BICAR® Sodium Bicarbonate and ISO 22000 Because she’s counting on us.
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e know where our product goes. We know what’s at stake. Each of us at Solvay Chemicals understands the real world impact of our commitment to food safety.
How strong is our commitment? Strong enough to achieve certification of our Parachute, CO facility to the ISO 22000 Food Safety Management System Standard. We stand alone as the first North American sodium bicarbonate production facility to reach this milestone. Count on BICAR Sodium Bicarbonate to address the most critical food ingredient issue: safety. Count on Solvay Chemicals.
SAFE • Produced in North America’s first and only facility with an ISO 22000 Certified food safety management system • Production managed by a quality system built on a Hazard Analysis of Critical Control Points (HACCP) program and the FDA’s Good Manufacturing Practices (cGMP) LOCAL • Domestically manufactured in Parachute, CO, North America’s newest sodium bicarbonate production facility GLOBAL • Solvay Chemicals is a member of the Solvay Group, the world’s largest producer of sodium bicarbonate Solvay Chemicals. We make your choice an easy one.
Solvay Chemicals, Inc. 1.800.SOLVAY C (800.765.8292) www.solvaychemicals.us
Copyright 2011, Solvay Chemicals, Inc. All Rights Reserved.
$*URXSDFWLYHLQ&KHPLVWU\
6 RECYCLABLE
Kwik Lok Is The Bag Closure Of Choice When It Comes To Function, The Environment And Consumer Convenience! Environment The Kwik Lok Bag Closure is designed to be reused and RECYCLED. The closure has earned a recyclable symbol of 6, making Kwik Lok a truly recyclable closure. Other closures, such as wire surrounded by paper or plastic, or polyvinyl and polypropylene tape with paper between the two ends, cannot be recycled. Wire and tape closures are typically thrown into the garbage each and every time, seldom ever reused. During our extruding process, no processed water is used or expelled into our city’s sewer system. Kwik Lok cools its extruders within a closed loop cooling system. Our new enhanced filtration system prohibits nearly all particulates from being expelled into the air. Kwik Lok is actively seeking to reduce our electrical demands by inventing and installing new, efficient closure manufacturing machinery. No hardeners or additives are added to our plastic. Newly developed additives such as PLA (Polyactide Acid), Polystarch or others are not used. Such additives, while claiming to make plastic degradable, present a couple of problems. (1) Recycling of products made with additives is problematic. The Biodegradable Products Institute concurs, “The recycling of plastic products made with these types of additives is poor, the plastic products have to end up in the landfill ... they cannot be recycled in their original form.” (2) The use of these additives creates methane gas which is 20 times more potent than carbon dioxide emissions! Every landfill has a different content, be it wet or dry, compost, or general waste, mixed with or without moisture and oxygen. Thus the process of degrading is highly dependent upon each landfill’s composition. Should the Kwik Lok closure be tossed into the garbage, its degradation process began at the moment the closure plastic left the extruder since no inhibitors or additives were added to the Kwik Lok. When you compare the choices, Kwik Lok, wire or tape ... Kwik Lok is the logical answer to your bag closing requirements.
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Market Trends Clean-Label Products Continued from page 44
chips, BBQ corn chips and crunchy cheese curls, a consumer favorite. “Customers coast-to-coast have said that our cheese curls are the best they’ve tasted,” states Crowe. The company plans to launch the cheese curls as a standalone product in 2012.
“Customers should feel great about buying any bag of The Real Deal because we have perfected the art of the tortilla chip, corn chip and cheese curl and plan to continue to innovate with the best, most healthy ingredients without ever compromising great taste and texture,” says Crowe.
Another company manufacturing clean-label snack mixes is Healthient, Inc., Jupiter, Fla. It recently launched the LOLICRUNCH line under its SnackHealthy brand. The LOLICRUNCH line is entirely cholesterol-, dairy-, wheat-, and glutenfree. Both the Almond Crunch and Cashew Crunch varieties contain either almonds or cashews, peanuts and are sweetened with evaporated cane juice and brown rice syrup. They also come topped with a hint of sea salt. For consumers who aren’t nuts for just nuts, the Cranberry Nut Crunch option contains dried cranberries alongside almonds, peanuts and cashews. Consumers can imagine they’re snacking on a far away island with the Tropical Fruits and Nut Crunch variety, which offers dried mangoes, papayas and pineapples with almonds, peanuts and cashews. It also offers a little cayenne pepper kick in the seasoning blend. Clean label doesn’t apply only to snack products. Home Free, LLC of Windham, N.H., manufactures clean-label cookies for the sweet-toothed consumer. “Our name refers to the homemade feel of our products and to the cookies being free of most allergens, as well as of trans fat, cholesterol and anything artificial,” says Jill Robbins, president. “It also means that with our products, you are ‘home free’—you can relax because we took care of making sure the product is wholesome and allergen safe.” Home Free, LLC’s cookies come in a variety of shapes, sizes and flavors. “Some people like soft cookies, some like crunchy, some like big and some like mini,” states Robbins. “We offer all those options so everyone can enjoy their favorite kind of cookie.” Robbins adds that Chocolate Chip is one of the more popular selections the company provides. The favored cookie joins the Chocolate Chocolate Chip, Oatmeal, and Vanilla Continued on page 48
46
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With the resources you need to make the right choice,
ADM Milling works for you. As one of North America’s leading millers, ADM provides its customers with a little added something you don’t get everywhere else — expertise. Our technical experts are skilled at providing R&D teams with recommendations that give your products a competitive edge, all while keeping a close eye on your bottom line. It’s just one of the many ways we’re working for you. To learn more about how ADM Milling works for you, contact us at
[email protected]. Or, visit us online at adm.com/milling.
For customers around the world, ADM draws on its resources—its people, products, and market perspective—to help them meet today’s consumer demands and envision tomorrow’s needs.
800-422-1688 |
[email protected] | www.adm.com/milling © 2012 Archer Daniels Midland Company
*Information is accurate as of October 2011, to the best of Archer Daniels Midland Company’s knowledge.
Market Trends Cookies Continued from page 46
varieties, which are all nut-free and made with whole grains. Home Free, LLC also offers gluten-free and organic versions of all its cookies for a consumer with a more specialized cleanlabel need.
“People with food allergies are already telling us that their bodies are sensitive and susceptible, so it seemed especially important with this population to keep the food clean,” says Robbins.
