Dairy Foods June 2011

TRENDS IN NATURAL, ORGANIC | FAGE USA | CULTURES & ENZYMES

June 2011

Innovative Ideas for Dairy Processors

Packaging that

Shows and Sells www.dairyfoods.com

4VYL:OHWLZ 4VYL:PaLZ .YLH[LY-SL_PIPSP[`

6UL4HJOPUL—Huhtamaki Systems

™

FM-4000

The only package forming machine with quick-change capability. If you’re not forming your paperboard packaging in your plant, Huhtamaki’s FM-4000 system gives you plenty of reasons to start. Consider its flexibility. In as short as a shift change, you can switch the size and shape of your packaging. For meeting changing market demands, this fast flexibility is key to optimizing plant production. And because your pre-printed Huhtamaki packaging is shipped flat, transportation, warehousing and handling costs can all be reduced. The FM-4000: packed with so many possibilities.

To find out more, call Penny Staats at 800.255.4243.

:LL[OL5,>-4PUHJ[PVUH[ ^^^PUWSHU[MVYTPUNJVT

CHY-MAX M ®

The best now better The most specific coagulant available with benefits including; t
)JHIFTU
CFOFmUJOVTF t

)JHIFS
ZJFME
UIBU
EFMJWFST
QSPmU t
#FUUFS
nBWPS
XJUI
MFTT
CJUUFSOFTT t
)JHIFTU
XIFZ
WBMVF t
-POHFS
TIFMG
MJGF
GPS
TPNF
DIFFTF
UZQFT t
)JHI
QVSJUZ
XJUI
OP
TJEFBDUJWJUJFT t

#FUUFS
QSPDFTT
DPOUSPM


$IS
)BOTFO
*OD


8FTU
.BQMF
4USFFU

.JMXBVLFF
8*

5PMM
GSFF
 XXXDISIBOTFODPN

June 2011 Vol. 112, No. 6

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

Show & Sell: Dairy Packaging Dairy processors expect an awful lot from packaging. It must protect the product, carry ingredient statements and nutritional information, fit on retailers’ shelves and inside consumers’ refrigerators, and be attractive and recyclable. p. 36

Trends in Natural, Organic Foods On our cover: Fat makes food taste good. A pat of butter on a muffin or on a stack of pancakes boosts the flavor of those treats. Butter has a short ingredient statement: sweet cream and salt (but the latter is optional). Butter can be considered a natural and an organic food. Read more about these categories on page 44. And don’t miss our other features about packaging (page 36), tradeshows (pages 50 and 52) and Greek yogurt maker Fage USA (page 55).

Dairy processors respond to shoppers’ interest in where and how foods are produced by developing natural and organic products. p. 44

Dairy Show Previews The International Dairy Foods Association moves its International Dairy Show to Atlanta in September. Anuga sets up shop in Cologne, Germany, in October. p. 50 and 52

Features News & Trends 10 Newsline Students learn dairy processing; IDFA supports trade pacts; Alpina opens U.S. plant

Products & Marketing 20 Dairy Market Trends

26

Orange juice squeezes the competition

22

Departments 8 15 17 76 78 80 85 86

Ingredient Technology

New Product Review Dove, Magnum and other ice cream novelties

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

30

34

Cultured Dairy

REPORTS

Acidulants, cultures and enzymes

55

Fage USA Dairy Industry

Wellness Watch

64

Behind The Scenes

Aging gracefully with dairy foods

66

Sustainable Packaging

Dairy & Nutrition

72

Global Insights

Dairy has the total nutrient package

74

Quality on the Line

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.

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

www.dairyfoods.com

5

June 2011 Vol. 112, No. 6 www.dairyfoods.com A Publication of BNP Media II, L.L.C. Editorial and sales offices 155 N. Pfingsten Road, Suite 205 Deerfield, IL 60015 Phone: 847-405-4000 • Fax: 847-405-4100 Publisher Thomas S. Imbordino 773-755-8990; 248-502-2093 (fax) [email protected] Editorial Chief Editor Jim Carper 847-405-4009; [email protected] Executive Editor Marina Mayer 847-405-4008; [email protected] Product Development Editor Donna Berry Art & Production Art Director Lindsay Leusby Production Manager Lisa Webb [email protected] Sales Amy Vodraska 973-970-9000 [email protected] Wayne Wiggins Jr. 415-387-7784 [email protected] Catherine Wynn 847-405-4010 [email protected] Gabriele Fahlbusch 49-(0)202-271690-15 [email protected] Classifieds Suzanne Sarkesian 248-786-1692 [email protected] Marketing Marketing Manager Elizabeth Wright [email protected] Editorial Reprints Jill DeVries 248-244-1726; [email protected] BNP Custom Media Group Christopher Wilson 248-244-8264; [email protected] List Rental Postal: Senior Account Executive Kevin Collopy 800-223-2194 x.684; [email protected] Email: Senior Account Executive Michael Costantino 800-223-2194 x.748; [email protected] Audience Development Audience Development Manager Kourtney Genereaux Multimedia Specialist Katie Jabour Audience Audit Coordinator Carolyn M. Alexander For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected]

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

6

Dairy Foods | June 2011

We Stand Behind Our Results Choose Neogen

Try Neogen develops and offers an array of rapid and simple food safety tests for the dairy industry. Beta-lactam Testing BetaStar® Plus is used to detect beta-lactam am antibiotic residues, including amoxicillin, ampicillin, cephapirin, cloxacillin, penicillin and ceftiofur in raw, commingled cow milk.

on us!*

s Clear detection of ceftiofur residue s Simple-to-use format s Proven technology

Also ask about Food Allergens Microbial Detection Sanitation Monitoring

Deteect beeta-laactaam antiibiioticc resiiduees inn 5 minuttes

Learn more about BetaStar Plus on your smartphone

* Call today to schedule your free evaluation of BetaStar Plus 800/234-5333 (USA/Canada) or 517/372-9200 FOODSAFETY NEOGENCOMswww.neogen.com

From the Editor’s Desk

Dining on Dairy eing in the media, I consume a lot of media: newspapers, magazines, television, radio, websites and billboards. And being editor of this magazine, I’m particularly interested in the portrayal of food, especially dairy foods, in these media. This country really has a lot of hangups about what, how and when we eat. There is sensible advice to cut down on portions, reduce salt and sugar consumption, and don’t be distracted by food while driving. But some of television’s finest talking heads can beat news stories like a soufflé, whipping the public into a fear frenzy about food. Jaime Oliver made a splashy demonstration on his Food Revolution television show about the quantity of sugar added to chocolate milk that’s served to children in Los Angeles schools. He filled a school bus with sugar (sand, actually) and when it was full, he said even that quantity did not represent all the sugar. His point was that schools should not serve flavored milk to children because of the added sugar. I disagree with his position. (You can read my reasons in the October 2010 Dairy Foods, “Cafeteria Food Fight.”) I am waiting for another equally graphic demonstration in which Oliver fills a school bus with protein, calcium, vitamin D, riboflavin, phosphorus and other nutrients to demonstrate milk’s inherent healthfulness. Last month, The New York Times examined food marketers (including dairy processors) and their promotional claims related to the addition of functional ingredients. In “Foods With Benefits, or So They Say,” the Times asks, “Are all these products really healthy, or are some of them just hyped?” The newspaper acknowledges that “such claims are perfectly legal, provided that they are backed up by some credible science.” The food industry sees value in making these claims, and in the United States, they make claims until they are told by regulatory agencies to stop. Last December, the

B

8

Dairy Foods | June 2011

Federal Trade Commission told Dannon to stop saying that its yogurt, dairy drinks and probiotic foods or drinks reduce the likelihood of getting a cold or the flu unless the Food and Drug Administration approves the claim. Dannon also agreed to stop saying its products can relieve temporary irregularity. It paid $21 million to resolve investigations by the state’s attorney general. Things are a little different in Europe where the European Food Safety Authority must sign off on applications submitted by food companies. Currently, an independent panel of experts has 2,700 claims to review, according to the Times. I was in flight on my way to visit a manufacturer of functional ingredients when I read “Snacks For A Fat Planet” about PepsiCo’s efforts to make healthier foods. Despite that provocative headline in the May 16th The New Yorker, it’s a fair look at the food giant’s strategies. CEO Indra Nooyi “wants to increase what she calls its ‘good for you’ products — snacks and drinks made of grains, fruit, nuts, vegetables and dairy” from $10 billion to $30 billion by 2020, according to the article. PepsiCo is out to “drinkify” snacks and “snackify” drinks. Tropolis, which is in test markets in the Midwest, is a fruit juice in squeezable form. PepsiCo will be selling a drinkable oatmeal beverage in Mexico and Brazil later this year. The beverage contains fruit juice, sugar and 8 grams of protein from skim milk. The June Cooking Light arrived in the mail, touting “25 Healthy Dishes for a Perfect Summer.” I was ready for plates of celery sticks, lemon juice-drenched salad greens and skinless chicken breasts. I was more than delighted to find dairy foods used as ingredients in 14 of the 25 recipes, including the first one — the chilled avocado soup with seared chipotle shrimp calls for ¾ cup of reduced-fat sour cream. Greek yogurt and buttermilk show up in salad dressings, and Greek yogurt appears again

Jim Carper

in a curried potato salad. Blue cheese is an ingredient in a mayonnaise spread on hamburgers; feta is found in salads. There’s a pizza with shredded fontina cheese, and yogurt in a curried chicken wrap. Even my good friend high-fat butter gets some love. For dessert, there’s 1% milk in a chocolate pudding pie and butter and reduced-fat ice cream in margarita ice cream sandwiches. Here at last was an adult conversation about eating. I think it is significant that a magazine that is all about promoting low-fat, low-calorie and low-sodium meals found a role for milk, cheese, ice cream, butter and cultured dairy foods. The magazine gives these foods a seat at the dining table without a scary warning or lecture about the dangers of consuming butter or ice cream. Elsewhere in that issue, Cooking Light offers a shrimp chowder with ⅓ cup heavy whipping cream, mashed potatoes with milk and sour cream, blackened catfish sandwiches with Greek yogurt, flank steak with Gorgonzola cheese and butter, shrimp korma with yogurt, and soufflés calling for butter, fat-free milk or buttermilk. Every recipe lists values for calories, fat, protein and other elements. There are no surprises. I don’t consider government dietary guidelines and research into food to be a nanny state intrusion. We need information to make informed choices. Americans have plenty of healthy options that embrace dairy foods. If we cook from scratch (allowing for some packaged foods) at home more often, reduce dining out, ditch some snacks and just walk every day, we’d be a whole lot healthier and a lot less scared about food. Rather than being whipped soufflé-like into a food-fear frenzy, we should sit down and enjoy a cheese soufflé with a side of milk and buttered toast. And ice cream for dessert.  Jim Carper is chief editor of Dairy Foods. Phone: 847-405-4009. Email: carperj@ dairyfoods.com.

