new facility, we anticipate growth in these channels,” Roth says.

 Vice president of sales Frank Elliott (right) reviews accounts with foodservice sales manager Pat Lehrer and vice president of new business development Ronnie Levinsohn.

Spreading the word Pierre’s supports product sales and launches with social media, in-store specials, promotions, free-standing inserts, 30-second radio advertising and public relations. Yet selling comes down to two factors. Continued on page 64

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Dairy Foods | October 2011

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Corporate Profile

 Treasurer David Creps (clockwise, from top) is joined in the lobby by sales assistant Melanie Lechner, administrative assistant-accounting Sandy Valente, vice president of finance Rick Zenobi and controller Todd Kauppila.

“Price and quality are what move ice cream,” says vice president of sales Frank Elliott. CEO Roth adds a third quality: “You have to present yourself well.” To be successful, an ice cream processor has to create exciting brands and flavors, she says. Elliott manages a sales force of 18 and a direct-store-delivery business that makes deliveries as often as three times a week for some customers. Four telemarketers call on restaurants, foodservice accounts and supermarkets and follow up on leads. It helps that the company has name recognition. Pierre’s has been entwined in the fabric of Cleveland for 80 years, supporting local events and charities. “We like to participate in special events where we can coupon and have people experience our new products in a fun forum,” says Matt Thornicroft, assistant marketing and communications manager. Pierre’s participates with a local radio station in its annual “free lunch” promotion in downtown Cleveland, with dessert coming from Pierre’s. Continued on page 66

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Corporate Profile “We are also the presenting sponsor of a local event called Ice Cream Weekend held at Lake Metroparks Farmpark,” says vice president of marketing Laura Hindulak. Visitors learn about ice cream making, “from farm to cone,” and sample Pierre’s ice cream. Another annual event is the Juvenile Diabetes Research Foundation

Walk to Cure Diabetes event at the Cleveland Metroparks Zoo. Pierre’s promotes its sugar-free ice creams at the walk. Promotional ice cream parties, given away by Pierre’s or in partnership with radio stations, are another way the ice cream processor takes new flavors to market.

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“We give them enough ice cream for about 25 people, so they can host their own party or share with their families,” Hindulak says. “We supply them with everything they need, including ice cream soda hats, scoopers and coupons to continue the fun.” The Pierre’s Sweet Rewards program is a UPC collection program created as a fundraising option for non-profit organizations. Pierre’s donates cash, based upon how many UPCs a group collects. The company also donates to the Cleveland Foodbank. Pierre’s partners with local colleges by providing students with curriculum material and case study assignments about Pierre’s and the dairy foods industry. For example, student-created advertisements decorate the lobby of the corporate headquarters. Concession stands in Progressive Field, the home of Major League Baseball’s Cleveland Indians, sell Pierre’s frosted cups (a smoothie product), novelties and ice cream cones. Pierre’s has been on Facebook for nearly two years and created separate pages for Pierre’s, ¡Hola Fruta! and Yovation. “We view Facebook as a window into our company that you wouldn’t otherwise have access to if you are not a fan,” Hindulak says. “We try to make it a casual, open forum for our fans. Customers can talk to us directly, post photos, share opinions, recipes and talk about ice cream in general. We post photos of initial runs of limited-edition flavors, alert customers to online coupons, upcoming FSIs. We also provide sneak peeks at new flavors.” “We had a lot of fun announcing black cherry lemon ¡Hola Fruta! and posting photos of ‘Top Secret New Flavor Meetings’ to build up excitement and to give our Facebook fans information they wouldn’t get without being a fan,” Hindulak says. Fans also could follow the construction of the new plant because Pierre’s posted photo updates on Facebook. A loyal management team Sol Roth was running Royal Ice Cream Co. when he acquired Pierre’s in 1960 (see accompanying article, “Who Was Pierre?”). Shelley Roth was in her early 20s and working in the recording industry in New York. At the request of her father, she moved back to her hometown Continued on page 68

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Dairy Foods | October 2011

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Corporate Profile to join Pierre’s in 1979, and became chief executive officer in 1991. Sol died in 2005. Her brother, a doctor, decided not to join the business. Roth’s husband, Bruce Schwartz, works outside of the dairy processing industry. While Pierre’s cannot be considered a family business, longtime employees describe the company as has having a family feel. Many on the management team have worked at Pierre’s for 20 years and more. Half of Pierre’s 85-person workforce has 10 or more years of service. Roth’s mother drops in at the plant every now and then, and still gets a thrill from eating just-filled ice cream pints, Roth says. Early on, Shelley tried to get her father to modernize business equipment, but an early use of computers and punch cards ended badly. She persevered. Even today, she reads computer and technology magazines, looking for ideas that staff can implement. She recalls that her father had “an ear” for the equipment and could tell if a piece of machinery was running properly, based on its hum. The soft-spoken Roth herself is comfortable in the plant, as well as the boardroom. One morning, before a meeting with private-label clients, Roth had been in the factory. When she met a visitor, she was still dressed in lab coat and hair net. “We work very hard to be as efficient as possible while working with our vendors and suppliers to proactively explore what other efficiencies we can incorporate into our business. This allows us to continue to manufacture a high-quality ice cream at a reasonable price for our customers,” Roth says. Like other dairy food processors, Pierre’s is dealing with rising ingredient, packaging and fuel prices this year. “The uncertainty of the commodity markets adds to the concern,” Roth says. “Earning and keeping shelf space is always a factor in the ice cream category, which is why we put a lot of effort in creating new products across all of our product lines, products that are unique to Pierre’s.” Membership in professional associations keeps Pierre’s upto-date on business and regulatory issues as well as consumer and culinary trends. Pierre’s memberships include Associated Grocery Manufacturers’ Representatives, International Dairy Foods Association, International Ice Cream Association, MidTown Cleveland and Women’s Business Enterprise. It is also a member of Ohio Proud, a marketing program of the Ohio Department of Agriculture that promotes food and agricultural products that are made and grown in Ohio. MidTown Cleveland is a 501 (c) 3 economic development corporation serving a two-square-mile area between downtown and University Circle, to the east. Executive director James Haviland called Pierre’s “a key MidTown stakeholder” for the past 80 years. “Their $9.2 million expansion on Euclid Avenue along the Health-Tech Corridor is a significant investment in the area. Pierre’s Ice Cream joins other MidTown businesses who have chosen to remain in Cleveland, citing accessibility to major highways, access to a trained workforce and commitment to putting Cleveland on the map with a quality ice cream product.” The road ahead Pierre’s has plans to introduce its brand and products into new markets, says Frank Elliott, the vice president of sales. “We intend to focus on pursuing additional private-label and export business. Pierre’s is able to customize recipes to precise specifica68