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Snack Food & Wholesale Bakery - January 2012
Another company making sweet snacks clean is Crispy Green of Fairfield, N.J. The company specializes in manufacturing freeze-dried fruits, making it easier for consumers to enjoy a sweet, healthy snack on the go. There are no worries about refrigeration, peels, cores, seeds or rinds with Crispy Green’s FruitziO products. The FruitziO line includes Strawberries, Peaches, Apricots, Apples and Strawberries and Kiwi options, the latter of which is the most recent offering to launch. All the FruitziO products have 100 calories per bag and contain no fat or cholesterol. The company’s flagship Crispy Green line offers a variety of fruit at 55 calories per serving including Apples, Mangoes, Asian Pears, Bananas, Canteloupes and Pinapples. The line comes in a singleserving six-pack, making it easy to eat on the go. Consumers can keep the packages in their cars, lunch boxes, desk drawers or briefcases for easy, clean-label snacking. Kashi Co. of La Jolla, Calif., has long been an advocate for cleanlabel food products. Recently, it launched a new variety of its TLC Layered Granola Bar line. The Peanutty Dark Chocolate Layered Bar offers a fruit and dark chocolate spread over a chewy peanut, peanut butter and granola bar base. Topped with chopped peanuts and chocolate chunks, the bar has 4 g. of protein and 7 g. of fiber. It joins the Pumpkin Pecan and Dark Chocolate Coconut to round out the company’s sweet and savory line. Clean-label food options are versatile, offering consumers plenty of snack and bakery options to satisfy anyone looking for a simple, healthful way to improve their diets. SF&WB
www.snackandbakery.com
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New Products 1 4 2
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Lentil Crackers
Company: Mediterranean Snack Food
1
thinkThin Fruit and Nut Bars
Company: thinkproducts, Ventura, Calif. Website: www.thinkproducts.com Introduced: January Distribution: National Suggested Retail: $1.69-1.99 for a 1.41-oz. bar or a 14.11-oz. box Product Snapshot: The thinkThin lineup now includes Fruit and Nut Crunch bars, which offer two times more protein and 60% less sugar than leading fruit and nut bars. These gluten-free, vegan-friendly bars come in Blueberry, Cherry and Cranberry Apple varieties. Ingredients (Blueberry): Peanuts, almonds, brown rice syrup, soy crisps (soy protein isolate, tapioca starch), chicory fiber, cashews, currants, dextrose, natural flavors, blueberries (blueberries, apple juice concentrate, sunflower oil), soy lecithin, sea salt. Contains: peanuts, soy, almonds, cashews.
Co., Boonton, N.J. Website: www.mediterraneansnackfoods. com Introduced: May Distribution: National Suggested Retail: $3.49-$3.99 for a 4.-5 oz. box Product Snapshot: Mediterranean Snack Food Co.’s all natural Lentil Crackers are a line extension to the company’s Baked Lentil Chips, which are the first to feature the super food benefits of lentils. The Lentil Crackers are available in three naturally gluten-free flavors (Sea Salt, Rosemary Herb and Cracked Pepper) and offer a great taste, satisfying crunch and 5 g. of protein with only 110 calories, the company says. Ingredients (Rosemary Herb): Lentil flour, corn flour, potato starch, vegetable oil (olive oil and/or sunflower oil and/or palm fruit oil) milk protein, sugar, milk cream, sea salt, rosemary, leavening. Allergen Information: Manufactured in a facility that also processes product containing egg yolk. Contains: Dairy.
3
Fullbar
Company: Fullbar, LLC, Greenwood Village, Colo. Website: www.fullbar.com Introduced: January Distribution: National Suggested Retail: $5.99 to $11.99 for a 9.54-oz. box Product Snapshot: Fullbars are clinically proven weight loss bars made with Slendesta, a fullness ingredient. Similar to bariatric surgery, Fullbar works with consumers’ “wiring” to stimulate a complex neural and hormonal feedback loop that fills up and promotes fewer eating occasions. The bars come in Chocolate Caramel and Chocolate Peanut Butter varities. Ingredients (Chocolate Peanut Butter): Brown rice syrup, puffed wheat cereal (durum wheat, ferric orthophosphate, niacinamide, thiamine, mononitrate, riboflavin), peanut butter (peanuts), soy protein concentrate, honey, glycerin, agave syrup, gum Arabic, dry roasted peanuts, canola oil, salt, natural flavors. Contains: wheat, peanut, soy.
Krispy Kreme Glazed and Dipped Donuts
Company: Krispy Kreme, Winston-Salem, N.C. Website: www.krispykreme.com Introduced: November 2011 Distribution: National Suggested Retail: $1.09 for a 4-oz. package of Glazed Chocolate Pie; $4.29 for a 14.9-oz. box of Dipped Cake Product Snapshot: Krispy Kreme is expanding its product lineup with new chocolate-flavored donut offerings. For instance, the Glazed Chocolate Pie option consists of a smooth chocolate filling and Krispy Kreme’s Original Glazetopped crust and comes in a microwavefriendly box. The Dipped Cake version features a donut fully immersed in chocolate-flavored dip. Ingredients (Glazed Chocolate Pie): Enriched flour (wheat flour, niacin, reduced iron, thiamine mononitrate, riboflavin, folic acid), high-fructose corn syrup, water, palm oil, fractionated palm oil, sugar. Contains less than 2% of the following: vegetable shortening (palm oil, fractionated palm oil, mono- and diglycerides, polysorbate 60), food starch (modified), cocoa, vegetable shortening (interestified soybean oil, hydrogenated cottonseed oil), corn starch, salt, cocoa processed with alkali, sodium propionate preservative, corn syrup, soybean oil, dextrose, wheat flour, malted barley, vegetable shortening (palm oil, fractionated palm oil, soy lecithin), titanium dioxide color, chocolate liquor, potassium sorbate preservative, xanthan gum, glucono delta lactone, sodium stearoyl lactylate, artificial flavor, sodium benzoate preservative, sodium alginate, calcium carbonate, corn syrup solids, citric acid, yellow 5, yellow 6, agar-agar, maltodextrin, wheat starch, propylene glycol, mono- and diglycerides, soy lecithin, sorbitan monostearate, baking soda. Contains: wheat, soybeans.
E d i t o r ’s No t e : Go t o w w w. sn a c k a n d b a k e r y. c o m t o r e a d a b o u t m o r e n e w p r o d u c t s.
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Thought for food. At Viterra our best ideas go into every product we provide. Our research and development specialists work closely with our customers to ensure that we deliver the exact formula and profile to meet their food ingredient needs. We’ve got the people, the expertise and the technology to create the highest standard of nutrition, texture and flavor in a wide range of products. We deliver innovative essential ingredients and we are dedicated to our customer’s success. Visit us at viterra.com or reach us at
[email protected] 21C Oats, Inc., a subsidiary of Viterra Inc.