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

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

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

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

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

News & Trends

NEWSLINE... Food Science Lab Brings Kids off the Streets and Into an Ice Cream Processor t City Kidz Food Science Educational Lab, there’s more to ice cream than meets the scoop. Whether it’s learning the behind-the-scenes production process, understanding food science and technology or working to put a product on national stores’ shelves, the lab provides more than just a typical classroom experience. The ultimate goal is to recruit talented students who can actually comprehend the subject matter of food science and food technology, says Pastor Clinton Bush, co-founder of City Kidz Ice Cream Café, director of the City Kidz Food Science Educational Lab and president of the Springfield Area Merchants and Business Association, Jacksonville, Fla. Students are encouraged to understand how chemistry, biology and calculus are used and applied to food science, whether it’s through research, engineering, formulation, product development, production, nutrition, manufacturing, packaging, biotechnology or computer software. The City Kidz Food Science Educational Lab National Initiative was created because most students in middle school and high school do not realize that food science and food technology careers exist, says Bush. In fact, from 2005-2010, the U.S. Department of Agriculture, Washington, D.C., reported that there is a shortage of students pursuing careers in food science and food technology industries, he adds. In that mix, African-Americans, Latinos and Native Americans are seriously underrepresented in this industry and at the post-secondary educational level. In an effort to address this problem, the USDA is offering multi-cultural grants to encourage African-Americans, Latinos and Native Americans to consider pursuing an education and career in food science and food technology.

A

10

Dairy Foods | June 2011

 Students conduct a sensory taste on national ice cream brands for flavor and texture. Recruitment The lab enforces an extensive strict recruiting process. Students must maintain a minimum 3.5 GPA, must be currently taking advanced placement (AP) or international baccalaureate (IP) honor courses and must complete all homework assignments. Additionally, students must write a 300-word or less essay explaining why they want to be in the program and must participate and complete all lab assignments. There are currently 21 students enrolled, with an average of 17 students per class. Sixty-five percent of the students attend Stanton College Preparatory School, also in Jacksonville, Fla. Classroom instruction and curriculum The City Kidz Food Science Educational Lab is run by college and university professors, as well as food industry professionals, such as ingredient and flavor suppliers, product development, food processing

equipment professionals, experts, researchers, co-packers, food manufacturers, national food brands, marketing, branding, media, and more. The classroom instruction is designed to give students a better understanding of what food science is and how food science plays a major role in every day life. Depending upon the agreed product to be formulated at the lab, commercialization of the City Kidz-branded product determines the course curriculum for that particular semester. The laboratory The lab is a collaboration of City Kidz Ice Cream Cafe LLC, Jacksonville, Fla., colleges, universities and food industry leaders and companies. This partnership enables students to apply AP and IB math and science in the marketplace by creating food products to be consumed through national chain grocery stores, supermarkets and club stores. Continued on page 12

We Know Product Safety Matters

IntelliTop® 2.0 Control Technology

Better control for safer processes Norit Südmo’s IntelliTop 2.0 maximizes plant safety and efficiency by controlling, monitoring and reporting on all valve functions in the process plant. With the IntelliTop 2.0 installed on your Norit Südmo valves, product safety is enhanced as you always know the valve positions and maintenance requirements. With the ability to customize the unit to your plant’s specific requirements, the IntelliTop 2.0 puts you in control.

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

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

News & Trends

In addition, a portion of the profits from the products formulated in the lab and sold under the City Kidz brand are transferred to the City Kidz Educational Endowment Fund, which is a scholarship managed by Community Foundation, Jacksonville, Fla., to offset college costs for students. Putting product on the shelves One of the components of the City Kidz Food Science Lab is to identify ingredient, flavor, dairy plant, copacker, production and distribution partners for the City Kidz Viva Vanilla Premium ice cream recipe. By accomplishing this goal, it will position the lab as a national model and help enforce national recruitment efforts. From a marketing standpoint, Bush believes the students must accomplish their flavor objective. For example,

12

Dairy Foods | June 2011

the Viva Vanilla flavor is not just another catchy name; the students chose four natural vanilla extracts to reach their target flavor goal for the premium vanilla ice cream. “However, I believe students may have unknowningly created other niche markets for our flavor Viva Vanilla breakfast syrups, Viva Vanilla cookies and other baked goods,” Bush says. On May 28, the lab hosted a city-wide sensory taste test of its Viva Vanilla Premium ice cream at the City Kidz Ice Cream Café. Food industry executives, supermarket general managers and vice presidents of private label brands, national food magazine writers, local and regional writers, food critics, chefs and media personalities were invited to be a part of the guest panel and provide feedback on the ice cream.

“This is an opportunity for the City of Jacksonville to rally behind students who have dedicated 12 Saturdays to create something special for our city,” Bush says. “It’s our goal to make sure every student in Duval and surrounding counties get a pint of Viva Vanilla Premium ice cream.” National endowment fund In order to create a national impact, City Kidz plans to move into other markets in spring 2012. The City Kidz Food Science Educational Lab will establish a food science educational lab and curriculum in Philadelphia, Pa., under the leadership of Bush’s brother, Anthony Miles, chief executive officer of City Kidz Ice Cream Café in the Northeast region market. Virginia and Washington, D.C., are also under consideration for spring 2012, and Chicago and Dallas for 2013. This year though, the goal is to create a national educational endowment fund for students nationally to attend college for food science. — Marina Mayer, Executive Editor

WA S H I N G TO N WATC H

News & Trends

IDFA Supports U.S. Plan to Resolve Trucking Dispute with Mexico, Progress on U.S.-Colombia Free Trade Agreement Outlining the need to regain full duty-free access to the U.S. dairy industry’s largest export market, the International Dairy Foods Association, Washington, D.C., strongly supports the proposed cross-border trucking agreement between the United States and Mexico developed by the U.S. Department of Transportation (DOT), also in Washington, D.C. The proposal addresses safety concerns and U.S. compliance with trade obligations to Mexico that will allow the two countries to fulfill their respective obligations under the North American Free Trade Agreement (NAFTA). Under the terms of the DOT proposal, Mexico and the United States have agreed that 50% of the retaliatory tariffs currently in place will be suspended when the agreement is signed. The re-

maining 50% will be suspended when the first Mexican carrier is authorized to operate under the pilot program. Meanwhile, President Barack Obama announced an agreement with Colombia on an action plan to resolve outstanding issues that will clear the way for the U.S.-Colombia Free Trade Agreement to gain official approval from Congress. The agreement was signed in 2006 under the Bush administration, but Congress has yet to vote on it. Until now, the Obama administration refused to push for its approval, citing outstanding issues involving Colombian labor rights. The value of U.S. dairy exports to Colombia last year was $6 million. The estimated benefit to the U.S. dairy industry over the first several years of an

implemented agreement with Colombia would be an additional $25 million in exports per year. Once implemented, the U.S.-Colombia agreement is expected to boost U.S. dairy exports through immediate open and unlimited access for most whey and lactose products, as well as duty-free access for sizable amounts of cheese and skim milk powder, among other dairy products. The United States will achieve additional dairy market access in Colombia as tariffs are ultimately phased out completely. The agreement will still need to be officially submitted to Congress and ratified for it to take effect. IDFA has strongly supported passage of this freetrade agreement, along with the pending agreements with Korea and Panama. Continued on page 14

Specialists in Sterile Sampling Supplies QMI™ Aseptic Process Sampling

Q-Swab Letheen Broth Device

Inline sampling without risking contamination • Proactively monitor potential contamination • Effective post-pasteurization monitoring of psychrotrophic spores

Handily delivers 1 mL of sample onto a petri dish, film or tube • Ready-to-use environmental collection swab • Neutralizing Letheen or Peptone media • Lowest prices anywhere

Dippas® Sterile Sampling System All-in-one dipper and container! • Long handle neatly snaps off after sampling • Leak-proof container

Request your FREE copy today of our 265-page buyer’s guide!

Sponge Handle Sampling System Sample hard-to-reach surfaces – no need for sterile gloves • Quick release handle – no tricky snapping or sharp edges • Aseptically transfers Capitol Vials sponge to included FREE FREIGHT! sterile twirl bag • Ships from 3 locations – • Pre-moistened with East, West and South 10 mL neutralizing • Many sizes and colors buffer

Legendary for great prices since 1959

800-328-8378 weberscientific.com www.dairyfoods.com

13

News & Trends

B R I E F LY … Dannon Receives Hall of Fame Award for Corporate Citizenship The Dannon Co. was a w a rd e d t h e 1 0 t h annual Business C o u n c i l o f We s t chester Hall of Fame Award for Corporate Citizenship. The award recognizes Dannon’s long-standing commitment to the Westchester community, to helping people lead a healthy lifestyle, as well as the company’s endeavors to promote nutrition education for children. For the past six years, Dannon has increasingly focused its community relations on supporting nutrition education for children. In 2006, Dannon established the Next Generation Nutrition Grants to help combat the childhood obesity epidemic in the United States and fund local not-forprofit organizations working to improve children’s eating habits. Since the program’s inception, more than $580,000 has benefited nearly 14,000 children and their families. Alpina Opens First U.S. Yogurt Plant Alpina, a leading dairy processor in Colombia and South America, will open its first specialty yogurt manufacturing plant in the

United States. The new 28,000-squarefoot facility will be constructed in the Genesee Valley Agri-Business Park in Batavia, N.Y., and will generate 50 new jobs. Lifeway Hosts Starfruit Café at Wrigley Field Lifeway Foods’ Starfruit Cafe will become a permanent fixture in the main concession area at Wrigley Field, home of the Chicago Cubs, offering an assortment of its creamy Lifeway Frozen Kefir. Located next to the main entrance at Wrigley Field, Starfruit Cafe offers both original and pomegranate flavors of its yogurt-like frozen smoothie that provides calcium, probiotics and protein. Numerous allergen and gluten-free toppings are also available. As part of its partnership, Lifeway will also hand out free Lifeway Kefir samples and offer post-game coupons to fans on “Lifeway Day” on July 17, and will sponsor the first pitch when Cubs play the Florida Marlins at 1:20 p.m.

Are you sour on your

current milk analyzer?

Take a close look at our new NIRMaster™ FT-NIR spectrometer, featuring a hygienic design specifically for at-line dairy applications. Its ease of use and low cost of ownership, combined with Buchi’s applications expertise and customer focus, make it a quality alternative to tired old milk analyzers. And remember to contact us to learn how our SpeedDigester and KjelFlex instruments can expedite and automate your Kjeldahl protein and NPN determinations.

BUCHI Corporation 1-877-MYBUCHI or visit www.mybuchi.com New Castle, Delaware

14

Dairy Foods | June 2011

Visit us at: IFT I Jun 11-14 I New Orleans, LA I booth 5300

Quality in your hands

News & Trends

PEOPLE American Dairy Products Institute, Elmhurst, Ill. Diane Lewis received the 2011 Award of Merit at the ADPI annual conference in Chicago, April 24-17. Lewis is a former senior vice president with the U.S. Dairy Export Council. Prior to that, she worked for the U.S. Department of Agriculture.