Dairy Foods | October 2011

Who Was Pierre? Pierre’s Ice Cream Co. started in Cleveland as a corner ice cream shop in 1932, where Alexander “Pierre” Basset sold freshly made ice creams by the cone and cup, or hand-packed for take home. Basset supplied restaurants, country clubs and gourmet markets. Pierre’s soon outgrew its small space on Euclid Avenue, expanding numerous times into larger and more efficient manufacturing facilities. Yet Pierre’s always remained within three miles of its original location at 82nd Street and Euclid Avenue, in the heart of Cleveland. The company moved to St. Clair Avenue, then to East 60th Street and Hough Avenue in 1960. The Hough Avenue plant was shared with another small ice cream maker, Royal Ice Cream Co., owned by Sol Roth. Royal’s history was similar to Pierre’s: a small ice cream shop with a commitment to quality. In 1960, Royal Ice Cream acquired Pierre’s Ice Cream Co. Royal then began showcasing the Pierre’s brand and special recipes, and devoted all of its resources to expanding the line and building the Pierre’s name. The next direction for Pierre’s was expansion into half-gallon packages, broader distribution beyond Cuyahoga County and the creation of unique and popular flavors for sale in retail stores, as well as ice cream parlors. In 1967, Pierre’s/Royal acquired the Harwill Ice Cream Co. at East 65th Street and Carnegie Avenue. It consolidated all operations to that one plant and expanded the facility several times before out-growing it. Pierre’s moved into its new state-of-the-art distribution center and office headquarters at East 65th and Euclid Avenue in 1995, just one mile west of its original shop. The most recent expansion was the addition of a $9.2 million, 35,000-square-foot, state-of-the-art manufacturing facility, which opened on June 13. 

tion to suit any need,” he says. The company has exported to accounts in Aruba, Puerto Rico, South Korea and Pakistan. “Our customers are really what drive us,” Roth says. “People are paying a lot more attention to what they are spending nowadays. Enjoying ice creams and frozen desserts is all about the experience, and we want people who enjoy Pierre’s to have the best experience possible. We want them to feel that what Pierre’s makes, we make just for them.” Without layers of management that larger companies have, Pierre’s can quickly turn ideas into action. Co-workers say Roth is knowledgeable in every aspect of the business. Roth says Pierre’s continued focus will be on developing “delicious, new and quality products” for current and future customers. “Innovation is really important, especially considering all the competition that exists in the category. Interest in better-for-you products like Pierre’s Slender no-sugar-added reduced-fat ice cream, ¡Hola Fruta! pure fruit sherbet and Yovation probiotic frozen yogurt continues to grow,” Roth says. Pierre’s competes not only against other brands of ice cream, but generally against other dessert choices. “The million dollar question always is: What’s for dessert? We want them to choose Pierre’s,” Roth says. With a track record of creating new flavors and new products, it looks like Pierre’s has the answers. 

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Pierre’s Runs on the Fast Track The Cleveland-based processor broke ground on a new facility, moved in and started making ice cream, sherbet and frozen yogurt in just 10 months.  Jim Carper Chief Editor

uclid Avenue runs east from downtown Cleveland and out to the University Circle neighborhood and the famed Cleveland Clinic medical center. The boulevard is dotted with abandoned buildings and empty lots. But there are signs of redevelopment here and there. While other businesses have shut down or left, an ice cream processor remains committed to the MidTown area. Pierre’s Ice Cream Co. has been operating within three miles of its current location since it was founded in 1932. In 1995, Pierre’s built a 56,000-square-foot headquarters office and distribution center to the west of the plant. In September 2010, the independent ice cream processor broke ground on a 35,000-square-foot

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Dairy Foods | October 2011

manufacturing facility on its campus. Remarkably, the new $9.2 million plant was operational in just 10 months. Before shutting down the old plant, Pierre’s increased production so it had enough product in the warehouse until the new plant was up and running. The new, one-story factory replaces Pierre’s former 34,000-square-foot production building located nearby on Carnegie Avenue, which was built in the 1920s and acquired through mergers and purchases. With the new facility, the ice cream processor has increased its manufacturing productivity and potential output. The move positions the company to grow by making more of its own brands and to handle additional co-packing accounts.

Plant Close-up

 Above: Ryan Holland awaits shrink-wrapped bundles, which are exiting the spiral hardener. They will be moved to the warehouse. Left: With lids applied, packages move on the conveyor through a metal detector and date stamper.

The new plant was designed to ensure food safety, increase efficiency and promote sustainability, says chief executive officer Shelley Roth, who points to several improvements in equipment and processes, including: • New and energy-efficient automated production equipment, including a flash-freeze spiral hardening system that enhances freshness and quality • Special paneling, floors and equipment to maximize food safety • New stainless-steel holding tanks for liquid ingredients • New flavor tanks, mixing equipment, piping, pumps and filling equipment • New conveyors • Energy-efficient construction practices to manage energy consumption The Cleveland Plain Dealer newspaper reported that at the ribbon cutting this summer, Roth said her late father, Sol Roth, would be thinking: “Are you crazy? What do you think you’re doing? Do you know how much ice cream you’ll have to sell to pay for this?” Taking the tour When Dairy Foods toured the new facility this summer, plant manager Tom Settle explained that he runs 10-hour produc-

tion shifts from Tuesday through Friday. The other three days of the week are devoted to additional maintenance and cleaning projects. Pierre’s makes ice creams, frozen yogurts, sorbets and sherbets for retail and foodservice accounts. Three milk silos hold 4,000-6,000 gallons each. Pierre’s built the silos on the outside of the building so they would not take up space on the production floor. (Silos were inside the former production building). The silos feed five milk tanks that are accessible from alcoves inside the building. Each alcove is clearly labeled with a number and a letter. Milk arrives several times a week from local sources. Pierre’s uses the high-temperature/short-time pasteurization process on the milk. All other raw materials are also pasteurized before use. Allergens are labeled by vendor and with an internal label. They are stored in a designated area. Suppliers must meet Pierre’s rigid supply chain quality procedures. Certificates of Authenticity must be in hand before the ice cream processor accepts deliveries. “We work hard to source the freshest ingredients from the very best suppliers,” Roth says. “Each and every cookie, brownie, candy, chocolate chip, berry and chunk earns its place in a Pierre’s recipe following a meticulous evaluation process.”

Continued on page 72

www.dairyfoods.com

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Plant Close-up

 Above: Ray Kralik checks on the flavor vats. Right: Production manager Beckie Bragg inspects the CIP system.