The Nutritional Corner
A Rapid Response Program Update ast year, I provided you with a snapshot of the Grain Foods Foundation’s efforts to share positive messages about the health benefits of bread and grains to the media through our rapid response program. As we kick off the new year, I am happy to share the tremendous progress we’ve made in this area during the past few months. It’s discouraging to acknowledge that the health of Americans has been on a significant decline in the last decade and an already booming weight loss industry thrives because of it. More often than not, carbohydrates, particularly grains, are vilified and misrepresented in these diets “du jour.” At a time when one fad diet after another is released, it’s crucial that we maintain a strong voice for our industry, reinforcing the facts about grains to influencers and consumers alike. This is the purpose of our rapid response program. Since September, the Grain Foods Foundation (GFF) has issued some two-dozen letters to top-tier media outlets, including The Chicago Tribune, MacLean’s, Glamour, and Fox and Friends. Most of the letters educate reporters on a variety of topics. Yet one of the most significant issues we faced this fall was the anti-grains rhetoric from cardiologist Dr. William Davis in his fad diet book, Wheat Belly: Lose the Wheat, Lose the Weight, and Find Your Path Back to Health. In it, Davis asserts that wheat consumption is solely responsible for Americans’ health ills, and that cutting wheat from our diets is the cure-all solution to conditions such as obesity, diabetes, celiac disease and rheumatoid arthritis. Through both traditional and social media channels, we have been working closely with our scientific advisory board to point out that this book is just another low-carb
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diet book with a catchy title (it restricts grains, potatoes and most fruits and vegetables) while highlighting the sound science supporting the important role wheat plays in a healthful diet. Another ongoing issue for GFF has been the spreading of misinformation by physician and talk show host, Dr. Mehemet Oz. Known for his extreme positions on carbohydrates. Dr. Oz has discouraged consumption of bread and grains during multiple show segments throughout the years. During that time, GFF has sent the host and show producers numerous letters correcting this misinformation. As a result of our ongoing response efforts, including a video rebuttal on YouTube, Dr. Glenn Gaesser, chairman of our scientific advisory board, was invited to appear on a recent segment of The Dr. Oz Show. The segment aired on November 28, and in a point-by-point discussion, Dr. Gaesser challenged the host on topics ranging from eating right to the best indicator of good health. As professor and director of the Healthy Lifestyles Research Center and the Exercise and Wellness Program at Arizona State University, Dr. Gaesser highlighted the large body of scientific evidence supporting carbohydrates’ role in maintaining a healthy weight. In fact, he shared data from peer-reviewed journals indicating an inverse relationship between
Judi Adams, president, Grain Foods Foundation and the Wheat Foods Council
carbohydrate intake and weight. The Dr. Oz show reaches approximately 4.35 million viewers across the country each day. He is one of the most powerful influencers in the media and we couldn’t be more pleased with how well Dr. Gaesser held his own and so clearly represented GFF’s messages on the show. While we are thrilled about this media success, there is still work to be done. Although these are only two examples of
our efforts, they demonstrate the need for constant vigilance, which is the cornerstone of our rapid response program. Furthermore, these situations show that influencer engagement often isn’t a matter of instant gratification. Only with consistent interaction were we able to develop a connection with Dr. Oz and establish GFF and Dr. Gaesser’s position as a credible resource in the minds of the show producers. We look forward to future opportunities for growing the industry’s reputation, and most of all, keeping the facts straight in today’s overwhelming media environment. SF&WB
www.snackandbakery.com
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Special Report Packaging Innovations
New Packaging Dimensions It doesn’t take 3D glasses to see the new develop– ments and trends in snack and bakery packaging. Bob Garrison, Contributing Writer
W
hat do consumers want? It doesn’t take special glasses to see these trend lines. With 3D theater movies, 3D televisions, 3G and 4G smartphones, it’s clear consumers want added dimensions and extra features. They want to more closely connect with a momentary diversion, to create more of a custom experience. They also want to feel better about how their purchase impacts the environment. Experts agree that new products and packaging carry those themes right into the snack and bakery food categories. “Increased competition, an uncertain
global economy and growing sustainability demands are driving packaging developments across all categories, including snack foods and bakery,” says Timothy Bohrer, CPP, a packaging materials expert and owner of Pac Advantage Consulting LLC, Chicago. “These trends have companies working harder to differentiate themselves when it comes to how consumers perceive their product quality, convenience and value. The familiar equation of ‘cheaper, better, faster—choose any two,’ no longer creates success. Today, consumers and retailers demand all three product attributes.” A 25-year industry observer, Rick Lingle is Editor-in-Chief of BNP Media’s Food & Beverage Packaging magazine. “Convenience, paired with product differentiation, is a potent combination,” says Lingle. “We see continued snack and bakery interest in convenience. This includes zipper resealability or easy-open techniques such as full, top-of-pack peel and reseal features for cookies. Meanwhile, every company is chasing sustainability, often as one component within a larger Corporate Social Responsibility initiative.”
Form and function Courtesy of ConAgra Foods
Architects used to say, that “forms follows function.” Although that phrase may be
Courtesy of Jolly Time Homemade Pop Corn
lost to the past, packaging engineers are keeping it alive in new products as different as soup to nuts—or, perhaps, biscotti to nuts. What are consumers’ “functional” food needs? On some levels, it’s clear they’re looking for snacks that do it all: Either satisfy individual needs or create a “sharing” experience for two or more. Among those tapping the latter trend are American Pop Corn Co., Sioux City, Iowa, and ConAgra Foods, Omaha, Neb. Last year saw American Pop Corn roll out a Jolly Time microwave bag that, with the pull of a string, turns into an “Insta-Bowl” for sharing. Similarly, ConAgra launched its own Pop Up Bowl, which includes a transparent lid so that consumers can watch their popcorn pop. Not everyone shares the same tastes? That’s okay, too. ConAgra came back last September with Orville Redenbacher’s Flavors, individual 3.24-oz. popcorn bags, each with a separate seasoning packet. Flavors seasonings include White Cheddar, Extra Cheese or Sea Salt and Vinegar. Continued on page 58
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Special Report Packaging Innovations
And the award goes to …
S
nack foods and bakery products earned top honors in 2011 competitions hosted by the Flexible Packaging Association (FPA) and the Paperboard Packaging Council (PPC). Flexible Packaging Achievement Awards: Weaver Popcorn Co., Inc., Van Buren, Ind., earned a silver award for environmental and sustainability achievement for a new Trail’s End caramel corn bag developed by Danafilms Inc. and Plastic Packaging Technologies Inc. FPA credited Weaver and its suppliers for a “dramatic” packaging conversion from historical rigid tins and pails. Of-
ficials said the in-line Quad Seal Bag provides improved shelf presence, a three-ply barrier film combination and Inno-Lok zipper. Say FPA contest judges: “This package provides a compelling case study for marketers to convert to flexible packaging for an improved package at a lower cost, while reducing disposable waste by 80 to 85 percent.” National Paperboard Packaging Competition: ConAgra Foods’ Slim Jim 16-Count Snack Sticks package (provided by Graphic Packaging) earned an “Eco” Excellence Award. PepsiCo’s Quaker Oats unit earned a Gold award (general category) for new Quaker Life Soft Baked Bars (Graphic Packaging). Where there’s smoke … There’s fire. Want to know who’s hot
in private-label new products and packaging? Snack and bakery products earned as many as eight awards in the Private Label Manufacturers Association’s (PLMA) 2011 annual “Salute to Excellence” new product competition. PLMA showcased winners during the PLMA show last November in Chicago. Snack and bakery product honorees included Delhaize America (parent to Hannaford Bros. Markets, Food Lion and others) for its Home360 Baby Strawberry-Apple Little Puffs. Visit www.plma.org to see all “Salute to Excellence” winners.