D.D. Williamson, Louisville, Ky. Margaret Lawson, vice president of science and innovation, has been bestowed a fellow from the Institute of Food Science & Technology. Meanwhile, Jennifer

Brown has been named an application scientist, responsible for focusing on color solutions for each customer’s unique formulation challenges in bakery, snack and savory applications. Continued on page 16

California Cheese & Butter Association, Clayton, Calif. David Viviani, president and co-owner of Sonoma Cheese Factory, Sonoma, Calif., received the 2011 CCBA Hall of Fame/Lifetime Achievement award. He has been involved with the CCBA for more than 30 years, and served on the board of directors for the past 15 years. He also was the association president from 2007-2010. Sensient Colors LLC, St. Louis Michael Geraghty has been appointed general manager for U.S. food colors division, responsible for strategic planning, marketing, sales and day-to-day operations. Geraghty most recently was general manager and founder of Ready Solutions Inc., a Davidson, N.C., company that markets emergency preparedness products. David Michael & Co., Philadelphia Nancy Fogg-Johnson and John Stanton have joined the Strategic Alliance Advisory Board, responsible for assisting with the mission to strengthen current corporate partnerships and develop, cultivate and nurture new, mutually rewarding strategic alliances with food and beverage manufacturers throughout North America. Fogg-Johnson currently works as a principal at Technology and Business Ventures, Inc., and is a founder of Nutri+Food Business Consultants. A 30-year food industry veteran, Stanton is currently professor and chairman of the food marketing department at Saint Joseph’s University in Philadelphia.

www.dairyfoods.com

15

News & Trends

PEOPLE Takasgo Flavors, Rockleigh, N.J. Slavica Pesic-Klajn has been named senior beverage technologist. Previously, she worked at Signature Design Spirits, developing customized spirits. She also developed vitamin and energy drinks targeting the Asian market, and designed and assisted in the launch of more than 50 products that are currently offered in both U.S. and international markets. Michael Paul has

been appointed new senior marketing coordinator, responsible for assisting with public relations, media, advertising and sponsorships of special events and tradeshows. Shweta Kumari joins as flavor sensory analyst, responsible for conducting sensory descriptive, discriminative and consumer tests and performing statistical analysis and writing reports. She’s also involved in library testing.

Intelligrated, Cincinnati Chris Barber has been appointed vice president of Southern operations, distribution and fulfillment, responsible for overseeing sales, concepts, estimating, engineering and project implementation services for the company’s distribution, warehousing and fulfillment clients. Barber served five years as a senior sales engineer and sales manager for Intelligrated.

IN MEMORIUM Edward Phillips of Talenti Gelato, Dallas Edward Phillips, founder of Talenti Gelato, Dallas, passed away from multiple myeloma at his home in Minneapolis on April 29. The son of “Dear Abby” writer Pauline Phillips was known for his many entrepreneurial and philanthropist projects. Mr. Phillips started out in his grandfather’s business, Ed Phillips & Sons and was later named chief executive officer of its beverage, gift and glassware business. In 1995, he formed Millennium Import Co., and became

16

Dairy Foods | June 2011

the sole U.S. licensee of two brands that it later positioned as luxury brands in the United States. In 2008, Mr. Phillips joined his Millennium partner and purchased a majority stake in Dallas-based Talenti Gelato, a maker of high-end gelato and sorbetti. He also served as chairman of the board of Children’s Hospitals and Clinics in Minneapolis, helped run two family foundations and served as a director for the Apollo Theater in Manhattan’s Harlem. He was also an advisor to the Worldwide Orphans Foundation, Maplewood, N.J.

SUPPLIER NEWS Palmer Wahl Instrumentation Group celebrates 175 years of manufacturing industrial instrumentation. Palmer Wahl has been a consistent innovator since the 18th century, developing the first thermometer made in America — the Foster Cup — in 1852, as well as the Foster Automatic Oil Tester, a closed cup design instrument known for being the first thermometer manufactured in the United States. During Vit afoods 20 11, May 10-12, Johnny Thylin, technical director for Fortitech Europe A p S , presented a technic al seminar on the formulation and fortification challenges of food and beverages aimed at men’s health concerns and the issues associated with developing a dynamic premix blend.

Fortitech

DS M Nutritional Products increased the worldwide price of several products for use in animal and human nutrition applications. In particular, the price of all vitamin B2 and B6 forms will increase by 15%, while all vitamin E and A forms and Calpan will increase between 5-10%, both for new orders. C D F Corp. displayed Cheertainer’s flexible packaging solutions for Walmart and Sam’s Club at the Packaging Sustainable Value Network’s 6th Annual Sustainable Packaging Exposition, April 12-13. The Cheert ainer is a U N-certified, formfit bag-in-box, ranging in capacity from 3-25 liters, CDF Corp. that provides significant environmental benefits in logistics, storage and waste disposal. Lantech extended the warranty period for its Q Series semiautomatic and simple automation stretch wrappers from three years to five. The new warranty covers the Q -250, Q -300, Q-300XT, Q-400, Q-400XT and Q-300XT Plus models. Deacom provides interface and full functionality available on iPad 2. This means that software can connect to the iPad via remote desktop protocol, with simple, secure integration into business environments anytime and anywhere.

Continued on page 18

News & Trends

SUPPLIER NEWS Flavorchem Corp. received SQF 2000 Level 2 certification. Ta k a s a g o A m e r i c a s a p p o i n t e d a q u a l i t y s y s t e m s t e a m t o e n s u re completion of the Global Food Safety Initiative certification by

J u n e 2 0 1 2 . E a ch Ta k a s a g o re g i o n est ablished a regional quality control model, featuring a lead person and a support team. The mission is focused on the assurance that quali t y p ro c e s s e s a n d p ro c e d u re s a re firmly in place.

CLear Lam Clear L am Packaging earned the industry’s first US DA-certified, biobased product label as part of a new voluntary labeling program to help purchasers choose products made with bio-based commodities. Clear Lam was among the first companies to submit applications for the program, including five product lines in the packaging category.

RB Dwyer

No... really ... it makes you smile. Analyze cheese, dairy powders, butter and other dairy products quickly, accurately and with little or no clean-up. The DA 7200 NIR Dairy Analysis System: • Save money: fast, accurate results allow tightening of safety margins • 6 second analysis: Increase throughput & capabilities • Versatile: 1 instrument measures many product types for multiple parameters

Please visit us at www.perten.com for more information.

www.perten.com SPECIALISTS IN QUALITY CONTROL OF GRAIN, FLOUR, FOOD AND FEED

18

Dairy Foods | June 2011

The RB Dwyer Group helps Barn Dad Innovation Nutrition, a division of Angle Foods, launch Ultra Fiber DX with a shrink sleeve label printed on its infinitely variable cylinder offset web press. The print technology allows for a shrink sleeve label with gravure quality and zero cylinder costs and a 360-degree image area containing information and nutrition facts on the back of the label, while the front shows a distinctive graphic that includes a brilliant metallic green. Westfalia Technologies completed commissioning its automated storage and retrieval system (AS/RS) and Savanna.NET warehouse control system for Pepsi Beverages Co.’s Tampa, Fla., facility. The flexible, high-density AS/RS meets Pepsi’s need for maximum storage, high throughput, buffers for handling peak production from

SUPPLIER NEWS Westfalia

their bottling plant and aids in preparing various types of pallets to ship to customers. The plant handles the Tropicana, Lipton Iced Tea, Starbucks Frappuccino, Dole and SoBe brands, among others.

5HDO %OXHEHUULHV

Sixty percent of Sealed Air’s global manufacturing facilities attained “zero waste-to-landfill” for plastic raw material usage in 2010, as part of its SmartLife sustainability commitments. As a result, Sealed Air reuses its own products, recycles into other useful products and uses for energy recovery to produce a 72% improvement. Yamato Corp. and Key Technology’s Integrated Solutions Group teamed up to offer complete line solutions from processing through weighing. Line integrations include sorting, conveying, processing and weighing systems for the global food industry. Sensient Colors LLC recently achieved Safe Quality Food 2000 Level 3 certification, the highest within the SQF program, designating a comprehensive mastery of safety and quality management systems development. Sensient also routinely excels in third-party audits and has a superior record with the FDA and CFR on conformance. GEA Process Engineering received a $58 million project to build a whole milk powder plant for Fonterra in New Zealand. The project, known as the Darfield project, is due to be commissioned in August 2012, and will be similar in capacity to three plants previously built by GEA for Fonterra. D.D. Williamson named Pui Yeu (Rei) Phoon, a graduate student in food science at Purdue University, as winner of the annual Beverage Coloring Competition for Students. Phoon received a trip to the Institute of Food Technologists Annual Meeting, June 11-15 in New Orleans, where she will display her winning entry, a citrus-flavored beverage fortified with betacarotene, a bioactive lipid antioxidant that contributes vitamin A and coloring. MicroThermics, Inc. received the 2011 Food Technology Industrial Achievement Award from the Institute of Food Technologists, Chicago, for its laboratory-scale UHT/HTST direct-indirect process system with full automation. The use of the process simulator significantly reduces time-to-market, costs associated with developing and processing new products and results in advanced quality, safety and efficiency of food product production.

,I

\RXU SURGXFW FRQWDLQVFXOWLYDWHG EOXHEHUULHVLQDQ\ IRUP³IUHVKIUR]HQ OLTXLGGULHGIUHH]H GULHGMXLFHSUHVHUYHG SRZGHUFRQFHQWUDWH³ FRQVXPHUVDUHORRNLQJIRU\RX  6WDQGRXWLQWKHFURZG 7KH5HDO%OXHEHUU\6HDOŒ VLJQDOVLQVWDQWO\³DWDJODQFH³ WKDW\RXUSURGXFWFRQWDLQVUHDO EOXHEHUULHV6KRZ

www.twitter.com/dairyfoods

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

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

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

40

Dairy Foods | June 2011

Grafton Village Cheese launched a new line of traditionally aged cheddars called Grafton Tavern Select, named for an historic Vermont country inn.

Continued on page 42

Packaging. Processing. Powerful.

North America’s Largest Packaging and Processing Show Has It All Find every solution you need for improving food safety, freshness, convenience and efficiency—all at one show. For options, innovation, information and networking, no event comes close to PACK EXPO. More Processing Solutions Across the Board More than 400 companies display processing solutions at PACK EXPO Las Vegas. Start in the new Processing Zone and explore hundreds of total systems solutions under one roof. s s s

1,600 exhibitors 25,000 professionals Countless total system solutions

THIS ICON IS YOUR KEY TO PROCESSING SOLUTIONS

Register Today! www.packexpo.com/food

PACK EXPO Las Vegas 2011

P R O D U C E D B Y:

September 26-28, 2011 Las Vegas Convention Center Las Vegas, Nevada USA

CO-LOCATED WITH: C

Cover Story

 Nature’s Touch milk, processed by Kwik Trip, is sold in half-gallon plastic bags at the company’s convenience stores in Wisconsin, Minnesota and Iowa.

the milk. In Europe and the United Kingdom, processors use pouches with a foot so the package can stand up on a table. Retailers like the format because there are no returns, Hume says. Ontario province has a mandatory bottle-deposit law. Dairies like it because there are no bottles to clean. A drawback is the higher possibility of leaks compared to jugs, Hume says. In addition, the pouches must be hand placed into cases. The packing can’t be mechanized. Kwik Trip has been using pouches since the 1980s, says Steve Wrobel in the company’s corporate communications department. Kwik Trip is a convenience-store chain in Wisconsin, Minnesota and Iowa (where it is known as Kwik Star) that processes its own milk, bottles juice and water, and makes frozen pizzas in its own bakery.  Kroger switched to an oval-shaped pint container for its Private Selection ice cream. Strawberry Peppercorn is a new flavor.