At the beginning of each shift, operators consult a flavor start-up list so they know what is being made and which cups and lids are required at each filling station. Pierre’s also co-packs for retailers and private-label clients. (The company’s ice cream sandwiches and frozen novelties are manufactured by another processor. Pierre’s sources from suppliers who share its requirements for food safety, ingredient quality and kosher certification, Roth says). Three batch tanks sit in a separate room. Dry goods are added to a liquefier, then pasteurized and homogenized. From the flavor vats, mix is pumped at 20°F to any of the six new freezers on the manufacturing floor. The freezers are outfitted with touch-screen controls. Recipes, now stored in a database, can be called up on any touch screen. This is a manufacturing improvement, resulting in a more consistent product and one made with less waste of raw ingredient materials, says Rick Zenobi, vice president of finance. Mix from the freezers flows to the fillers. (Inclusions and ribbons are added before the filler). Flexibility in manufacturing was central to the design of the plant. Pierre’s fillers are on casters so they can be easily connected or disconnected from the freezers and rolled to various produc-

tion lines, depending on what’s being produced that day. The plant fills pints, quarts, 48- and 56-fluid-ounce scrounds and 3-gallon foodservice cans. After filling, lids are added by machine and the containers pass through a metal detector and code and date stamper. The ice cream packages move by conveyor to a wrapping station where an operator consolidates eight pints to a tray, which are then shrinkwrapped and stacked. Trays move on to the spiral hardening freezer where the temperature can reach -40°F. This is another improvement. The new freezer flash-freezes ice cream in less time than in the old plant. Faster freezing better preserves Pierre’s signature fresh and creamy taste, Roth says. Product is loaded directly onto pallets after exiting the freezer and moved into the distribution warehouse. Again, this is an improvement over the old plant. The old factory had a static freezer that required two days until product froze to the required hardness. Then, after the ice cream was frozen, Pierre’s loaded partial pallets onto trucks for transport across the campus to the warehouse. The new plant eliminates this double handling. The warehouse has a loading dock with six bays. Though most Continued on page 74

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Dairy Foods | October 2011

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Plant Close-up so that they can transmit orders from the field to the office. The software “helps them be more efficient. They can spend time merchandising the product in the store,” Zenobi says. Over the last few years, Pierre’s purchased rack servers that have built-in redundancies, virtualization and uninterruptable power supplies. A VPN network with remote access allows the freezers to be monitored and controlled by an off-site technician. Pierre’s designed the building itself, which was built by Fogg Construction, a Cleveland design-build contractor. Though not a LEED-certified green building, the plant does incorporate many of the practices encouraged by the organization Leadership in Energy and Environmental Design. Pierre’s used insulated panels to optimize heating and  Transportation manager Albert Pursel (left) and day distribution manager cooling. The plant’s process heat Paul Ward keep an eye on the loading dock, which has six bays. and process cooling is recycled to heat and cool rooms throughout the complex. Windows and skylights provide natural light on the of the product is distributed in the Midwest, Pierre’s ships across manufacturing floor. the country and exports to customers in the Caribbean and southMany of the new technologies in the plant are computerwest Asia. automated and designed to work together. This increases efficiency, reduces energy usage, maintains a consistent level of Updating warehouse and sale technology ingredients and allows Pierre’s to consistently achieve a creamy CEO Roth reads widely, including technology magazines. texture in its ice cream products. Zenobi says Roth will leave articles for him, asking about the All Pierre’s employees are fully trained and certified for their applicability of certain technologies to ice cream processing or job responsibilities and participate in an annual safety review. back office automation. One technology investment was in new Pierre’s also publishes a monthly “Scoop on Safety” newsletter warehouse voice-picking software that increased accuracy to to reinforce safety tips and procedures. Enhanced ergonomic 99.9% from 99.7%. That two-tenths of one percent improvefeatures in the new layout and equipment include conveyors ment is meaningful and cost-saving, Zenobi says. The software at comfortable heights for less lifting and an overall improved reduces re-work and increases customer satisfaction because environment. deliveries are more accurate. “We want to make our employees’ jobs better through autoThe software is also easy to learn and use, which is impormation and continual investments in technology,” Roth says. tant because of the seasonal workforce. Pierre’s employs summer help, usually college students, who master the system after Emphasis on food safety one or two days of training. Pierre’s is in the final stages of Safe Quality Foods certification. “They are very good in three to four weeks,” Zenobi says. “This will enable us to continue operating at the highest (With the old picking system, the learning curve might last all standards of food safety,” Roth says. “It is also a visible assursummer). ance to our customers that Pierre’s is committed to making the Pierre’s sales ordering systems allow customers to order safest, highest-quality products available.” from a delivery driver or a sales rep, from a website or over the HACCP procedures are refined every year. The company phone. A proactive telemarketing department keeps an eye on runs quality assurance tests in its lab and sends samples to a customers’ ordering histories and makes sales calls, as needed. third-party lab. “Everything gets tested twice,” says plant manDrivers use handheld devices to record customer signatures. ager Tom Settle. This allows them to be paperless, something certain customers Pierre’s prides itself on a “robust” HACCP plan and a thorhad requested. The devices can also be used as telephones. Sales ough emergency contingency plan is in place. reps have order-entry software installed on their cell phones, 74

Dairy Foods | October 2011

Plant Close-up

 Pierre’s production managers are (from left): quality assurance manager Adam Tohill; production manager Dave Condon; plant manager Tom Settle and production manager Beckie Bragg.

“We have a very stringent vendor qualification program. Through our HACCP program, we created a robust vendor evaluation, and require high standards of our vendors. Internally, we uphold our HACCP program, and perform weekly and monthly self-audits,” Roth says. “We work with

AT A GLANCE Pierre’s Ice Cream Co. Plant location: Cleveland Year opened: June 2011 Size of the plant: 35,000 square feet Number of production employees in the plant: 25, 85 total Products made: Premium ice cream; light ice cream; no-sugaradded reduced-fat ice cream; lactose-free ice cream; frozen yogurt; probiotic frozen yogurt; sherbet; sorbet Total processing capacity: 10 million gallons Number of shifts: Two (one production shift and one clean-up shift) Storage silos (number and capacity, if applicable): 3, from 4,000-6,000 gallons each Pasteurization type/units/capacity: High temperature/short time Number of filling lines: Two, with the ability to add a third. Warehouse size: 40,245 square feet

suppliers to ensure full traceability of products, ingredients and packaging, which is in full compliance with the food defense program.” Pierre’s has one clean-in-place program for its raw processing operations and another CIP one for pasteurization. The mix room and the production room each receive a thorough washdown at the end of each day. COP tanks on the production floor clean implements and other accessories. Pierre’s has an on-site lab where all incoming ingredients and finished products undergo general microbiological and organoleptic testing. Although basic microbiological testing is done on site, Pierre’s takes an extra step by sending samples to an outside lab for further testing. Multiple samples are taken at various stages throughout each product run. QC technicians look for proper taste, texture, color, consistency of mix-ins as well as a battery of microbiological tests. Testing is performed by Pierre’s own quality assurance manager with assistance from the plant manager, production manager, lead flavor man and a designated daily taste panel. The Ohio Department of Agriculture and the U.S. Food and Drug Administration have jurisdiction over the manufacturing. With a new manufacturing facility, better workflows, flexible lines and upgraded technologies, Pierre’s is in position to continue to grow its own portfolio of dairy foods, and to help its co-packing accounts succeed.  www.dairyfoods.com

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Plant Close-up

Behind the Scenes A photo gallery of Pierre’s Ice Cream Co., Cleveland Photos by Vito Palmisano

 Top: Pierre’s maintenance team includes (from left) maintenance manager Bill Cantale, Marvin Blythe and Johnny Catron. Right: Dave Day watches newly filled ice cream cartons head to the coder.