Continued from page 56
Jesse Spungin is ConAgra’s vice president and general manager for the Orville Redenbacher’s brand. “We’ve found consumers more than ever want to control the flavor of their food, and the flavor packet in Orville Redenbacher’s Flavors allows popcorn lovers to sprinkle on the preferred amount of seasoning to control the flavor intensity.”
Courtesy of ConAgra Foods
Of course ConAgra isn’t the only one easy for travel. Officials say they developed thinking small (packaging) to creatively a flexible, durable new bag that bends and deliver big flavor. Still more interesting new folds effortlessly. offerings include PB2, a powdered snack in “In order for us to better service our 0.85-oz. glossy, multi-colored packets. Bell consumers, we wanted to find out what we Plantation Inc., Tifton, Ga., tells consumcould do better to enhance their experiers they simply need to add ence with our product,” says water and stir to make a marketing director Matt quick snack using PB2 peaDuffy. “Biscotti Bites are an nut butter or PB2 peanut easy solution for consumbutter with chocolate. ers who want to snack on Others use packaging gourmet cookies on-the-go; it to facilitate eating expericommunicates a less ‘fancy’ ences. One of those is and more ‘every-day’ biscotti. Nonni’s Foods LLC, Tulsa, The easy- to-use bag makes Okla. In conjunction with biscotti snacking effortless its summertime launch of and convenient; just open and Biscotti Bites, Nonni’s says wrap back up for another it wanted complementary biscotti break.” packaging to make its biteAlso targeting new usage Courtesy of Nonni’s Foods LLC size snack less messy and occasions is John B. SanContinued on page 60
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Snack Food & Wholesale Bakery - January 2012
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verybody knows what it
means on the football field but did you know the Slipstick Conveyor’s horizontal motion gently glides your product along the conveyor so degradation is reduced or eliminated, delivering the product intact, retaining any added seasonings or coatings. Call 1.800.527.2116 today or visit www.sssdynamics.com to see how the Slipstick can safely simplify your operation and increase your profits.
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Special Report Package Handling Systems Continued from page 58
filippo & Son, Inc., the Elgin, Ill., marketer of Fisher nuts.
Courtesy of John B. Sanfilippo & Son, Inc.
“Consumer research led us to reinvent the baking nut category and create the Fisher Freshness Seal Bag,” says Howard Brandeisky, vice president of John B. Sanfilippo’s global marketing, innovation and customer solutions. “After opening, this
new bag offers a pressto-seal closure that locks in the flavor and crunch of the nuts. The upright design also makes it easier to scoop right out of the bag, into the mixing bowl and store after use.” Many food processors hope their packaging literally clicks with consumers in other ways. One of those companies is Jack Link’s Beef Jerky, Minong, Wis. When the company recast its MATADOR beef jerky communications and packaging design last fall, it used the opporCourtesy of Jack Link’s Beef Jerky tunity to take packaging
just a little bit further to reach MATADOR’s millennial target consumer. “As part of MATADOR’s new, unique and vibrant package design, the brand has incorporated a QR (Quick Response) code to bring the latest news and happenings from MATADOR directly to its fans,” says Mark Catlin, direcContinued on page 62
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Special Report Packaging Innovations Continued from page 60
tor of marketing for the brand. “When scanned with a smart phone, the twodimensional barcode will connect fans directly to MATADOR’s Facebook page,
and provide elements like event sponsorship videos and product special offers. The QR code will also be used across many of MATADOR’s marketing and sales ele-
ments, such as in-store point-of-purchase, on MATADOR mobile marketing trucks, integrated into trade show activations and for field training.”
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Because green is good With the introduction of Freschetta Simply…Inspired Pizza, The Schwan Food Co., Marshall, Minn., took a fresh look at the product packaging. Officials say that each of the eight new varieties of Freschetta Simply…Inspired pizzas is wrapped in new Fresch-Taste Seal packaging to lock in the flavor while using 30% less packaging by weight than a traditional pizza carton. By removing the outer paperboard carton, Schwan estimates that Freschetta Simply…Inspired pizza saves 1,378 tons of paperboard, which adds up to 23,433 trees saved each year. This new package design also sets Freschetta Simply… Inspired pizzas apart within the retailer’s frozen pizza section. SF&WB
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Want to learn more about snack and bakery packaging material trends? Visit www.snackandbakery.com for an exclusive interview with Tim Bohrer, CPP, Pac Advantage Consulting, LLC, Chicago. Bohrer has more than 30 years of packaging industry experience from executive posts at American Can, Fort James, James River and Ivex.