 McConnell’s dropped the image of the Mission Santa Barbara in favor of a spoon and ice cream.

The company’s Nature’s Touch milk is sold in one half-gallon bags. It gives away a plastic pitcher for dispensing the milk. (Kwik Trip also bottles milk in conventional containers.) Kwik Trip sells whole, 2%, 1%, skim and chocolate milk and orange juice in the pouches. Nine bags fill a dairy tote, which is placed on the bottom of convenience-store coolers. The packages are printed with the Nature’s Touch logo and are color-coded for flavor and fat content. Kwik Trip can price milk in pouches cheaper than in jugs because the bags are cheaper to produce. Wrobel cites the sustainability features of pouches. One spool of plastic can create 4,300 half-gallon bags, he says. Three million bags can be created from one semi truckload of plastic compared to 18,000 plastic gallon containers on a similar truck. American shoppers have tuned into eco-friendly and sustainability messages. s. Will more buy their ir milk in pouches? That at remains to be seen. n. One thing is for certain: n: Processors will conntinue to refine the messsages and images theyy print on dairy foodss packaging. 

 JVM Sales created a more appealing package for its Italian cheeses sold in 1-pound bags.

42

Dairy Foods | June 2011

Liquids to Value

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

GEA Mechanical Equipment

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

®

Natural & Organic

Clean labels resonate with consumers. So do the claims “organic” and “zero fat” on product packages. Dairy processors respond to shoppers’ interest in where and how foods are produced by developing natural and organic products.  April Miller Contributing Editor

fter dipping 1% in 2009, organic dairy sales in the United States rebounded nicely in 2010. The category was up 9% (an additional $322 million for a value of $3.9 billion) and accounted for nearly 6% of the total U.S. market for dairy products, reports the Brattleboro, Vt.-based Organic Trade Association (OTA). The association’s 2011 Organic Industry Survey showed very strong growth for organic milk and cream, as well as organic yogurt. The Innovation Center for U.S. Dairy, Rosemont, Ill., notes that research shows 43% of adults are interested in organic foods with dairy consumers having a higher interest than nondairy consumers. Some of the growth, says Barbara Haumann, OTA’s senior writer/editor, can be attributed to high conventional commodity prices since 2009, while organic pricing has remained relatively stable. “Consumers who had previously traded down from organic to conventional are coming back to purchase organic,” explains

A

44

Dairy Foods | June 2011

Haumann. Consumers eating at home more often and the growth of sales of private-label dairy products also added to the increase. “We are seeing more and more consumers choosing organic when it comes to dairy if they can afford it,” says Rostom Baghdassarian, chief operating officer of Karoun Dairies, Sun Valley, Calif. “If it is too expensive, they are choosing all-natural, clean ingredients, rBST-free dairy products. I believe the category is growing because consumers are becoming more conscious of what they eat. [They] are taking the extra steps of investigating where the product and its ingredients are coming from.” No synthetics “Consumers are more and more interested in products they perceive as ‘better for you,’” says Eva Balazs, spokesperson for Buffalo, N.Y.-based Upstate Niagara Cooperative. “They reach for items with fewer ingredients and some actively avoid certain ingredients they identify as negative.” Continued on page 46

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

Natural & Organic g

K Kreider Farms, Mannheim, Pa., has c come out with a new smaller-size ice c cream packaging (below, shown in mock up). It features a cow and a statement about the product’s local o origins. The older packaging is at left.

One such ingredient is rBST (also known as bovine growth hormone), a synthetically produced hormone used to boost milk output in cattle. Although Balazs explains that research by the Food and Drug Administration, Washington, D.C., shows no significant difference in milk derived from rBST-treated and non-rBSTtreated cows, she says, “milk produced without the use of synthetic hormones is becoming more the norm in the marketplace due to widespread demand.” In April, the almost-400 member cooperative became one of the last in the country to ban rBST. The International Dairy Foods Association’s position on rBST reiterates the FDA’s findings, and the IDFA’s website states that the association supports the constitutional right of dairy processors to make truthful and non-misleading claims on their labels. Last October, a federal court ruling in Ohio banned the state from forbidding processors to make labeling claims about rBST and dictate the placement of disclaimer statements. IDFA, Washington, D.C., originally filed the lawsuit in 2008 and filed its appeal in conjunction with the OTA. “As a result of the ruling, processors may continue to label these products with accurate compositional claims, providing consumers with the products they want and the information they need to make informed decisions,” according to an IDFA press release. While a 2009 report from The Hartman Group, Bellevue, Wash., (“Sustainability: The Rise of Consumer Responsibility”) found that 49% of respondents said “hormone-free” was an important label or phrase when selecting food and beverages. OTA’s Haumann says the term can be misleading as there is no such thing as hormone-free milk; all milk contains hormones. Scott A. Rankin, associate professor and chair of the Food Science Department at the University of Wisconsin-Madison, Madison, Wis., says it behooves consumers to do their homework to make informed decisions and at the same time, it’s important for companies and brands to be clear and accurate in terms of what education they put out. At Stonyfield Farm, Londonderry, N.H., Amy Elkes, brand program and consumer insights manager, says the company tries to be as transparent as possible, “using our website to show our consumers the farms — and introduce them to the farmers — where we source many of our ingredients.” Giving shoppers what they want Karoun Dairies is responding to customer demand for simple and natural ingredients with new products and packaging. Earlier this year, the company debuted a Mediterranean yogurt and a Mediter46

Dairy Foods | June 2011

ranean kefir cheese; a light cheese version will soon debut. “All the health benefits (such as rBST-free, all-natural, probiotic, live and active cultures) are incorporated on the label and packaging,” Baghdassarian says. “Also, we have introduced our Indian Dairy line under the Gopi brand cheese, d — Paneer cheese Indian yogurts and Lassi yogurt drink.” The company, notes Baghdassarian, is receiving more inquiries from consumers asking about the source of its milk and “what we put to culture or coagulate the milk.” Customers also ask about the source of the rennet or enzymes used in the cheese; if the rennet, enzymes or cultures used contain genetically modified organisms (GMO); how the cows are treated; do the cows pasture; and what is fed to the cows. Lifeway Foods, Morton Grove, Ill., announced in April that its entire beverage line (probiotic kefir, frozen kefir, Helios, ProBugs and BioKefir) are enrolled in the non-profit Non-GMO Project. Once verified, the products will be able to be marketed under the non-GMO label. “Enrolling in this program,” says Lifeway CEO Julie Smolyansky, “signals our commitment to producing real alternatives to conventional genetically modified products.” In January, Stonyfield Farm re-branded its fat-free line as a 0% line. “We believe that consumers looking for a fat-free yogurt will more easily see our 0% fat positioning,” says Caroline Miron, brand manager, “and it definitely stands out more on the shelf.” Later this summer, the company will launch Oikos Organic low-fat drinkable Greek yogurt smoothies and two new flavors (honey fig and peach mango) of Oikos Organic 0% Greek yogurt. A low-fat certified Stonyfield Organic Activia is also on the horizon as well as a re-launch of its 0% Fat Smooth and Creamy SKUs in 100 calories per 6-ounce-serving. In frozen, consumers will see new Stonyfield Nonfat Organic frozen yogurt novelty bars dipped in organic dark chocolate in two flavors. Manheim, Pa.-based Kreider Farms updated its milk labels this past year to include an rBST-free statement. In May, the company plans to launch a new upgraded ice cream container. Continued on page 48

Visit us at IFT Booths 6839 & 5621 June 11–14 in New Orleans

When you can count on your supplier…

Visit cornproducts.com/trends/beverage to download our beverage formulation naturally sweetened with Enliten® Reb-A Stevia Sweetener. NUTRITIVE SWEETENERS | POLYOLS | LOW CALORIE SWEETENERS | HEALTH & NUTRITION INGREDIENTS | STARCHES | GLUTEN FREE SOLUTIONS

Natural & Organic  Stonyfield Farm nonfat organic frozen yogurt novelty bars are dipped in organic dark chocolate. They are available in vanilla and chocolate flavors.

“It will state the ice cream is made using c our own rBST-free milk o aand cream from our own ccows,” explains Dave Andrews, vice president A of sales and marketing. The old half-gallon container will be replaced by a 1.5 quart to better compete with others in the marketplace. While consumers may not want synthetic hormones added to their dairy products, they are not opposed to other additives. OTA’s Haumann notes that a recent study (done in conjunction with KIWI Magazine) found that on average, more than six in 10 respondents said they would be more likely to buy an organic food fortified with any of the following: omega-3 (69%), calcium (67%), antioxidants (64%), vitamin D (63%) or probiotics (63%). Kreider Farms’ Andrews says that perhaps even more important to consumers than what is, or isn’t, included in dairy products may be where it comes from.

Automated Milk Component and Somatic Cell Testing

“People want local,” he says. “We grow our own feed, produce our own milk and ice cream and deliver directly to local stores. We produce our milk and ice cream with the smallest carbon footprint possible.” The Innovation Center for U.S. Dairy finds that there is a growing trend among adult dairy consumers. “[They] are more interested in local and fresh foods compared with organic,” says Miriam Erickson Brown, chair of the Health and Wellness committee for the Innovation Center for U.S. Dairy. “Consumers are associating better taste, quality and healthier products with local foods and beverages. They also are associating key dairy equities such as nostalgia and real people with local products,” says Brown, who is also the chief executive officer of Anderson Erickson Dairy, Des Moines, Iowa.  April Miller is a Cleveland-based business writer. She wrote “The Ambassadors of Cheese” in the March 2011 Dairy Foods.

 Stonyfield Farm capitalizes on two trends, organic and reduced fat, with its Oikos Organic low-fat drinkable Greek yogurt smoothies due out this summer.

Spend less time searching for information and

more time using it

Engineered for dairy laboratories and dairy processing facilities that require highly reliable and accurate instrumentation.

www.dairyfoods.com/ buyersguide

Dairy Foods Buyer’s Guide & Sourcebook • Fat, protein, lactose and solid analysis by FTIR spectroscopy • Up to 500 samples per hour

• Search by product category or company name • Downloadable product spec sheets • Alpha company listings • Live web & email links • Product photos

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

CALL: 952.448.7600 (USA) EMAIL: [email protected]

B R O W S E

C LI C K

C O N N E CT

VISIT: www.bentleyinstruments.com

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

48

Start your search today! (www.dairyfoods.com/buyersguide)

Dairy Foods | June 2011 DF-Qtr-Directories ad.indd 1

5/13/11 1:34 PM

Show Preview

Atlanta Show Promises Solutions If you seek to reduce sodium in cheese, develop new milk products or update your processing facility, then head to the International Dairy Show in September. his year’s International Dairy Show in Atlanta offers something for everyone involved in dairy-foods processing. C-suite executives can brush up on business management practices and consumer trends. Lab technicians can stay current with the latest information about food safety and traceability, while food scientists can share information about product development and nutrition. Finally, facility managers can learn about sustainability efforts and see the latest equipment for dairy processing plants. The International Dairy Show, produced by the International Dairy Foods Association, Washington, D.C., runs from Sept. 19-21 at the Georgia World Congress Center, Atlanta. Among the challenges for cheesemakers is how to reduce sodium in cheese. The show promises to give solutions. Milk processors can learn how to grow market share and maintain brand loyalty. Educational programs will deliver consumer research and show milk’s role in the competitive beverage set. Experts in food safety will discuss the Food Safety Modernization Act, the Reportable Food Registry and technology to help processors to implement the regulations. Plant managers will hear the latest on corporate social reporting and sustainability reporting, automating production scheduling, lowering transportation costs, overcoming hurdles and accelerating sustainability results. Register and see more details about the seminars and exhibitors at www.dairyshow.com. 