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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.

 Pierre's built its $9.2 million, 35,000-squarefoot manufacturing facility next to its corporate headquarters in the MidTown neighborhood east of downtown Cleveland.

 Above: Purchasing manager Jerry Galaska and production manager Beckie Bragg review accounts. Left: After warehouse operators began using voice recognition software, picking accuracy increased to 99.9% from 99.7%.

www.dairyfoods.com

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Packaging Technology

Rigid Packaging Designers Prove To Be Flexible Package designers collaborate with dairy processors to develop rigid packaging that is cost-effective, protects foods and stands up to the rigors of handling and transportation. Dairy Foods: Dairy processors are developing specific foods to appeal to children. These might be eaten at home or at school. Discuss the key points a processor must know about packages intended to be opened by young children and consumed away from home. Erin Reynolds: As the primary supplier of school milk cartons, Evergreen Packaging understands the importance of packaging tailored to meet children’s needs. Children desire packaging [that] is easy to open and provides a good drinking [experience]. [Our] Twist-It spout carton delivers well on those expectations. The Twist-It carton is also re-sealable, helping to prevent spills and is usable with or without a straw. In test markets, 90% of children preferred the Twist-It carton to their present package, and overall consumption increased 15%.

 Scott Bossong of Sealed Air Corp.’s Cryovac food packaging business unit says one packaging solution geared for a child’s needs is a press-to-close reclosable format, such as this packaging for cubed cheese. This same press-to-close technology can be incorporated into flexible rollstock packaging as well, he says. Dairy Foods: Product packaging for club stores often calls for unitizing two or more cans or other rigid containers. Discuss some of the ramifications for a dairy foods processor.

Scott Bossong: Packaging designed for children has to be safe and extremely user-friendly. For example, rigid packaging designed for children should always feature rounded edges to prevent cuts that could result from sharp straight edges. Also, making a package easy to open and reclose for children can prove challenging, as they may not be at the development stage to fully close a zipper or secure a lid tightly onto a tub. Additionally, processors should avoid using oxygen scavenging sachets in a package meant for children to avoid the risk of accidental ingestion. If a product is highly oxygen-sensitive, processors can consider incorporating oxygen scavenging film into their packaging solution.

PJ Corcoran: The criteria for unitizing containers from the club stores imposes both limitations and opportunities on the package design and raw material choice for these containers for dairy food processors. There are three key elements to keep in mind. First, the secondary packaging may need to be handled separately in production; [this] could add cost and complications for production. The secondary packaging typically must be robust in order to keep the pack intact, hence another increase in cost. In addition, all dairy food processors need to be extremely careful that all the products in the pack have the same expiration dates, so the products can remain in the store for sale. If not, loss of revenue could be incurred.

Meet the Panel

Dairy Foods: What color trends do you see in dairy foods packaging? Do the colors depend upon the product (that is, milk, cheese, yogurt, ice cream, etc.)?

Scott Bossong, marketing director of dairy packaging, Sealed Air’s Cryovac Food Packaging, Duncan, S.C. PJ Corcoran, director of DPET sheet, Octal, Muscat, Oman Erin Reynolds, senior marketing manager, dairy, Evergreen Packaging, Memphis Michelle Schmitt, container marketing supervisor, Berry Plastics, Evansville, Ind.

Reynolds: Children live in a world of multi-colored, bold, entertaining packaging. [We advocate] the use of full-color graphics and interesting content on milk cartons as a way to effectively engage children and encourage them to become lifelong milk consumers. Michelle Schmitt: Dairy artwork seems to follow the ingredients for the health-conscious consumer: pure and simple. Continued on page 80

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Packaging Technology European Supplier Showed Yogurt Cup at Pack Expo At Pack Expo in September, Paccor demonstrated a new application of its most popular packaging, DuoSmart. It was used with a PLA cup developed for Danone’s Activia yogurt. The packaging is made up of a plastic cup and a detachable cardboard sleeve. DuoSmart is said to contain less plastic with a “zipper” option; the inner cup and sleeve are easily separated to different waste streams. Paccor also showed its technologies for high-barrier packaging. Intended to block humidity and oxygen, the multilayer material helps extend the preservation of products by up to 24 months, the company states. Its offerings include cups combining plastic and paper, containers, lids, trays and coextruded sheets for food and non-food applications. For more information, visit www.paccor.com

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Dairy Foods: Describe any special effects you are creating on packages through the use of coatings, foils, holographic films, etc. Schmitt: [Our] indirect flexographic printing offers photographic quality that cannot be achieved with offset print. Details of light-colored food, water droplets and blended colors come to life with this CMYK process print applied directly to the container. This technology is more cost effective than pressure-sensitive labels or shrink sleeves. Opaque printing on clear containers prevents contents from affecting artwork. Bossong: [Our] printing capabilities allow for specialized flood printing that can give films the look of a metalized bag or parchment paper. These printing options can give cheeses a high-end or premium look, while providing the protection and performance of a barrier bag or rollstock. Dairy Foods: Share some examples of the best packaging of dairy foods from your company in the last year. Describe the processor’s requirements and how your company fulfilled them. Reynolds: Processors are looking for consumer-preferred packaging. [Evergreen Packaging’s] Fresh-Look cartons deliver on that expectation. The Fresh-Look carton is a new paperboard package with a window that allows customers to preview the product inside when shopping, as well as gauge how

Packaging Technology much is left so they know when it’s time to buy more. In market research, consumers gave paper cartons with windows an overall “A” or “outstanding” rating. Consumers believe a carton with windows will be superior to current packaging options at providing key benefits such as making the product inside more appealing, allowing them to easily see how much is left inside and use of renewable resources.

[and critique] the concepts, providing us with immediate feedback to give them what they desire. This radically reduces design lead-time. We can turn around prototype models within hours on our in-house prototype system. The result: very creative, feasible and cost-effective concepts.

Corcoran: Even though crowdsourcing seems like a great tool for collaboration, at this point crowdsourcing has not been used by the Octal staff to assist with rigid packaging design/manufacturing. In the past several years, Octal’s staff has been asked to collaborate with processors/designers with many rigid packaging Continued on page 82

Dairy Foods: Describe how your company collaborates with the processor and the package designer on rigid packaging. Have you participated in a crowdsourcing program involving package design? Schmitt: Our design center is fully staffed with industrial designers solely dedicated to package and consumer product creativity. We can work side by side with our customer via on-site ideation meetings. Designers communicate their imagination and concepts through hand sketching and 3D computer modeling based off the customer’s project brief/idea. Customers witness the package concepts coming to life  The Fresh-Look carton from Evergreen Packaging is a paperboard package with a window, which allows a shopper to preview the product. At home, consumers can see how much remains, so they know when it’s time to buy more.