www.snackandbakery.com
Exclusive website details from Tim Bohrer
Special Report Package Handling Systems
Because we’re living in a materials world Snack Food & Wholesale Bakery talks packaging trends with Timothy Bohrer, CPP, president of Pac Advantage Consulting LLC, Chicago. SF&WB: What factors are driving today’s food packaging trends? Timothy Bohrer: Increased competition, an uncertain global economy and growing sustainability demands are driving packaging developments across all categories, including snack and bakery. These trends have companies working harder to differentiate themselves when it comes to how consumers perceive their product quality, convenience and value. The familiar equation of ‘cheaper, better, faster – choose any two,’ no longer creates success. Today, consumers and retailers demand all three product attributes.” SF&WB: You follow numerous product sectors. What have you observed in snack and bakery food packaging? Bohrer: Specifically, we see snack and bakery food manufacturers – and their suppliers – upgrading graphics. It’s clear that they’re striving to simplify printing press changeovers, increase productivity and reduce costs. We see increased use of sophisticated seven- and eight-color systems to eliminate spot colors. This creates new benefits for both package converters and users. SF&WB: What’s happening in food packaging graphics? Bohrer: Packages need high-impact graphics to convey brand confidence and “newness” in the fraction of a second while consumers scan store shelves. PACK EXPO Las Vegas had an interesting exhibit sponsored by Clemson University’s Sonoco Institute of Packaging Design and Graphics. The institute is using state-of-the-art “eyetracking” technology to study the reaction of real consumers to real package designs – in a realistic mini-mart setting. Later, suppliers and manufacturers will be able to leverage results from these studies and create even more “bang” for a company’s graphic design buck. SF&WB: How are manufacturers and suppliers making packages more convenient? Bohrer: Consumer convenience and package reliability improvements dominate package upgrades. You see re-closeable stand-up
pouches continuing to make inroads and now they’re evolving to more “dump-fill” product formats. New technologies include … … Toray’s TreaTear™ directional-tear PP sealant films. Here, Toray is trying to address and consumer complaints about tear notches that don’t provide predictable results; … Ampac’s E-Z Zip® pull-tab opening feature retains the package header and its messaging after opening. It also streamlines [in-plant] filling by not exposing zipper elements to product until the package is opened; … an EASY-LOCK® micro-hook closure system. France’s Aplix is addressing the problem of zipper misalignment on reclose. Known for its hook-and-loop closure systems, Aplix has introduced and patented this product, which closes securely without requiring perfect alignment. … Zip-Pak’s Zip360™ system, which applies zipper reclosure to the full width of a gusseted pouch or bag. This greatly increases the consumer’s access to the product as well as his or dispensing options. … a joint venture between T.H.E.M. and Zip-Pak. These two suppliers have developed a new product that combines the rigidity and barrier of a laminated folding carton – with the reclose of zipper technology in the Zipbox® package. Liner elimination offers the potential to deliver simple, cost effective opening and reclosure. SF&WB: How is sustainability impacting package material development? Bohrer: Package materials and formats are always competing and these advances drive cost savings and convenience improvements for manufacturers. Now, sustainability represents a new battleground. The packaging industry always has delivered source reduction (to package users) as technology progressed. Today, however, this topic has become more sophisticated in regard to how you measure the parameters of sustainability. It’s become a much more complex playing field for those who specify packaging. Now we’re talking about everything from simple calculations of weight reduction and related transportation energy savings – all the way to comprehensive lifecycle analyses. The entire packaging value chain
is experimenting at the moment to identify the most practical and economically viable packaging solutions to reduce environmental impact. SF&WB: How are these trends playing out in snacks and bakery foods? Bohrer: Renewably sourced raw materials are receiving increased attention, with the North American market placing greater emphasis on bio-derived vs. biodegradable attributes. Officials are still questioning the conversion of traditional food producing acreage to bio-energy or biochemical end uses. Meanwhile, researchers also are looking at ways to increase the efficiency of bio-sources from perennial plants on marginal lands. Cellulose film – one of the earliest clear films used to package bakery and snack foods – has reemerged as a highly desirable component in laminations, with multiple metallized and barrier coated grades available. Several U.S. suppliers now offer biaxially oriented corn-based PLA and are incorporating into snack packaging. You can see that the stakes are high; Frito-Lay is involved in lawsuits in both the United Kingdom and the United States in regard to ownership of two patents covering biodegradable bag materials. These trends should continue into and through 2012 because there is much more room to grow in performance improvements. You’ll see suppliers and manufacturers applying this knowledge to the next generation of sustainable packages. About Timothy Bohrer A 30-year-plus packaging industry veteran, Bohrer works with both flexible and rigid structures in plastic, paper and composite packaging and the materials that form the foundation of these package types. Bohrer has also led R&D efforts at American Can, James River, Fort James and Ivex Packaging. SF&WB readers can reach Bohrer by visiting www.pacadv.com, calling (773) 268-2232 or emailing him at
[email protected].
62a
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Is your company a leader in bakery or snack food innovations? You should be here in 2012 or beyond. We are looking for bakers, snack food producers, and packagers to showcase in future issues. Contact Editor-in-Chief Lauren Lau R. Hartman at
[email protected] [email protected] or 847-405-4015 847-405-4015.
Thank Yo You
Some of our best ideas come in small clusters. Creating the perfect oat cluster and coated whole grain ingredients to meet tight formula and final product specifications is only possible when your team is... creative. We work closely with our customers to ensure the perfect flavor and texture, every time. That’s unique. That’s essential. That’s how we roll. viterra.com/clusters
21C Oats, Inc., a subsidiary of Viterra Inc.
Ingredient Technology Inclusions
Inventive, Creative Inclusions As more consumers scrutinize ingredients in the foods they buy, bakers and snack producers are turning to inclusions to create better-for-you products that deliver irresistible taste. Romy Schafer, Contributing Writer
akers and snack producers have been using inclusions for years to create tasty treats that appeal to consumers. These include nuts, dried fruit, crunchy grain clusters, moist fillings, sugar-coated chocolate disks and other items. Inclusions add flavor, color and texture to everything from cookies and snack bars to granola mixes and tortilla chips. Despite the many inclusions available to them, bakers and snack producers are always looking for new ingredients to help
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Photos courtesy of Georgia Nut Co.
them expand or improve their product lines, so they can meet changing consumer demands and differentiate themselves. Today, this means seeking out inclusions that will help create baked goods and snacks
for health-conscious consumers who want products that are made with all-natural ingredients, contain less sugar and unhealthy fats and are fortified with vitamins and minerals. Not surprisingly, inclusion suppliers are ready to deliver. Georgia Nut Co., for instance, has been receiving many requests for products with added protein and calcium, all-natural flavors and colors, and reduced sugar, says vice president of sales and marketing Kurt Thorsen. The Skokie, Ill.-based company’s wholesale offerings include fruits, nuts, seeds and yogurt-covered pretzel, carob and sugar-coated choclate pieces. “We’ve being doing a lot of all-natural, GMO-free Gems, which is our sugarshelled version of an M&M,” Thorsen says. “We refine a lot of calcium-fortified Photo courtesy of Quali Tech Inc.