T

 At the International Dairy Show in Atlanta, dairy processors can see new equipment and packaging.

Dairy Show Highlights, At A Glance Monday, Sept. 19 9-10 a.m. Signature Session with Karl Rove 10-11:50 a.m. Concurrent educational sessions 10 a.m.-5 p.m. Exhibit hall open 11:30 a.m.-4 p.m. iDairyShow and cooking demonstration 5:30-7 p.m. Reception

50

Dairy Foods | June 2011

Tuesday, Sept. 20 9-10 a.m. Signature Session 10-11:50 a.m. Concurrent educational sessions 10 a.m.-5 p.m. Exhibit hall open 11:30 a.m.-4 p.m. iDairyShow and cooking demonstration

Wednesday, Sept. 21 9-10 a.m. Signature session 10-11:50 a.m. Concurrent educational sessions 11 a.m.-3 p.m. iDairyShow and cooking demonstration 10 a.m.-4 p.m. Exhibit hall open 3-4 p.m. Closing reception. Passport Awards presentation on the exhibit floor.

Œ(ERMWGS97%-RG

'LIIVW

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

ˆ7SHMYQ6IHYGXMSRˆ*MFIV%HHMXMSRˆ0EGXSWI6IHYGXMSRˆ2EXYVEP*SSH4VSXIGXMSR

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

Show Preview

Anuga Is the Innovation Destination The trade fair for the global food industry runs Oct. 8-12 in Cologne, Germany. See suppliers and top decision makers in the retail, trade and foodservice/catering markets. nuga is a global food and beverage tradeshow held every two years in Cologne, Germany. It is produced by Koelnmesse, which puts on shows around the world. Anuga consists of 10 specialized segments, which match exhibitors with their right target audience. The segments are: bread, bakery and hot beverages; chilled and fresh foods; dairy; drinks; fine food; foodservice; frozen food; meat; organic; and RetailTec. Dairy foods can be found in many of the halls, but of course, those involved with the dairy industry make the Anuga Dairy segment their No. 1 destination. In 2009, this hall was home to 350 exhibitors from 35 countries and had nearly 50,000 visitors walk through it. About 85% of the visitors claimed to have a decisive role in purchasing decisions at their companies or share responsibility for such decisions. The international dairy industry uses the dairy segment to demonstrate its capabilities and innovations. Global dairy leaders exhibiting this year include Alpro (Belgium), Bauer (Germany), Conaprole (Uruguay), Ehrmann (Germany), Emmi (Switzerland), FrieslandCampina (The Netherlands), Goldsteig (Germany), Hochwald (Germany), Hoogwegt (The Netherlands), Humana Nordmilch (Germany), Milchunion Hocheifel (Germany), Milkpol (Czech Republic), Saputo (Canada), Uhrenholt (Denmark), Valio (Finland) and Zott (Germany). These companies present a comprehensive range of milk and dairy products and offer domestic and foreign buyers from the trade and foodservice markets a platform for gathering information and placing orders. Global demand for milk and dairy products is helping boost exports and opening up new target and sales markets for many manufacturers, including U.S. companies. In fact, according to the U.S. Dairy Export Council, Arlington, Va., U.S. dairy suppliers shipped 304 billion pounds of total milk solids overseas in 2010, accounting for nearly 13% of all the solids produced in the United States during the year. The United States also exported 3.7% of its overall cheese production in 2010, 7.9% of its butterfat, 55% of its dry whey and 68% of its lactose. Ice cream exports grew 25% from 2009 to 2010, with Southeast Asia driving this growth. Anuga Dairy, along with the United States Department of Agriculture-endorsed U.S. Pavilions at Anuga, which offer U.S. food and beverage marketers cost-effective visibility in the global food market, can help grow exports. Specifically, the U.S. pavilions are a prime destination for buyers and distributors from other countries seeking out high-quality and safe American-made products. The pavilions are offered in five halls: Drinks, Fine Food, Frozen Food, Meat and Organic. Dairy products can be found in all pavilions excluding meat. In 2009, about 150 exhibitors partici-

A

52

Dairy Foods | June 2011

 Unlike any other tradeshow, Anuga’s unique concept of featuring 10 specialized tradeshow segments, one of which is dairy, in a single exposition forum, has been highly successful in matching exhibitors with their right target audience. pated in the U.S. pavilions. According to the USDA, these companies generated an estimated $7.8 million in on-site sales and more than $158 million in 12-month projected sales. “Anuga is a serious order-writing show. Our U.S. Pavilion program makes it easy for buyers to find American-made products,” says Mette Petersen, president and managing director, Koelnmesse Inc., Chicago. “Over 80% of the U.S. companies in the U.S. pavilions receive assistance via Market Access Program (MAP) funding from the Foreign Agricultural Service, an excellent way to provide U.S. companies with great visibility at a very affordable price. Imagine, more than 150,000 trade attendees from 180 countries all waiting to meet with you in one location.” Expo highlights For 2011, Anuga organizers have identified nine trend topics that will be highlighted throughout the 10 segments. They are: finger food, gourmet products and regional specialties, halal food, health and functional food, industrial ingredients, kosher products, organic products, private label and vegetarian products. Italy is Anuga’s partner country this year and about 1,000 Italian companies will attend and be involved with a special pavilion named Italian Quality. A new segment, named Anuga Foodservice, will include live cooking demonstrations. A special exhibit called “taste” returns. It features the most innovative new products, as chosen by a prestigious jury. For more information on attending or exhibiting, visit www.anuga.com. 

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

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

Liquids to Value GEA Mechanical Equipment US, Inc. 100 Fairway Court · Northvale, NJ 07647 Phone: 201-767-3900 · Fax: 201-767-3901 Toll-Free: 800-722-6622 · 24-Hour Technical Help: 800-509-9299 www.wsus.com

1504

GEA Westfalia Separator Division

Sound Performance Just two words to keep in mind

Equipment built with a long-term quality requirement. Solutions that enable the efficient production of products safely, minimizing the consumption of energy, water and other resources. Sound performance. Just two words to keep in mind. Tetra Centri® AirTight Separators

Tetra Plex® Heat Exchangers

Tetra Alex® Homogenizers

Complete Processing. Innovative Solutions. Visit us at www.tetrapakprocessing.com or directly; [email protected] 800-806-9675

Tetra Pak, , PROTECTS WHAT’S GOOD and Tetra Alex, Centri, and Plex are trademarks belonging to the Tetra Pak Group.

sneak peek a look inside…

Protect the Product

REPORTS

ackaging that prevents spoilage of dairy foods is eco-friendly, but there is more to being green than that. Dairy Foods asked vendors about their advances in sustainable packaging. Page 66.

P

Columnists USDEC’s Tom Suber on exports, Page 72. Henry Randolph’s “Quality on the Line,” Page 74.

Equipment Showcase N

ew equipment for filtration. Page 76.

Photo courtesy of Fage USA

Just Plain Extraordinary X-Flow

Thanks to a host of all-natural products and a mission to remain authentic, Fage takes charge of the Greek yogurt category by just being true to itself and to its consumers.  Marina Mayer Executive Editor

fast forward what’s coming in July & August… In July:  Buyers Guide & Sourcebook In August:  Plant of the Year  Flexible Packaging  Labeling Showcase

hen it comes to Greek yogurt, there are usually a few buzzwords that come to mind — authentic, natural and healthy, just to name a few. But when it comes to describing Greek yogurt from Fage, well, it’s just plain extraordinary. That’s because Fage yogurt isn’t just your run-of-the-mill traditional yogurt.

W

In addition to pairing up with other breakfast items or being used as a snack, Fage yogurt also is developed as a healthy cooking alternative to sour cream, mayonnaise and fresh cream. “Our yogurt, with its rich history, taps into a strong consumer demand for products that are authentic, original and all natural,” says Russell Continued on page 56 www.dairyfoods.com

55

Corporate Profile Evans, marketing director for Fage USA Dairy Industry, Inc., a subsidiary of Fage, based in Greece. “Our 85-plus years of history have been guided by the principle of providing the very best to our consumers. We treat them the same as we would our own family.” Fage Greek-strained yogurt is made using a proprietary process that blends 100% all-natural ingredients with whole milk, cream and cultures supplied from rBGH-free cows. Unlike some of the flavored yogurts out there, Fage yogurt doesn’t contain any added sweeteners, thickeners or preservatives and no powdered milk, powdered cream or powdered protein. Other label-friendly terms include protein rich, gluten-free, vegetarian and diabetic and pregnancy friendly. “Our product appeals to all consumers who demand great taste and quality,” Evans notes. “To put it simply, Fage Total delivers what we all desire — a high-protein, low-carbohydrate and low-fat indulgence that is truly healthy. We see our product as an attainable indulgence for all.” The lineup of Fage products includes a variety of fat contents and packaging. Fage Total 0% is available in 6-, 17.6- and 35.3ounce containers. Fage Total 2% and Fage Total come in 7-, 17.6- and 35.3-ounce packages. Fage also offers 5.3-ounce split cups in Fage Total 2% and Fage Total Classic paired with blueberry, cherry, peach, strawberry and honey offerings. Earlier this year, Fage introduced Total 0% with fruit flavors, which is a rich and creamy fatfree option ption that comes

56

Dairy Foods | June 2011

in plain, cherry-pomegranate, blueberry acai, honey, mango guanabana and strawberry goji flavors in 5.3-ounce split cups. “The heart of our business is built around our unique and delicious Fage Total plain yogurt and is led by our top-selling plain 0% 6-ounce cup,” Evans says. “The recent introduction of our 0% fruit cups has seen tremendous success with sales growth of 150%. The fruit cups are quickly becoming an important part of Fage Total’s family of products.”

In addition to pairing up with other breakfast items or being used as a snack, Fage yogurt also is developed as a healthy cooking alternative to sour cream, mayonnaise and fresh cream. Historically simple Fage started in 1926 when Athanassios Filippou opened a small dairy shop in Athens that provided creamy, one-of-akind yogurt. In 1954, Filippou brought in his sons, Iaonnis and Kyriakos, to help create the first wholesale distribution network Greece. By 1964, the Filippou sons opened Fage’s for yogurt in G first yogurt aand pastry production facility in Galatsi, Athens.