Just as fresh as your product: fillling technology from krones. www.krones.com

Packaging Technology A New Package for a New Beverage Dole Packaged Foods needed a container for its new make-athome yogurt smoothie beverage. Dole’s Fruit Smoothie Shakers are made with frozen fruit and yogurt. A big complaint consumers have about making smoothies at home is the need for a blender, says Paul Panza, director of marketing, based in Westlake Village, Calif. Dole’s found the solution in the packaging: consumers unscrew the cap, add about 7 ounces of juice to the fill line, re-apply the cap and shake for about 30-45 seconds. The bottle is made of high-density polyethylene and has a full-body PVC shrink sleeve. Panza says the package had to be designed in a way to easily break up the fruit and yogurt pieces inside the container when consumers add the juice. A flat surface at the top and bottom was needed, as well as sides that would not restrict movement of the product inside. Dole worked with blow-mold equipment maker Rocheleau Tools & Die Co., Fitchburg, Mass., to create various designs. Dole’s marketing and production teams balanced manufacturing concerns with consumer acceptability issues. Prototype designs were tested with consumers in focus groups to find the best shape that was easy for consumers to grasp and hold on to during shaking. Dole blowmolds the bottles at its Stockton, Calif., processing plant. The smoothies are available in three flavors: strawberry, strawberry banana and mixed berry. The beverages, with a suggested retail price of $2.19, contain low-fat yogurt with live and active cultures and prebiotics and probiotics. They will be available nationally by the first quarter of 2012. –Jim Carper, editor in chief For more information about Rocheleau, visit www.rocheleautool.com.

weight- and cost-reduction initiatives without losing a high aesthetic appeal. The first step we typically take is to pass along our frequently updated product specification sheets. Next, through open discussion and close collaboration, we strive to understand the exact requirements of the particular package they are redesigning. The collaborative dialogue helps our company provide them with a PET sheet product, which is tailor-made for their pertinent needs and demands, all at a cost-effective price. Lastly, we ensure that the correct processing of the sheet accomplishes their goals for weight and cost reduction.

 Berry Plastics says its flexographic printing offers photographic quality that cannot be achieved with other methods. The CMYK process print applied directly to the container brings foods to life, the company states. Bossong: We’re seeing global trends towards convenience and sustainability. Consumers are busier than ever and require products that simplify steps of consumption. Packaging can play to this trend with reclosable and easy-open formats. Our semi-rigid Multi-Seal package allows the consumer to have these benefits while also reducing packaging materials compared to many rigid reclosable formats. Globally, consumers are beginning to value packages that will leave less of a carbon footprint and provide long-term sustainability. Schmitt: IML labeling [in-mold labeling] continues to grow in the United States. Many customers are asking for customlooking stock packages. The Quad Series offers a film-sealable, 409-diameter tub with a non-round base. This package fits in existing filling lines and offers 180-degree decoration as well as a base label. Berry Plastics will also offer a new stock Greek yogurt package [in the fourth quarter]. This package will have a 95-millimeter diameter and will hold 5.3 ounces of Greek yogurt. It can be decorated with shrink sleeves or printed. Corcoran: We see two mega-trends. The first includes a major push to reduce carbon footprint and for companies to have a sustainable solution for their dairy foods packaging. As a result, there is a clear move away from polystyrene and towards PET as a primary packaging material in the dairy sector. The move is driven by recyclability, environmentally friendliness, flavor tainting, barrier performance and the price of PET material, compared to alternative options. The second trend is many traditional single-serve thermoformed items are moving to a form/fill/seal packaging solution. The move is driven by hygiene, speed, shelf life and cost considerations. In addition, these innovations in barrier films, sealing technologies, product automation and handling are helping to move the consumers to products with extended shelf life, hence improving their experience with the food and its packaging.  Moderated by Jim Carper, editor in chief. Responses were provided by e-mail and edited. Share your thoughts about the direction of rigid packaging or add your comments to this article at www.dairyfoods.com.

EXTRAS Berry Plastics ................................................. www.berryplastics.com Evergreen Packaging .....................www.evergreenpackaging.com

Dairy Foods: What are the mega-trends affecting the packaging of dairy foods? What is happening now in Europe, Asia or Oceania that might show up in the United States? 82

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Octal ...............................................................................www.octal.com Sealed Air Corp.’s Cryovac .................................. www.cryovac.com

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Processing & Operations Quality on the Line

Is HACCP Enough to Keep Your Plant Out of the Headlines? o one wants to wake up to food safety headlines about their plant. But in the past years, food manufacturers and American consumers alike have faced front-page recalls for produce, meat, nuts, peanut butter, cookie dough and even dairy products. It is not surprising that consumer confidence in the overall safety of the food supply has dropped dramatically as a result of recent recalls. Food safety is in the news and a hot topic of discussion at most industry forums. The dairy industry has done an excellent job of producing safe products for many years by following the regulations of the Pasteurized Milk Ordinance (PMO).

N

However, dairy products have become a part of the national and global food supply. Hazard Analysis Critical Control Points (HACCP) is recognized as an alternate program under the PMO and is an integral part of the Global Food Safety Institute-recognized food-safety certification programs. HACCP is a global standard for food safety. Developed by Pillsbury in the 1960s and regulated in the United States under 21 CFR 120 and 123, HACCP is an integral part of the GFSI certification programs. Many of the facilities that have produced and distributed tainted food in recent years have had HACCP programs in place. Did HACCP fail? What can the food industry do to reverse these disturbing trends?

The Seven Principles of HACCP 1. Hazard analysis: Potential biological, chemical and physical hazards must be evaluated for each ingredient and at each step of the manufacturing process.

4. Establish monitoring requirements: Used to assess whether the critical limits are met and to establish records for verification.

2. Identify critical control points: Those points in the process where control can be applied to eliminate or reduce an identified hazard to an acceptable level.

5: Establish corrective actions: The actions taken to bring a CCP back under control and the steps taken to prevent further contamination of the product as well as the steps taken to prevent the distribution of potentially contaminated product.

3. Establish critical limits: Defined as the maximum or minimum parameter that must be met to eliminate or reduce the hazard to an acceptable limit.

6: Establish verification procedures: Verification assures the plan is effectively implemented and followed. 7: Establish record keeping and documentation procedures: Includes record retention of types of records kept such as the hazard analysis, the HACCP plan, support documentation and operational records.