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Continued on page 66
www.snackandbakery.com
Ingredient Technology Inclusions
“Consumers seem to be a lot more concerned about where their food is coming from. They’re also trying to eat well, so that’s driving things like systems that allow for reduced sodium and reduced fat.” – Stan Tinsley, sales manager, QualiTech Inc., Chaska, Minn. Continued from page 64
products, so we can make our own coatings and enhance [them] with calcium.” The company uses the calcium-enriched coatings on a variety of products, including its yogurt-covered raisins and Gems, which are popular inclusions for cookies, muffins and granola mixes. Thorsen says Georgia Nut’s “tremendous processing capability” enables it to create innovative and new products not currently on the marketplace. “We do a lot of Gems, and sugar shelling is our single largest product line,” he says. “So we asked ourselves what we could do that’s different from everyone else. We [now] form our own lentils and refine our own coatings. We can add protein and other
inclusions to the center of the Gems. There are so many different things that we can do that we haven’t necessarily leveraged in the past that we’re working on now.” In addition to developing items on its own, the company routinely works with its customers to create new products. “We try to understand, directionally, where they want to go, along with showing them things we believe are relevant for the marketplace and might be a good addition to their line,” he explains. “So, it’s really a two-way street. We’re taking direction from them, and we’re also suggesting ideas that we have that they might not have thought of or understood that we can make.” QualiTech Inc., a Chaska, Minn.-based
Photo courtesy of QualiTech Inc.
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company that specializes in particulates, inclusions and savory blends that add flavor, function, mouthfeel and visual appeal to foods, also is seeing more consumers interested in their health and wellness. “Consumers seem to be a lot more concerned about where their food is coming from,” says Sales Manager Stan Tinsley. “They’re also trying to eat well, so that’s driving things like systems that allow for reduced sodium and reduced fat.” It’s not surprising, therefore, that QualiTech is also seeing more interest on the part of food processors in systems that can deliver nutritional ingredients, such as fiber, protein, fruit content and nutraceuticals. “Inclusions have typically been points of color, flavor and texture,” says Tinsley. “What we’re seeing now is their potential to add things like Omega 3s. They make it easy for manufacturers to add such supplements.” QualiTech’s lineup of standard and customizable food inclusions and particulates includes Pell-ettes, a carbohydrate-based, uniformly sized berry alternative; FlavorLites, round, flavor-coated, grain-based crisps; Season-ettes, unflavored, cerealbased pellets and granules that mimic spices and dry seasoning blends; Flavor Islands, which are soft, colorful particulates for wet and dry applications; FlavR-Grain, a 100% natural, stabilized corn germ; and Flavor-ettes, which are sweet or savory particulates that can carry nutritional supplements. A recent Flavor-ettes introduction demonstrates, however, that inclusions also can help bakers and snack producers create more nutritional products by what they don’t bring to the table. QualiTech’s new Cheese Flavor-ettes “is a big breakthrough for us,” says Tinsley. “It provides significant advantages to our customers over real cheese” because it doesn’t melt at high temperatures, yet delivers a rich cheese flavor into systems where real dairy products won’t work.” In addition, the company designed Cheese Flavor-ettes to offer “significant nuContinued on page 68
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Bulk material from A to B. Technology from A to Z. We understand that the efficient handling and processing of raw materials has a decisive impact on the cost-effectiveness of production in industrial bakeries. As a result, Bühler works with you to develop and implement solutions for every stage of the process: secure product intake, careful storage, exact dispensing, and precise weighing. System controls allow for customized recipes, and can easily be integrated into your production planning system. Bühler, providing the speed and precision you demand. Visit us at the 2012 BakingTech Conference March 4th - 7th, 2012; Chicago, IL. Bühler Inc., PO Box 9497, Minneapolis, MN 55440, 763-847-9900
[email protected] Innovations for a better world.
Ingredient Technology Inclusions Continued from page 66
tritional value over real cheese,” explains Tinsley. “Real cheese or cheese sauce is typically very in high fat and has a lot of sodium in it. We developed a product that has significantly less sodium and fat, but provides the eating experience of, say, a cheese dipping sauce.”
Tinsley says QualiTech typically works directly with its customers to develop inclusions for products on which they are working, rather than rolling out a product across the board. “Our value proposition is customization,” he says. “We have a standard list of
products that we can offer as samples on a fast turnaround, but we also turn around samples designed to meet a customer’s objectives quickly. We have a process for identifying a customer’s key requirements, so that we can make sure that we are sending them the right items the first time.” Tinsley continues, “We also understand that the needs and limitations of bakery and snack R&D. Many times, our customers have to do their testing on their production equipment. Our manufacturing process is very scalable. We can make production runs as small as 400 lbs. of a custom item. This way, a customer knows that the material they are testing with in their facility is what they can expect when they roll out a new item in full production. We work to understand the complete journey their product is going to make, from
Photo courtesy ofViterra Inc./21st Century Grain Processing Co.
conception to physical process to market.” Viterra Inc./21st Century Grain Processing Co., a global food ingredient company, develops grain-based inclusions with proprietary ingredients for customers who use them to create healthy or indulgent snacks, baked and chewy granola bars, energy and nutritional bars, baked goods, tortillas and more. “They can be based on textural differentiation, flavor-release uniqueness and targeted nutrition,” says Bill Bonner, senior technical adviser based at the company’s Kansas City, Mo., operations. Currently, Viterra Inc./21st Century Grain Processing is developing several new ingredients for use in future inclusions, including high-fiber oats and beta glucan concentrates from specific oat varieties. “These provide beta glucan in support of the [Food and Drug Administration] health claim for potential cholesterol claim reducContinued on page 70
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Snack Food & Wholesale Bakery - January 2012
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Ingredient Technology
Photo courtesy ofViterra Inc./21st Century Grain Processing Co.
Inclusions Continued from page 68
tion,” explains Bonner. Like QualiTech and Georgia Nut, Viterra interacts directly with the R&D staffs of consumer product companies when developing new products for them. “Our sales, technical service and product developers are in constant contact with
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customers to identify project solutions and new market concepts,” Bonner explains. “Our own consumer product development experience results in our development team understanding key parameters in the process allowing extremely quick identification of issues and solving them.”