Corporate Profile Eleven years later, thee Fage yogurt plant relocated to Metamorfiso in Attica, where ere it introduced branded ded yogurt products to the he Greek market. These se products, which car-ried the Fage trade-mark, were sold in smaller sealed tubs with attractively designed packaging. Then, in 1998, Fage began exporting yogurt to New w York City, grossing more than 2,000 tons by 2004. That’s when Fage developed a state-of-the-art, ate-of-the-art, 145-000-square-foot yogurt production facility in Johnstown, ohnstown, N.Y., which now employss more than 170 full-time people and distributes nationally to specialty and natural ural food stores, stores including supermarket chains. “We have invested $148 million to create a highly automated and specialized plant that allows us to make our authentic recipe with the highest standards of hygiene and safety,” Evans says. “Historically at Fage, we have always produced an all-natural product with only a few key ingredients,” he adds. Today, the dairy giant is Greece’s largest dairy company, producing milk, cheese and yogurt worldwide. The Fage Total brand is also the fifth largest brand in the U.S. yogurt category, according to Chicago-based SymphonyIRI Group. “Today we are still guided by the same principles of providing our consumer with healthy, authentic products and never compromising on quality,” Evans says. We are proud to play a leadership role in the food industry’s shift toward healthier products.” Marketing made simple Mar Fage’s growing business is a direct result of the Fag passion from its loyal consumers, Evans says. p ““This phenomenal ‘word of mouth’ has helped establish Fage Total as the first Greek yogurt brand in the U.S.,” he adds. However, consumers are just part of the puzzle. Fage’s growth spurt is also due in part p to its several marketing initiatives. Under its “Plain Extraordinary” TV campaign, Un example, Fage recently launched three comfor ex mercials that “exemplifies our commitment to the mercia brand and our unique premium positioning in the market,” Evans explains. One video starts out with a sea of yogurt that whips into surfboarding waves, then spla splashes together with honey and blueberry and spills over ove a yogurt-drenched cow. The second video

Fage Greek-strained yogurt is made using a proprietary process that blends 100% all-natural ingredients with whole milk, cream and cultures supplied from rBGH-free cows. features a porcelain woman draped in a sea of yogurt and the third one shows a cow plunging through a sea of yogurt. The ads were produced by Mullen, a Boston-based advertising agency. “Our products and marketing programs are designed to work across all channels of trade,” Evans says. “We are seeing tremendous success for Fage Total in mass merchandisers and supermarkets and are looking forward to continued momentum in the foodservice channel.” Fage also launched the The Fa-Yeh Away Tour 2011, where they tour the country and deliver free samples of Fage Total. “Dairy plays an important part in the American diet, but constant innovation will be necessary to maintain this position,” Evans says. “The yogurt industry is going to continue to evolve as the American consumer looks increasingly for products that are truly authentic and all-natural like Fage Total. We see ourselves continuing to lead this growth and we are very excited about the future.” Greek yogurt has carved out its own niche in the dairy world, but for companies like Fage, it’s all just plain extraordinary.  www.dairyfoods.com

57

Plant P lant C Close-up lose-up

 Six filled and capped 35.3-ounce containers undergo X-ray inspection and a final case closure before being palletized and shipped out to retailers. Photos by Wayne Labs, Food Engineering magazine

Ready, Set, Fage Fage USA’s Johnstown, N.Y., plant is equipped with all the bells and whistles to stay ahead of the game.  Marina Mayer Executive Editor

F

or years, yogurt has been marketed as the mainstay companion to a healthy breakfast. Pair it with fruit, oatmeal or a heartier dish such as eggs and consumers are sure to stick to their diets. But some recent ingredient and equipment innovations have enabled shoppers to turn to yogurt as more than just a lower-calorie treat. That’s why the folks at Fage USA Dairy Industry, Inc., a subsidiary of Fage (pronounced fa-yeh), based in Greece, built their 145,000-square-foot Johnstown, N.Y., plant, which has since been upgraded to withstand the ever-changing demands of Greek yogurt lovers. 58

Dairy Foods | June 2011

The plant, which became operational in April 2008, produces 85,000 tons, or 187.4 million pounds, of yogurt a year, and consists of four current filling lines, which are supported by corrugated material packaging and palletizing machinery, according to Bernard McConaghy, production manager. What’s truly unique about this plant is the absence of manual operation (except for the uncartoning of cups and trays, maintenance and some material handling), McConaghy says. From the time hormone-free milk arrives in tank trucks to the time finished yogurt is put in refrigerated storage, product is rarely visible to the human eye.

Plant Close-up

 The Johnstown, N.Y., plant produces 85,000 tons, or 187.4 million pounds, of yogurt a year nationally to specialty and natural food stores, including supermarket chains.

Farms and cooperatives in the Northeast supply Fage’s milk, which comes in by trucks via an enclosed bay with three receiving lines. After lab operators test the incoming milk onsite for bacteria, pH, solids, color and odors, it’s automatically pumped to one of the multiple milk storage silos. Flowmeters verify volumetric and weight information obtained from the truck weigh scales. Raw milk is then separated into skim milk and cream, and then pasteurized in dedicated HTST pasteurizers. The skim milk is directly added to an incubation tank, which is dosed with culture to produce yogurt curd with whey. The curd is separated from whey and then stored in a sterile holding tank, where it is blended with cream and then sent to the filling machines. After filling, packaging lines (consisting of tray lid applicators, integrated x-ray foreign object detectors and tray counters/labelers) complete the labeling and packaging tasks, thus handing off product to a robotics handling and palletizing system.

Once palletized, two floor-guided shuttles and one automated cooling tunnel provide conveyance into a high-density automated storage and retrieval system (AS/RS) in the refrigerated warehouse. “We basically are a paperless plant,” says McConaghy. “Certainly we have documentation that we use and rely on that is paper-based, but all the critical plant information is electronic-based. The interconnection of all these systems is critical to the plant operating well. It enables us to capture all pertinent data and to rely on that data to optimize plant operations.” The plant also is home to more than 400,000 gallons of unpasteurized milk storage, more than 19,000 gallons of pasteurized cream storage and 10,000 pallets of finished goods. Staying on target Within the past six months, Fage introduced five non-fat product SKUs to the marketplace. To accommodate the ability to increase productivity, McConaghy says, Fage has made Continued on page 60 www.dairyfoods.com

59

Plant Close-up Photo courtesy of Webber/Smith Associates

 This walkway in the interstitial space can be used for maintenance and access to process equipment.

AT A GLANCE Fage USA Dairy Industry, Inc. Location: Johnstown, N.Y. Interstate Milk Shipper Plant: No. 0129 Interstate Milk Shipper Ratings (April 1, 2011): Raw milk 90%, Enforcement rating 97% Year Opened: April 2008 Size: 145,000 square feet Employees: More than 170 Products: Greek yogurt Processing capacity: Four current filling lines help produce 85,000 tons, or 187.4 million pounds, of yogurt a year. The plant also is home to more than 400,000 gallons of unpasteurized milk storage, more than 19,000 gallons of pasteurized cream storage and 10,000 pallets of finished goods. Packaging: Four packaging lines; a fifth is planned for installation during the summer of 2011.

several equipment expansions, including milk reception and storage, pasteurization, separation and cup production. “Production demand has doubled in the past year,” he adds. “Employee headcount has gone up about 50%, the production

capacity has increased with additional milk, cream and incubation tank processing. Additionally, a fifth packaging line is planned for installation during the summer of 2011. These changes have enabled a significant increase in production output to 85,000 tons of yogurt annually,” he says. Product consistency, McConaghy says, is a result of the combination of culture, pasteurization process and the separating process. “We separate a large majority of the whey we obtain after the fermentation process. It takes approximately four pounds of milk to produce one pound of yogurt,” he adds. Fage also performs critical monitoring of the product from reception (typically 15-20 tank trucks of milk per day) through fermentation. “We don’t necessarily validate process data for regulatory compliance issues; we monitor analytical process data to ensure there are no surprises — a fermentation batch does not behave as expected,” McConaghy explains. The plant runs primarily on distributed control systems, which not only control the process, but also control the plant’s automated clean-in-place systems. The control room monitors every process detail, allowing operators to watch pumps, speeds, valves, pressures, flow, level and more in real time. Depending on the product, a batch process can take anywhere from several hours to a few shifts. Analytical instrumentation also provides the operators and control system with vital Continued on page 62

60

Dairy Foods | June 2011

Plant Close-up

 Fage containers enter the automatic filling station before traveling into the packaging area. information on process variables. Lab staff then collect and analyze samples off the control room on a regular basis. The control room also provides access to a building management system that monitors the central plant utilities, HVAC equipment, boilers, chillers and the perimeter monitoring system, which includes 40 cameras mounted in strategic areas of the plant and controlled gates. Additionally, all items produced by Fage are made to order. “This is projected over several months and is converted into real orders that provide product to retailers three weeks after an order is placed,” McConaghy adds. “Fage uses the freshest materials and highest quality manufacturing standards. No preservatives are used, so this process ensures Fage product is received by retailers with at least 28 days to expiration.” Aiming for the top Because Fage is committed to providing products that it would only serve its families, the U.S. plant follows Good Manufacturing Practices, maintains an exemplary record in quality system audits and in February, scored a 99% achievement rating for HACCP compliance. The plant is also regularly audited by the New York State Department of 62

Dairy Foods | June 2011

Agriculture and Markets for compliance to the Pasteurized Milk Ordinance (PMO). “Fage challenges its suppliers to deliver high-quality, ontime materials,” says McConaghy. “Changes in suppliers are triggered by enhanced quality requirements and capacity requirements. As Fage production demands have increased, the need for additional high-quality supplier services has also. Supplier performance is constantly evaluated.” Fage also places a strong emphasis on safety training. That’s why it conducts continuous and ongoing safety programs that are driven by the plant safety committee. “Fage has a unique manufacturing system that has created a superior quality product,” McConaghy adds. “As a result, increased demand for this product has spawned greater competition in the Greek yogurt market.” Regardless of the ever-changing demands from consumers, Fage keeps its eye on the target and continues to fire out quality, authentic products.  Editor’s Note: Parts of this article were written and published in the December 2009 issue of Food Engineering, a sister publication of Dairy Foods.

SQF Level 2 Certified

Plant Close-up

Behind the Scenes A photo gallery of Fage USA Dairy Industry Inc., Johnstown, N.Y. Photos by Wayne Labs, Food Engineering magazine

 Above, after lab operators test the incoming milk on-site for bacteria, pH, solids, color and odors, it’s automatically pumped to one of four 26,000-gallon silos. Right, a robotic arm maneuvers pallets of yogurt.

64

Dairy Foods | June 2011

Plant Close-up

BEHIND SCENES the

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

 Inoculation/fermentation tanks are outfitted with process instrumentation, feature multiple inlets and include a CIP system with mix-proof valves. Photo courtesy of Webber/Smith Associates

 Above, once palletized, two floor-guided shuttles and one automated cooling tunnel provide conveyance into a high-density automated storage and retrieval system (AS/RS) in the refrigerated warehouse. Left, a series of pumps and valves direct ingredients to the appropriate holding tank.

www.dairyfoods.com

65

Packaging Technology

Protect the Product Packaging that prevents spoilage of dairy foods is eco-friendly, but there is more to being green than that. Dairy Foods asked vendors about their advances in sustainable packaging.  Jim Carper Chief Editor

airy Foods: How do you define sustainable packaging?