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Henry Randolph

Is pending congressional legislation the solution? Even if the Food and Drug Administration and U.S. Department of Agriculture receive more funding, the responsibility for overseeing more than 40,000 food manufacturers and producers in the United States alone is overwhelming. Regulations alone will not do the job. Dairy and food processors must assume this responsibility. Processes must be evaluated and parameters established to ensure safe, quality foods. A HACCP program is a natural for this type of self analysis. Based on risk assessment, HACCP maintains tight control over highly perishable foods in place of the traditional “hold, test and release” approach. In retrospect, it has been prerequisite program failures rather than HACCP failures that have produced tainted food. A HACCP plan must be built on a foundation of sanitation standard operating procedures and prerequisite programs that include the following: • Buildings and equipment maintenance • Effective cleaning and sanitation programs • Safe water, steam and ice • Effective pest-control programs • Control of toxic materials • Employee training • Adherence to Good Manufacturing Practices Are you maintaining these SOPs and prerequisites as well as your HACCP plan? HACCP works, but only when these fundamentals are faithfully maintained. It is widely recognized as the global standard for food safety. Henry E. Randolph is the founder of Randolph Associates, Inc., which advises dairy processors about improving quality and operations. This article originally appeared in the October 2009 Dairy Foods.

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New Product Showcase

Warehouse Automation GEA Procomac launched Fluens 2000, a low in-feed, non-robotized palletizer that is capable of continuous operation at a rate of more than eight layers a minute. Using newly patented technology, the Fluens 2000 achieves high productivity with less stress on the key mechanical components, thereby keeping maintenance costs down and reducing the chances of unscheduled downtime. The design also reduces the costs of the conveyor system and maintains a small footprint. GEA Procomac S.p.A. + 39 0521 839411 www.procomac.com

RMT Robotics RMT Robotics introduced a case-and-crate picking solution designed to reduce the footprint of standard pick modules, pick in exact customer sequences and provide complete traceability of products. Using an advanced automated controls system, cases or crates will be delivered in exactly the desired pallet-build sequence for automated mixed palletizing at the dock. The robotic gantry-based solutions also have limitless layout options, can operate in chill stores set at – 20°C and can handle a large variety of products. RMT Robotics, a Cimcorp Oy company 905-643-9700 www.rmtrobotics.com Intelligrated released new zone control upgrade features to the Intelligrated Accuglide and IntelliQ powered roller accumulation case conveyors. Both conveyors provide quiet, positive transportation and true zero-pressure accumulation for rapid, virtually damage-free handling of a broad range of products. Zone control upgrades include enhanced sleep mode to reduce noise, energy usage and equipment wear; jam detection logic to identify flow interruptions and command zone shutdowns; photo-eye visibility to eliminate cost of additional sys-

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tem-level eyes; visible status lights, device and system-level diagnostics to streamline maintenance; and an on-board independent logic controller that stores commands to reduce programming requirements and central computer communication. Intelligrated 877-315-3400 www.intelligrated.com Schneider Packaging Equipment’s Pack/Pal case packer/ palletizer is designed for complete case packing and palletizing in minimal floor space or low ceiling environments. Equipped with a FANUC long-arm robot, this integrated case packer/palletizer automatically transfers pallets into position at floor level, eliminating pallet conveying and building full-height pallets. Pallets move out of the system at floor level, where they can be removed by a standard pallet jack or fork truck. Schneider Packaging Equipment 315-676-3035 www.schneiderequip.com Westfalia Deam installed its newly designed compact case stack depalletizing system for automatic empty case handling at Northumberland Dairies, Canada. Westfalia Deam’s empty case handling solution includes a case stack depalletizer, stack conveyors with 3:1 merging, a bottom-out destacker and wheel drives designed to transfer cases overhead to a new case washer. Westfalia Deam Systems 800-673-2522 www.westfaliausa.com ToolBox is a world market leader for high-performance manufacturing and intralogistics systems. Today, more than 600 plants in 30-plus countries around the world rely on dispoTool, a warehouse and production management system, every day. The new warehouse management supports online stock handling, placing and releasing stock and picking. ToolBox Software North America Inc. 800-488-1741 www.toolbox-software.com Dynamic Conveyor unveiled the DynaClean conveyor system, which is easy to clean and offers flexibility in configuration and reconfiguration not possible with traditional stainless steel conveyors. DynaClean conveyors are built to meet NSF, FDA, USDA and BISCC standards and can be custom designed, configured and reconfigured to include horizontal and multiple angle options. Dynamic Conveyor Corp. 800-640-6850 www.dynamicconveyor.com

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

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Buyers Mart

PLANT EQUIPMENT Buchi

Buchi introduces the NIRMaster, a standalone FT-NIR spectrometer. Its unique polarization interferometer offers high sensitivity, ensuring accurate and reliable results. It also includes a built-in PC, ready-to-use calibrations and an internal laser reference, eliminating the need for frequent and expensive instrument standardizations. Buchi Corp. 302-652-3000 www.mybuchi.com Clear Lam’s Peel and ReSeal technology features a reclosable tray and lid system for added convenience and lightweighting of cheese products. The easy-to-use lidding film eliminates the need for rigid lids and shrink bands, making the package easier to assemble. Clear Lam Engineered Packaging Solutions 847-439-8570 www.clearlam.com Foss

Foss released MilkoScan FT1, a milk analyzer designed for standardizing milk arriving at the dairy. A new intuitive software interface 88

Dairy Foods | October 2011

is said to make it easy to perform the fast and accurate milk analysis required for effective milk standardization. Foss 952-974-9892 www.foss.dk Parker Balston offers compressed air filters that are said to remove 99.9999+% microns of oil, water, rust, bacteria and other viable organisms from compressed air and other gases. These stainless-steel filters are said to be at least 30 times better than the accepted standard for sterile air filters, and come in ¼- to 1-inch line sizes with flow capacities of more than 700 SCFM. Parker Hannifin Corp., Filtration & Separation Division 800-343-4048 www.balstonfilters.com

Using water “polishing” techniques from GEA Filtration helps recycle the process water for cleaning purposes, or even to return it to the process, creating a plant self-sufficient in water. The “white water” is collected and treated using reverse osmosis, allowing the solids recovered to be returned to the process. GEA Filtration 715-386-9371 www.geafiltration.com Gamajet

Omega

The OMDC-MD series from Omega Engineering is a compact programmable DC speed control with digital closed-loop feedback and LED display. It features adjustable minimum/maximum speeds and acceleration/ deceleration, as well as display options such as decimal point positions and intensity. Its non-volatile memory provides programmable power-on initial settings and allows all custom settings to be stored for future use. Omega Engineering Inc. 203-359-1660 www.omega.com Nansulate Translucent GP insulation and mold resistant coating by Industrial Nanotech was created for insulation of food processing equipment to reduce energy costs. It cleanly insulates with a moisture-, mold- and corrosion-resistant formula that also reduces heat transfer to lower energy demand. This clear coating is waterbased, non-toxic, low odor and low voc, and insulates surfaces up to 256°F. Industrial Nanotech Inc. 800-767-3998 www.industrial-nanotech.com