Material issues As for most food processors, the makers of inclusions have seen their costs for raw materials increase, especially for all-natural ingredients, which often aren’t as plentiful or as accessible as regular inclusions. Cocoa, cocoa butter, fats, oils, sugar and peanuts are just a few of the items whose prices have gone up significantly, according to Thorsen. “It’s almost universal, I’d say, from a raw materials standpoint,” he says. “I’ve been doing this for 25 years, and I’ve never seen anything like this before.” Still, Thorsen says his company tries not to pass higher ingredient costs onto its customers. “It’s something we can manage,” he says. “We try to look at ways to reduce [product] costs, while still delivering the taste and flavor profile.” Tinsley concurs: “We’re looking at new ways of formulating ingredients to mitigate that cost effect. The cost of grains, grain products and sugar has gone up, but not at the same relative level. So there’s an opportunity to look at, for example, more intense sweeteners—Stevia or something like that—that allow you to reduce the impact of the cost of sugar.” The company is also continuing to look for new sources for natural ingredients, particularly colors. “We have found some really great natural sources for reds and greens,” says Tinsley, “as well as purples, which are more important for vegetable and fruit [products]. We’ve had really good luck, but they’re just inherently more expensive, which is something consumers may not always understand.” What consumers are starting to realize, however, is that a product can be both better-for-you and an indulgent treat. “Indulgence is still king,” says Thorsen. “[A product] still has to taste good. We try to deliver the functionality of indulgence and taste, but with that good-for-you twist.” SF&WB www.snackandbakery.com
Ingredient Briefs
Givaudan expands its TasteSolutions Sweetness program to help bakers achieve sugar reduction goals. Developed from botanical sources and biotechnology, these GRAS-certified modifiers provide sensorially-balanced profiles for both naturally and artificially sweetened low- and zero-calorie products by enhancing their sweetness characteristics while masking undesirable notes and improving flavor. Givaudan Vernier, Switzerland +41 (22) 780 9111 www.givaudan.com
Caravan Ingredients introduces a donut frying oil under the Trancendim line, which delivers a clean mouthfeel. This oil allows for a better-for-you nutritional panel with 0 g. trans-fat, a reduction in saturated fat and the elimination of hydrogenation from the ingredient declaration. Caravan Ingredients Lenexa, Kan. 800-669-4092 www.caravaningredients.com
SF&WBtv 72
Food Ingredient Solutions develops the FISclear line of transparent, stable micro-emulsion colors, extracts and oils made from paprika, beta carotene, carotenal, lycopene, carrot oil, palm carotene and canthaxanthin. These colors and extracts provide a wide range of shades, from pale to greenish yellow to various peach, orange and pink tones to a rich, deep red, ideal for confectionery items. FISclear employs GMO-free emulsifiers and produces particle sizes of 50-100 mm with unparalleled clarity, stability and shelf life. Food Ingredient Solutions, LLC Teterboro, N.J. 201-440-4377 www.foodcolor.com
Symrise’s consumer health business unit consolidates its botanical extracts under the Actiplants brand. This plant extract contains biofunctional ingredients that help strengthen the cardiovascular and immune system and ensure mental fitness. The Actiplants Bilberry, a standardized extract of Vaccinium myrtillus (bilberry), is said to contain antioxidant properties, support the function of capillaries and positively influence ocular health. Symrise Inc. Teterboro, N.J. 201-288-3200 www.symrise.com
Kalsec evaluates the stability of a variety of edible oils, comparing its line of natural antioxidants to a commonly used synthetic equivalent. The ingredient supplier compared peroxide values and oxidative stability instrument (OSI) induction times of TBHQ to Kalsec Duralox oxidation management system AN-110, XT. In both comparisons, Duralox met or exceeded the performance of TBHQ. Kalsec, Inc. Kalamazoo, Mich. 800-323-9320 www.kalsec.com
Nordic Naturals launches Omega-3 Fortify, a food- and water-soluble Omega powder with zero hints of fish. Omega-3 Fortify contains micro-encapsulated cod liver oil in powder form and is designed as an alternative to soft gels and liquids. This neutral-flavored formula can be used as a topping on virtually any snack and baked good. Each single-serving stick-pack contains 500 mg. of EPA+DHA. Nordic Naturals, Inc. Watsonville, Calif. 800-662-2544 www.nordicnaturals.com
View videos demonstrating the newest bakery & snack food ingredients by visiting
Snack Food & Wholesale Bakery - January 2012
www.snackandbakery.com www.snackandbakery.com
Ingredient Briefs Continued from page 72
Cherries Jubilee from Truitt Bros. consists of real Pacific Northwest cherries that add an elegant, decadent touch to a variety of desserts, muffins and cheesecake and work as a filling for crepes and pastries. They’re infused with brandy and nonalcoholic cognac, and come in an easy-tostore, shelf-stable pouch. Truitt Bros., Inc. Salem, Ore. 800-547-8712 www.truittbros.com
McIlhenny Co., the makers of Tabasco brand products, introduces Tabasco brand Pepper Paste, specially created for cakes and other baked applications. Tabasco brand Pepper Paste is an intermediate moisture ingredient prepared by combining Original Tabasco Pepper Sauce and Tabasco Processor’s Blend, which are both derived from aged red peppers, fermented with salt and mixed with vinegar. Tabasco Pepper Paste also provides texture, flavor enhancement and heat. McIlhenny Co. Avery Island, La. 337-373-6105 www.tabascoingredients.com
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Penford Food Ingredients introduces PenFibe RS, a potato-based resistant starch, designed for breads, cakes, muffins, pastries, cookies, crackers, tortillas, sheeted baked and extruded snacks, nutrition bars and gluten-free foods. PenFibe RS contains about 85% dietary fiber on a dry solids basis, maintains a low water-holding capacity—which allows for increased solids/bulk without affecting product quality—and provides a good recovery of fiber content level after manufacturing. Penford Food Ingredients Co. Centennial, Colo. 800-652-4732 www.penfordfoods.com
QualiTech’s Flav-R-Grain PBE is an allnatural, allergen-free, cost-effective solution that helps value-added products better utilize peanuts and peanut-based ingredients. This stabilized corn germ adds a nutty, whole grain flavor, emulates fried/toasted applications and is good for breads, cookies, bars and baked goods. QualiTech, Inc. Chaska, Minn. 952-448-5151 www.qualitechco.com
Z Trim is a multi-functional cellulose ingredient derived from natural sources such as oat bran or corn bran. Produced by Z Trim Ingredients, this cellulose ingredient contributes multifunctional attributes such as moisture management, texture and appearance quality, fat and calorie reduction, clean labeling and cost control for baked goods, fillings and toppings. Typical usage levels range from 0.5-2%, and its superior water binding capabilities help hold other liquids and ingredients in place to prevent pooling, weeping, separation and settling in an emulsified system. Z Trim Ingredients Mundelein, Ill. 847-549-6002 www.ztrim.com
Dawn Foods launched Dawn Mi Panadería, a line of authentic Latino bakery items, including a variety of mixes, ready-to-finish frozen churros and fillings. Included in the line are products for seasonal bakery events. This line is developed to help bakers prepare authentic Latino products. Dawn Food Products, Inc. Jackson, Mich. 800-248-1144 www.dawnfoods.com
View videos demonstrating the newest bakery & snack food ingredients by visiting
Snack Food & Wholesale Bakery - January 2012
www.snackandbakery.com
www.snackandbakery.com
making it easy to