D

Ron Cotterman, Sealed Air Corp.: For packaging to be sustainable, it must meet the demands for value and performance while minimizing environmental impact. For dairy food packaging, our priorities are to produce products that extend distribution and offer convenience, protection and efficiency while reducing waste, conserving energy and optimizing raw materials when possible. From an environmental perspective, many consider the ideal packaging product to weigh almost nothing and have the capacity to be recycled. But when you take a closer look at the role packaging plays in reducing waste, you realize you must quantify environmental impacts of packaging and the contents of the packaging throughout the entire supply chain. Understanding the impact throughout the supply chain is an important first step toward improving overall environmental sustainability.

Meet the Participants Murray Bain, vice president marketing, Stanpac Inc. Elisabeth Comere, director, environment and government affairs, Tetra Pak North America Ron Cotterman, executive director of sustainability, Sealed Air Corp. Paul Dean, vice president, commercial North American packaging, Scholle Packaging Jim Dwyer, CEO/president, RB Dwyer Group Roman Forowycz, group president/chief marketing officer, Clear Lam Packaging Hella Gourven, marketing manager, Crown Food Packaging North America Sveinar Kildal, director, corporate environment, Elopak James D. Taylor, business development manager, sustainability, Printpack Inc.

66

Dairy Foods | June 2011

 Scholle’s products for the dairy market feature tamper-evident seals and caps.

James D. Taylor, Printpack: Sustainable packaging is beneficial, safe and healthy for individuals and communities throughout its life cycle. It is sourced, manufactured, transported and recycled using renewable energy, and it is manufactured using clean production technologies and best practices. Hella Gourven, Crown Food Packaging North America: Crown approaches sustainability in three ways: social, environmental and economic. In other words, it’s the materials we use, the products we design and the way we do business. Murray Bain, Stanpac: We define sustainable packaging as a product that has as little impact on the environment as possible. The package however needs to meet the criteria of the customer and also meet the need of the consumer. Paul Dean, Scholle Packaging: A sustainable package reduces stress on the environment through less materials usage, and increases efficiencies in storage, shipping and end-use logistics. Jim Dwyer, RB Dwyer Group: Customers say they want an “environmentally friendly” product and it is sometimes challenging to understand what that means. One of our goals is to educate the customer as to what films are available. We offer PLA film, a compostable film made from plants, a renewable resource and PETG, a recyclable film. In some cases, we suggest that the film be down gauged, which reduces the amount of film used. The use of lighter film is a quick and easy way to make a sustainable change and reduce the amount of packaging used.

Packaging Technology Dairy Foods: Some dairy processors use seals and tamperevidence in their product packaging, but this can mean extra material that adds weight, and it needs to be recycled. How can a processor balance sustainability practices with its food-safety needs? Cotterman: We are in the process of introducing a new reclosable shredded cheese package with a peel-off seal that allows for immediate tamper detection and eliminates the need for a zipper and secondary seal. In some cases, this technology has resulted in a materials reduction of 2-4 inches. Sveinar Kildal, Elopak: Food safety and sustainability are both critical. The balance comes from continuous improvement in reducing the amount of raw materials. This is true even of renewable resources like the paperboard in our carton, which we have made significantly lighter over the years. Elisabeth Comere, Tetra Pak North America: Aseptic packaging is based on the principle of ensuring that both food and packaging materials are free of harmful bacteria at the moment the food is packaged. The result is a packaged food product that can be described as “commercially sterile,” which means that it can be preserved safely at ambient temperature from six months to one year or more. For dairy products specifically, the aseptic technology and ultra high temperature (UHT) processing makes milk products shelf stable, which brings benefits associated with not having to rely on a chilled distribution chain. The UHT process purifies the milk at a high temperature for a short time, killing all bacteria without harming the quality of the nutrients. The purified milk is then sealed in sterile cartons, which have six layers of protection to keep impurities, light and oxygen out.

UHT processing makes milk products shelf stable, which brings benefits associated with not having to rely on a chilled distribution chain. Gourven: One of the key benefits of metal packaging is that product is filled, retorted and shipped in a single container, without the need to add materials later in the process. This includes secondary packaging, which thanks to metal’s inherent strength, is often unnecessary. Since the material is rigid and robust, the can is more resistant to damage during shipping.

What’s Next in Dairy Packaging? A 2009 report from PMMI found these expectations over the next two to three years: • The shape of milk containers in greener bottles • Reduced package weight • Greater concentration on making a safer product • Case-less secondary packaging • Flexible packaging with re-closeable closures • Appeal to higher-value niche markets • Packaging and labeling more attractive • More packaging innovation Source: Dairy Industry Market Research Study, PMMI. PMMI is a trade association of companies that manufacture packaging, processing and related converting machinery.

Consumer safety and long shelf life, in fact, are arguably the metal can’s most notable and time-tested attributes. Cans are hermetically sealed, so microbes, oxygen, light and other agents cannot infiltrate, contaminate or degrade the contents. By choosing metal, dairy processors don’t have to pick just sustainability or food safety — they get both in one convenient package. Bain: Food safety is a given and can’t be compromised. The goal with tamper-evident solutions is to find one that has as little impact as possible.

Dean: A key part of sustainability for processors is the protection of their customers and the proper delivery and dispensing of their product. Our products for the dairy market feature tamper-evident seals and caps. Dairy Foods: Please share an example of how your company helped a processor convert to sustainable packaging. Roman Forowycz, Clear Lam Packaging: We worked closely with Stonyfield Farm over a two-year period to develop and commercialize new plastic yogurt cups made from renewable plant-based raw materials. This breakthrough technology replaced petroleum-based polystyrene plastics (PS #6) cups. In addition, Clear Lam invested significant resources into R&D and commercialized packaging technologies that minimize the impact on the environment. This is part of our Project EarthClear initiative. Three key areas of technology drive this. The first, renewable raw materials, includes rigid packaging and films made from bio-based materials instead of oil. The second focuses on recycled plastic and paper content for flexible and rigid packaging. The third, lightweighting, is designed to reduce the carbon footprint of packaging through less plastic while maintaining strength, quality and integrity. Comere: Bright Dairy is China’s largest provider of fresh milk, yogurt and cheese products. When Bright Dairy decided in 2008 that it needed a program to ensure long-term sustainable Continued on page 68 www.dairyfoods.com

67

Packaging Technology growth, the company turned to Tetra Pak. Since then, Tetra Pak has helped Bright Dairy implement a sustainable operational cost reduction (OCR) program that has achieved operational cost reductions of up to 10.9%. The scope of the OCR-CI program focused on the pre-processing and filling units and included a range of improvement actions. These actions included water flush control for pasteurization, more accurate raw milk reception, optimized milk recycling procedures, air push devices for UHT processing and overfilling reduction, leading to a reduction of product waste of more than 24%.

 Sealed Air Corp. helped cheesemakers convert to highperforming, lower-gauge films.

We pioneered a new lowacid aseptic filling system. Sustainability is enhanced through efficiencies gained by longer production runs, reduced chemical consumption and less energy use with ambient distribution of the filled package. Taylor: Our standup pouch offers a major producer of personal-care products the following sustainable benefits when compared to the existing paperboard carton: source reduction, fewer greenhouse gas emissions, less water consumption and fossil fuel reduction. The manufacturer saw a 72% reduction in total weight of the secondary packaging, from 1,529 tons per year to 434 tons. GHG emissions decreased 77% and water consumption was reduced 94% for the manufacture of base materials and conversion to finished secondary package. There was a 27% reduction in fossil fuel consumption for the manufacture of base materials and conversion to finished secondary package. Based on the individual packaging weight, unit volume and industry recycling rates, the comparative amount of our material to landfill after recycling is 395 tons per year versus 611 tons per year of CRB paperboard. This equates to a 35% reduction in solid waste to landfill. Bain: We have converted a number of customers from plastic ice cream packaging to paper. We use paperboard that is FSCcertified. The Forestry Stewardship Council follows best practices in forest management. Dean: We pioneered a new low-acid aseptic filling system. Sustainability is enhanced through efficiencies gained by longer production runs, reduced chemical consumption and less energy use with ambient distribution of the filled package. 68

Dairy Foods | June 2011

Cotterman: Sealed Air packaging specialists have assisted dairy customers using Cryovac branded products in the development of more sustainable packaging by converting their materials to high-performing, lower-gauge films for cheese products ranging from 8 ounces to 5 pounds. These reducedgauge films allow for a reduction in materials and resources while still offering consistent product protection. Dairy Foods: Has your company produced life-cycle analysis or greenhouse gas emission reports regarding packaging? Dean: We have completed an LCA study for its 3-liter bag-inbox wine market. The study showed bag-in-box packaging to have fewer impacts on the environment than other packaging. Continued on page 70

5 41 1 #1 201 sit vi oth w o ho e, or l b S y m n bg` air ar ` le dZ l D To IZ\ ona g ati ^^ rn `k t e ^k In >o the at

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

U

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

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

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

Packaging Technology Cotterman: As part of our SmartLife initiative, we help our customers assess the energy, carbon and waste implications for packaging and the products the packaging protects throughout the entire supply chain. We also demonstrate the wider cost, environmental and social impacts of food and product waste so customers can prioritize and implement more sustainable packaging decisions. We’ve found that the carbon footprint of packaging and the energy to produce packaging is far less than the carbon footprint associated with the production of the food product the packaging protects. The contents of the package are critical when assessing carbon footprint and conducting life cycle analysis. For example, by the time the food has reached the consumer, a significant amount of natural resources have been expended to grow, harvest, process, transport and store the product. Food that spoils in the consumer’s pantry or refrigerator wastes not only the product at hand, but all the natural resources that went into delivering the good to the home. Furthermore, food that ends up in a landfill can actually contribute to greenhouse gas emissions. Kildal: Studies show that carbon dioxide emissions from gabletop carton production are less than one-third the level produced by plastic and glass bottles, perhaps as little as onetenth as much. Over the past three years, Elopak has reduced its own carbon footprint, company-wide, by 14% Dairy Foods: Dairy foods are sold in multiple channels, including grocery, c-store, vending, foodservice and institutional. Do your sustainable packaging solutions vary according to channel of distribution? Taylor: The club store channel seems especially in need of sustainable packaging alternatives. Multipacks, in particular, are often over-packaged in heavy, expensive corrugated or paperboard. To the extent that Printpack can offer flexible packaging alternatives to traditional club store multipack formats, we can bring significant value to our customers that distribute products through these channels. Bain: Glass refillable bottles for milk and dairy products are gaining popularity in grocery stores and home delivery in some parts of the country remains strong. There is a benefit

EXTRAS Clear Lam Packaging ............................................www.clearlam.com Crown Food Packaging North America ........www.crowncork.com Elopak ..........................................................................www.elopak.com Printpack Inc......................................................... www. printpack.com RB Dwyer Group .................................. www.therbdwyergroup.com Scholle Packaging ................................................... www.scholle.com Stanpac Inc. .......................................................www.stanpacnet.com Tetra Pak North America ....................................... www.tetrapak.com Sealed Air Corp. ......................................................www.cryovac.com

70

Dairy Foods | June 2011

to using a container over and over again. And, with home delivery, one vehicle delivering milk and dairy products saves each family a trip to the grocery store, which reduces emissions greatly. Comere: Our packaging solutions do vary according to the channel of distribution. Our portfolio is broad and our cartons adapt according to the distribution channel used. The light weight and shape of the cartons drive efficient distribution in the dairy supply chain, which leads to a low environmental impact. Aseptic packages make the product shelf-stable, meaning they don’t need to be refrigerated for transportation and storage, helping to reduce greenhouse gas in transport.