Gamajet Cleaning Systems releases the Intrepid, a low-flow, full-coverage rinsing machine that offers fast, validated tank rinsing using 80% less water than the standard spray ball at the same pressure. This type of cleaning is ideal for cleaning light liquids and powders. The Intrepid utilizes a unique “directdrive” design, requiring no gear reduction. The average operating conditions are between 10-80 psi and 5-20 gallons per minute. Gamajet Cleaning Systems Inc. 610-408-9940 www.gamajet.com Fortress Technology introduced the Stealth metal detector, which offers full backwards compatibility, ensuring spare parts and upgrades are readily available for existing systems. Other features include digital signal processing technology, which provides high-speed precision detection, while ultra-sensitivity levels detect the smallest metal contaminants. Meanwhile, automatic testing and calibration allow for simple operation, and the true auto-balance enables recovery from large metal contaminants to avoid detector “blindness.” Fortress Technology 888-220-8737 www.fortresstechnology.com

Buyers Mart

the transfer of curd with little damage, producing a higher yield and fat content while reducing fines. Undamaged curd requires less dressing, reduces fines and prevents plugs in the drain table, resulting in less downtime and higher productivity. MasoSine 800-282-8823 www.masosine.com

Intelligrated

Intelligrated launched ShipSort and PackSort applications, as part of its InControlWare warehouse control software suite. Designed to manage high-speed tilt-tray and cross-belt sortation systems, this software combines advanced sortation functions with comprehensive warehouse control. ShipSort provides comprehensive routing and controls management for shipping sorter applications. PackSort is designed for order fulfillment applications, including returns, direct-toconsumer and packing operations with full support of pre-allocated or supply and demand item allocations. Intelligrated 877-315-3400 www.intelligrated.com

Roberts PolyPro introRoberts PolyPro duces a single-station multipack bottle handle applicator that’s specifically designed for lowest total cost of ownership, highest versatility and simplest operation. Available in automatic or semi-automatic configurations, the new applicator efficiently applies HDPE carrying handles to 4-, 6-, 12- and 24-unit cases for most common bottle and jug sizes and material compositions. In automatic operation, this multi-pack applicator can run for 45 minutes on average without handle-loading intervention. Roberts PolyPro 800-269-7409 www.robertspolypro.com Continued on page 90

Meyer & Sons The Klean-In-Place rotary airlock feeder from Meyer & Sons is a special-purpose valve suited for dairy plants. No tools are required to remove the head plate, which is attached to the valve housing with easily unscrewed release handles. The four-slide bar supports, using linear bearings, provide maximum support of the rotor while it’s pulled out, allowing for the valve to be thoroughly cleaned, sanitized and inspected. The unique design incorporates a built-in device that automatically re-establishes the close dimensional tolerances between the rotor and housing and a safety interlock switch. Wm. W. Meyer & Sons, Inc. 847-918-0111 www.wmwmeyer.com MasoSine’s sine pump technology is said to produce powerful suction with low shear and no pulsation. Large, open cavities allow

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89

Buyers Mart

R&D INGREDIENTS

90

Chr. Hansen introduces a series of FruitMax solutions developed specifically for applications in the American food and beverage industries. The FruitMax range includes seven shades from red to violet, and are all processed from edible, natural sources such as fruits, vegetables, herbs and spices, allowing food manufacturers to label ingredients as “color: fruit and/or vegetable concentrates.” Chr. Hansen Inc. 800-558-0802 www.chr-hansen.com

DSM Nutritional Products launches allergen-free ␤-carotene 10% emulsion red for improved performance in food and beverage applications. At low concentrations, this ␤-carotene offers pinkish pastel shades, which become a strawberry red color at higher dosage rate. It’s also process stable, delivers excellent color stability and provides superior resistance to ringing in beverage applications. DSM Nutritional Products 41 (0) 61 815 83 54 www.dsm.com

Autocrat now offers premium tea extracts in black, green and black and green combination flavors. These are ideal for ready-to-drink beverages, smoothies, protein bars and more. Autocrat Inc. 800-288-6272 www.autocrat.com

Wild Flavors commercialized a full line of taste modifiers and sweetness enhancers for use with stevia extracts. Along with the ability to label these modifiers and enhancers as “natural flavors,” this portfolio of solutions also allows for a reduction of up to 30% of nutrient sweeteners, thus reducing costs while still delivering great-

Dairy Foods | October 2011

tasting products. Wild Flavors Inc. 859-342-3600 www.wildflavors.com Utilizing a proprietary process, Z Trim from Z Trim Ingredients is created from either oat hull or corn bran to create powdered cellulose, yet still deliver smooth mouthfeel, easy dispersability and flavor neutrality. Z Trim enables formulators to replace more costly ingredients such as soybean oil or dairy solids. For example, Z Trim blended with skim milk replaced 30% of the cream cheese in a cheesecake formulation, while maintaining a smooth, creamy mouthfeel and texture. Z Trim also improves the nutrition profile as well, in this instance, cutting out 25% of the fat content. Z Trim Ingredients 847-549-6002 www.ztrim.com

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EQUIPMENT FOR SALE

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Dairy Foods | October 2011

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

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95

EMPLOYMENT

Judge INC is an industry-leading recruiting ¿rm specializing in food and beverage manufacturing for over 40 years. Contingency or Retained Search: Mfg./Operations/Plant Mgmt. Engineering & Maintenance Production/Maint. Supervision/Mgmt. Quality and R&D (plant and HQ) To submit your résumé or engage searches, please contact: Tina Gannon ƒ Vice President, Judge INC Ft. Myers Of¿ce ƒ (239) 332-0931 [email protected]

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Small dairy in the HUDSON VALLEY in need of a plant manager familiar with all aspects of dairy product production, including milk, butter, yogurt and other cultured dairy products. Salary and benefit package negotiable. 518-821-9438

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EXCEEDING EXPECTATIONS AS YOUR SEARCH PARTNER Our mission is to earn the privilege of becoming our client’s exclusive recruitment resource for key search activity. We do this by LISTENING to our clients needs to develop an understanding of the ideal candidate. We FOLLOW-UP throughout the entire recruitment process with conscientiousness and a respectful sense of urgency. We reliably DELIVER freshly recruited, qualified and interested candidates to fill our client’s positions. Our pursuit of excellence and our dedication to the Food Processing Industry, has earned our firm a reputation we are proud to have, and one that you can trust. To learn how your business can benefit from our extensive industry knowledge and experience, contact us today.

HENSON PARTNERS, INC. Phone / Fax: 866-898-9911 Web: http://www.hensonpartners.com

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96

Dairy Foods | October 2011

IDI, Inc. National Sales Manager IDI, Inc., a U.S. subsidiary of Ingredia based in France, is seeking a National Sales Manager for the U.S. market. IDI, Inc. is an international company based in Wapakoneta, Ohio that specializes in the processing, sales, and marketing of functional and nutritional dairy ingredients. Objectives include: • Actively develop sales in the U.S. market, • Identify new opportunities and make prospecting calls, • Able to purchase RM efficiently if required for our blend, • Document contact activity related to customer transactions accurately, timely, and completely, • Develop a sales plan and conduct, within budget, sales promotion activities to existing and prospective customers, • Propose ideas for new product development, • Resolve customer service problems to the mutual satisfaction of both the customer and the company, • Provide sales and market analysis, • Represent IDI, Inc. at regional and national trade shows. The ideal candidate will have at least five to seven years of sales and/or purchasing experience in the dairy ingredients industry in the U.S., has already existing and tight connections in order to sell and also rapidly purchase dairy raw materials and ingredients, must be willing to travel frequently, possess a degree in food technology/science, will have the ability to develop and maintain relationships with purchasing and R&D contacts, can work independently within guidelines, must be sales oriented and a good listener, and must be able to overcome objections within the sales process. IDI, Inc. offers an attractive benefits package for this challenging position. Please forward resume in confidence to: Carla Bonifas Human Resources Administrator [email protected]

Ad Index

Company Name

Page No.

Company Name

Page No.

Company Name

Page No.

ADM Cocoa ................................................ 29

GEA Niro Soavi NA .................................... 73

Pecan Deluxe Candy Company .............. 62

Admix, Inc. ..................................................... 14

GEA Tuchenhagen North America ........ 65

Powder Solutions...........................................6

Ajinomoto Food Ingredients LLC. ........... 58

Gelita .............................................................. 12

Relco .............................................................. 20

Amelia Bay, Inc. ........................................... 21

Gram Equipment ......................................... 80

Robert Reiser & Co. ............................45, 79

Ampco Pumps Co. ..................................... 42

Great Lakes Separators ............................ 44

Robertet Flavors, Inc. ................................. 23

Anderson Instrument Company Inc. ...... 51

H.S. Crocker Company, Inc. .................... 69

Seiberling & Associates ............................ 61

Bentley Instruments .......................................8

Heat and Control......................................... 87

Separators, Inc............................................. 66

Big-D Construction .......................................9

Huhtamaki ................................................... IFC

SPX Flow Technology Segment ...........IBC

Blommer Chocolate Company................ 31

International Dairy Foods Association...... 92

Blue Print Automation ................................ 61

iTi Tropicals ............................................16, 90

Cargill Salt..................................................... 49

Karl Schnell USA......................................... 64

Chr. Hansen, Inc. ............................................3

KRONES ...................................................... 81

CP Kelco ...................................................... 27

MasoSine ...................................................... 19

Danisco USA Inc......................................... 37

Mettler-Toledo ............................................. 46

Donaldson Company, Inc.......................... 40

MilkPEP ......................................................... 67

DSM Food Specialties .............................. 47

Mintel International...................................... 97

Flow Products, LLC .................................... 44

Nelson-Jameson, Inc. ................................. 64

Fortitech, Inc. ................................................ 33

Neogen .......................................................... 85

FOSS North America ...................................4

Novozymes.................................................... 35

Framarx/Waxstar ......................................... 20

Paul Mueller Company .................................6

Sudmo North America, Inc. ...................... 57 T.D. Sawvel Co. Inc. ................................... 18 Tate & Lyle ..............................................15, 17 Tauber-Arons Inc. ........................................ 89 Tetra Pak ........................................................ 63 *Tetra Pak Hoyer..................................10 A-B Tindall Packaging, Inc. ............................... 83 Tricore................................................................7 Urschel Laboratories, Inc. ......................... 41 Virginia Dare ................................................BC Weber Scientific.......................................... 13 Westfalia Technologies Inc....................... 43 *Indicates Regional Advertising

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

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97

Inside Perspective

We Talk To, Not At, Women t Alpina Foods, we believe that innovation and change should exist across all consumer touchpoints. Just look at how Alpina developed and marketed its new yogurt in the United States, and you will find innovation at every step of the way. The U.S. yogurt market is full of great brands, but it is dominated by sameness. To stand out, we needed a unique approach. Therefore, we partnered with renowned industry experts, including management consultants the Zyman Group, ad agencies Universal McCann and Brandiosity, and marketing specialist Dr. Clotaire Rapaille, in order to craft our strategy and identify a powerful insight that would resonate with American consumers.

A

 Alpina Foods used butterflies in a marketing campaign for its Restart yogurt. This butterfly is made with the quilling technique. Rapaille, a psychiatrist, anthropologist and marketing guru, was essential in helping us to adopt a uniquely revolutionary approach. With his assistance, we explored the ways in which the human brain influences everyday buying decisions. This led us to a poignant insight: Women constantly struggle to become their “ideal selves,” to look and act like they wish they would. This becomes a cycle of near-successes followed by disappointing lapses. To support women in all stages of this cycle, we launched Restart, a 0%-fat yogurt paired with low-fat crunchy granola. Restart provides women with a healthy yogurt that is rich in protein, calcium and fiber, yet is still tempting and indulgent due to its slow-baked granola and chef-made fruit marmalades. 98

Dairy Foods | October 2011

Carlos Ramirez

Whether women are succeeding or slipping in their efforts, Alpina empowers them to “Restart” with a tasty, better-for-you solution. We know that women are busy juggling their professional and family lives, so we made Restart perfectly convenient for wholesome, on-the-go nutrition. With our product defined, our next step was to introduce Restart to an audience that had been force-fed the marketing hype of other yogurt brands for so long. This was not an easy task. So, we made our insight the centerpiece of our campaign. In doing so, we remind women that “Every Day is A New Day” to achieve their goals. We focused on inspiring them to become their better selves with no judgments along the way. We had to execute our campaign on a limited budget, certainly nothing compared to what the larger brands were spending. Still, we launched a 360-degree marketing campaign, which included street sampling teams, out-of-home advertising, point-of-sale support and a social media program called “Wish for Women.” Making wishes and donations Through this program, we asked consumers to share their wish for women, be it for a friend, a family member or for womankind. We partnered with Women in Need (WIN), an organization dedicated to providing shelter and food to homeless women and children in New York. For every wish, we made a donation to WIN, helping more women to get back on their feet. To draw attention to our campaign and to Restart, we built a butterfly habitat in a storefront on Park Avenue in the heart of New York City. Even jaded New Yorkers were impressed and had to stop and stare. Hundreds of monarch butterflies fluttered in our butterfly habitat, a temperature-controlled environment complete with plants, flowers and a misting system. We embellished our storefront with beautiful branded quilling art (strips of paper that were rolled, shaped and glued together) and built a digital mirror with a silhouette recognition system. The mirror identified passersby, so virtual butterflies could “land” on them while they watched. Three seconds later, a photo was taken. People could obtain and share their picture directly on Facebook or Twitter. (For more information, see our website, www.alpina.com, and Facebook page www.facebook.com/alpinausa.) The response to this campaign was fantastic. Our results exceeded expectations, and 20,000 New Yorkers stopped to sample Restart. We collected more than 400 wishes for women. New stores requested to carry our product. With such innovative strategies and an outsidethe-box mindset, Alpina’s future is certain to be deliciously bright.  Carlos Ramirez is the general manager for Alpina Foods, Miami. Based in Bogota, Colombia, Alpina is building a yogurt processing facility in Batavia, N.Y. Dairy Foods seeks essay from dairy processors. Contact carperj@ dairyfoods.com.

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