The club store channel seems especially in need of sustainable packaging alternatives. Dairy Foods: Packaging can jam equipment resulting in waste and spoilage. How do your products (or your training) help a processor reduce waste on the production line? Comere: In the last year, we have further improved the environmental efficiency of our filling equipment by minimizing the energy and water consumption, as well as the operational waste. With these new generation filling machines, dairy processors will cut the waste generated by 30%. Specifically, our A3 filling line is the first in the world to receive an Environmental Product Declaration certification. This machine consumes 11% less energy, produces 30% less waste, uses 70% less water and 80% less cleaning agents. Taylor: We offer field technical service resources. We are available to troubleshoot when there are productivity issues and will often proactively provide line audits to help customers to reduce waste through the set up and run processes. Gourven: Metal packaging is also a cost-effective choice of format thanks to its fast filling speeds. It is efficient to manufacture due to material and design simplicity. In most canmaking operations, the metal starts as a flat sheet and then is manipulated into the familiar canister shape. Bain: Our ice cream filler is installed by our technical service professionals who focus on training the operators on the principals of running and maintaining the equipment so that it will run efficiently and with low waste. Dean: We develop and build filling equipment designed specifically for our bag-in-box packaging. We hold training events for our customers’ production line and plant engineering personnel prior to installing a filler. 

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

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

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

Global Insights

Are We There Yet? an you imagine anyone in the New Zealand or Australia dairy sector debating the merits of pursuing exports? Do industry participants in the Netherlands or Denmark ever ponder whether globalization is here to stay? Do they distinguish their customer base between domestic and overseas? Of course not. To question such things would be ridiculous. Some matters are simply understood. This is the space in which we compete. Over the last five years, the U.S. dairy sector has been trying to find its position on the global playing field. We are now the world’s third-largest dairy exporter, trailing only the 27-country European Union and New Zealand, with a 17% share of global dairy trade. We are the largest supplier of skim milk powder/nonfat dry milk, whey and lactose, and the third-leading supplier of cheese.

C

Two trends stand out for future growth: the expanding urban middle class and health and wellness. In the next 15 years, 60% of the global increase in GDP will come from the world’s top 600 cities. The baby formula sector is poised to double in size by 2015. Dairy finds itself aligned with key nutritional priorities, including weight management and healthy aging. There’s a greater understanding that most of our incremental production growth is being sold overseas. And at last, the entire U.S. industry is beginning to accept the stakes of globalization. This is evident in the debate swirling about improving our dairy policies. The upcoming farm bill negotiations will address aspects of our pricing regulations. Some policies (such as the support price) clearly hinder the creation of a more diverse product portfolio to meet the needs of global customers. We also see more dairy processors actively exporting. That said, we are still growing into our new role as a global supplier, and the maturation is far from universal. For instance, the recent decision by the National Conference on Interstate Milk Shipments to retain the outdated somatic cell count threshold of 700,000 cells/milliliter hurts our global competitiveness, both by damaging customer perceptions of our quality and also increasing supply chain complications for exporters who must meet certain market standards, such as those of the EU-27. 72

Dairy Foods | June 2011

Tom Suber

Technical barriers to trade have proliferated. In the last year, China, Russia and Algeria – three of the world’s largest dairy importers – have thrown up thorny new certification requirements that undercut our export potential. In addition, price volatility has persisted and our use of risk management tools hasn’t really progressed, even as Oceania and Europe cut their learning curves and develop tools of their own. And yet, the size of the prize is undeniable. According to the Food and Agricultural Policy Research Institute (FAPRI), world cross-border dairy trade is growing three times as fast as U.S. domestic consumption. Two trends stand out for future growth: the expanding urban middle class and health and wellness. Consider: 60% of the global increase in gross domestic product over the next 15 years will come from the world’s top 600 cities, says McKinsey & Co. The baby formula sector is poised to double in size by 2015, says Euromonitor, and dairy finds itself nicely aligned with key nutritional priorities such as weight management, protein intake and healthy aging. These trends were identified in the Globalization Study conducted in 2009 by the Innovation Center for U.S. Dairy (with support from Bain & Co.). Later this year the Innovation Center will release a refresh of Bain’s findings to see if they still hold. Among the original conclusions: • Developing markets have continued to see strong consumption, outstripping domestic supply. • Export supply continues to be lagging behind. • U.S. suppliers are well-positioned, but buyer feedback affirms we must still address weaknesses in commercial practices, such as improved customer focus, in-market presence and commitment to regular deliveries with longer-term pricing arrangements. Over the last decade, we’ve ggone from exporting p g 5% of our production n to exporting 13%, and we’ve matured along the way. But maturation is an ongoing process. I’d like to think we don’t have to answer the question estion of whether globalization is here to stay anymore. Instead, we need to decide what role we will play in this growing, globalized balized market, and we need d to focus our resources on what we need to do to get there.  Tom Suber is president of the U.S. Dairy E x p or t C ounc i l , Arlington, Va. He can be reached at tsuber@ usdec.org.

Enter the MilkPEP Awards online and win great prizes.

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

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

Processing & Operations Quality on the Line

Controlling Listeria Monocytogenes, The Bad Bug in Dairy Plants isteria monocytogenes (L. mono) is a gram-positive bacterium and a specific member of the Listeria family. It is capable of causing severe illness and even death. The mortality rate from L. mono in susceptible populations is one of the highest of any known food pathogen. Individuals with compromised immune systems are particularly vulnerable. The Centers for Disease Control and Prevention (CDC) report that L. mono is responsible for more than 2,000 reportable foodborne illnesses and more than 500 deaths annually. L. mono is a “bad bug.” There are many different species in the Listeria family. They are widely distributed in nature and are often prevalent in plant environments. Most species of Listeria are considered to be non-pathogenic. However, the non-pathogenic species “hang out” and attend the same “parties” as the pathogenic and feared L. mono. Recent USDA and Food and Drug Administration surveys have reported that Listeria are present in more than 10% of all raw milk from commercial U.S. dairy farms. The Listeria family of bacteria, especially L. mono, is considered to be psychrotrophic (capable of survival and growth at refrigerated temperatures). Listeria are not destroyed by freezing. Thus, they often thrive in dairy plant environments where milk, soil, dirt and moisture can accumulate. Prime areas for Listeria to thrive are: raw milk receiving/ storage, refrigerated storage, cooling unit condensate lines or drip pans, drains, crevices in walls and floors, cooler conveyors and waste compactors. Also, Listeria bacteria are capable of attaching to equipment surfaces and forming a thick polysaccharide biofilm that protects them against the lethal effect of chemical sanitizers. These biofilms can be a potential source of contamination.

L

74

Dairy Foods | June 2011

Controlling L. mono in dairy plants Effective cleaning and sanitizing of equipment and environmental surfaces is essential to controlling L. mono in dairy plants. Fortunately, L. mono is highly susceptible to most sanitizers if the biofilm has been completely removed by proper and effective cleaning. Therefore, the control of Listeria is an issue of effective cleaning. For sanitizers to be effective, all food residues and the polysaccharide biofilm must be removed from the bacteria attached to surfaces. Chlorinated clean-in-place, foam and manual cleaners are effective in removing the biofilms. Special attention must be devoted to environmental surfaces such as floors, walls, ceilings and other nonprocessing areas. Environmental areas that are in ill repair will make the control of Listeria almost impossible. Drains, floor gutters and trenches must be thoroughly cleaned and sanitized on a daily basis. Using iodine or Quat blocks in floor drains is highly effective when used in conjunction with proper cleaning and sanitizing. Floor foamers are more effective than foot baths. Most sanitizers, when properly used on clean food contact and environmental surfaces, will be effective against L. mono. An effective cleaning and sanitizing program must be supported by a robust Good Manufacturing Practices (GMP) program. People are the No. 1 means of distributing Listeria throughout the plant environment, whether by clothing, utensils, cleaning supplies, pallets, forklifts, trash totes or unacceptable hand/glove washing and sanitizing practices. Plant personnel must understand the importance of the GMP program. GMPs must be enforced – every day! The control of Listeria in plant environments must be verified by a formalized environmental sampling and testing

Henry Randolph

Pasteurization kills L. mono

program (see my March 2011 Dairy Foods column). Testing should be for Listeria, not specific for L. mono. Remember – the non-pathogenic species are members of the same country club as L. mono. Controlling L. mono is an ongoing and continuous “cold war” battle that must be won one day at a time. Effective cleaning and sanitizing is a basic requirement for controlling this dangerous pathogen.  Henry E. Randolph is the founder of Randolph Associates, Inc., which advises dairy processors about improving quality and operations.

Go In-Depth Learn more about food safety at Randolph Associates Inc.’s training courses. Dairy Technology Workshop, Oct. 10-13 and Pasteurization Workshop, Dec.1215. Contact Kristy Clark at 205-5956455 or [email protected].

She doesn’t know how technology can make her food safer. But you do. At DuPont Qualicon, we believe that science— particularly biotechnology—offers the potential to help ensure the safety and quality of our global food supply. Our innovative science can help you perform fast, accurate food quality testing to address a broad range of challenges—so you can get products to market faster and help ensure the safety of the foods people enjoy every day. 1-800-863-6842 Qualicon.com Technology rules. Results matter.

DuPont Qualicon Copyright © 2011 DuPont. The DuPont Oval Logo and The miracles of science are trademarks or registered trademarks of E.I. du Pont de Nemours and Company or its affiliates. All rights reserved. ™

New Product Showcase

Filtration Ecolab

Save time, money and membranes with the Ecolab Ultrasil program, which is a two-part, enzyme-based, cleaning program, including Ultrasil 67 and Ultrasil Extend. Used together, this unique combination of stabilized enzymes, surfactants and sequestering agents are said to provide better soil penetration and protein breakdown. Benefits include increased membrane life and production time, reduced water and energy consumption during clean-in-place and significant effluent impacts, such as phosphorus and potassium reduction. Ecolab 800-392-3392 www.ecolab.com

The Pall Aria FB system provides consistent downstream quality. This user-friendly, automated system uses robust PVDF hollowfiber microfiltration membranes to retain suspended contaminants and achieve microbial bioburden reduction. A unique air scrubbing and flux maintenance process provides high-recovery yield >98% and consistent performance, with typical turbidity