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Create cleaner label products with the Pristine® line of bases and functional ingredients for breads and tortillas All natural Minimize ingredient declaration length Free of undesirable additives SERVICE AND TECHNOLOGY WORKING FOR YOU www.caravaningredients.com
Insider Perspective
A Bakery’s No-Huddle Offense T his is the greatest time of year! New Year’s resolutions are made and perhaps already broken. But this is pro football playoff time, and college football championship bowl time. Watching football reminds me that we can learn something from anything. Meaning that the best teams employ what they hope is a winning football strategy. There are many strategies. Certainly, one of the most exciting is the no-huddle offense. About 99% of the time, after the referee whistles a play is over, the offense forms a huddle to call the next play. After a lot of scratching, spitting and trash-talking, the coach uses some fancy electronics to tell the quarterback about the next play and the quarterback relays the play to the team. In perfect unison, the team members slap their hands and slowly trot to the line of scrimmage with high expectations that the next play will surely be the one that scores a touchdown. This very slow process must take no more than 40 seconds, which may not seem long, but there are many things that can get accomplished in this short 40 seconds—not the least of which is watching a repeat of the last play about a dozen times at many different speeds and from many different points of view. Once in a while, the offensive team uses a no-huddle offense, a speedy, high-risk strategy whereby as soon as the last play has ended, the offense immediately approaches the line of scrimmage while the quarterback screams the next play; rather than taking the time—some 30 seconds— to huddle. Maybe one second after the team is set, the next play is started. There’s no time for huddling, trotting slowly, instant replays, or even a lot of hoping. The next play is running right after the last play ended—almost continuous action. Think about this concept for a second. Can a team win a lot of football games with this strategy? Can football teams sustain this type of strategy for a whole game? Some do—albeit very few.
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Like very few football teams, bakeries need a no-huddle offense every hour of the day and every day of the week. Even 40-second meetings aren’t allowed. We produce some products at 1,000 to 1,800 pieces a minute. If we take 40 seconds to talk and trot around, 1,200 biscuits wind up in the trash. It’s continuous action. A bakery no-huddle offense is a winner strategy for the same reasons it is for football—to get a competitive advantage and to be as effective as possible with the short amount of time available. We accept the high risks of continuous action in order to score “financial touchdowns.” Few football teams are successful at a no-huddle offense—even with big payoff—because of its high risks and strict requirements. The strict requirements for high-speed flawless execution for football teams are the same as for us. Here are a few key elements: Planning is paramount. Failing to spend at least 30% of the time planning can result in disaster. Planning needs to include not only the overall plan but all the details too. Just as coaches who have many plays scripted ahead of time can call them quickly, we need to have our detailed game plan established considering, for instance, each product’s quality requirements and each customer’s specific needs. We don’t score financial touchdowns if products aren’t just right and customers aren’t happy. The team’s coaches—bakery managers and supervisors—aren’t the only personnel who need to be informed of the overall game plan. The quarterback—the forepersons and leads—also need to know the plan. Directives can be relayed quickly and seamlessly if forepersons know the overall plan. What happens if an audible—changing the play at the line of scrimmage (at the last minute)—needs to be called because of changing conditions? Easy to execute if the floor personnel are involved in the plan. Communication must be crisp, accurate and easily understood if the no-huddle is to
C. Thomas Harrington
be effective. This will involve full advance communication of the plan, with all aspects of its execution details. “Players” will have many questions that need to be answered in such a way as to build an effective language about the detailed process that everyone understands. Football teams use practice sessions to build a universal language that results in full and immediate understanding through repeated interaction among players. We use extensive training sessions and buddy systems for on-the-job training, training manuals and pictures to accomplish the same thing: Seamless communication. Obviously, the final key element is flawless execution. Without players who routinely pay careful attention to the special requirements of their job—and can execute on those requirements—a football team using the no-huddle goes nowhere. It’s the same thing at the plant. Training sessions and training aids are great, but careful, patient and detailed coaching allows a staff to understand the job’s special aspects. Paying careful attention to detail results in the kind of financial touchdowns that make customers—and stockholders—smile. See, watching championship football is actually an opportunity to see how the great teams function. So the next time you see the no-huddle executed to perfection and marvel at the coordination necessary, think about your plant. How’s your nohuddle? Are you ready to score financial touchdowns? SF&WB C. Thomas Harrington is the chief financial officer and chief operating officer of Tennesee Bun Co. (The Bun Companies), Nashville, Tenn. Tom has more than 30 years of experience assisting businesses in all stages of development with strategic financial decisions. A graduate of Millikin University, Tom managed his own regional public accounting firm for years. Tom has been instrumental in the financial decisions concerning bakeries since 1996.
www.snackandbakery.com
Process. Package. Prosper!
Get more machinery, for more applications, from one source you can always rely on. Heat and Control will help you profit with efficient machinery for all types of snacks, corn products, nuts, and even donuts, muffins, and baked products. We supply equipment designed specifically for your products, operations, and sustainability. And we support you from start to future with sales, installation, service, parts, and training. Contact Heat and Control today to discuss your next project and see demonstrations of our latest equipment. • Raw product unloading, storage & preparation • Batch & continuous fryers • Spiral & linear ovens • Seasoning applicators • Ishida multihead weighers • Ishida snack bagmakers • Ishida checkweighers, X-ray inspection, seal checkers • CEIA metal detectors • Conveyors, accumulators, distribution systems • Container fillers, tray sealers • Packaging platforms • Real-time line management & control systems
One Call Delivers 800 227 5980
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Production Technology Conveyors & Belts
All the Right Moves Bakery and snack producers want durable conveyors that are easy to clean, maintain and versatile for current and future production needs. Manufacturers say new equipment designs address these objectives. Romy Schafer, Contributing Writer
urchasing a conveyor system is a major capital expense for most bakers and snack producers, so they want to be sure they choose one that meets their current and future production needs. They want durability and equipment that’s easy to maintain and clean. They also want a system they can retrofit to accommodate new product lines and future technologies. Recent equipment introductions by leading conveyor manufacturers meet all of these requirements and more. Undoubtedly, sanitation is one of the most important considerations for today’s bakers and snack producers. Unsanitary food-processing conditions can lead to a host of problems for food processors,
P
Photo courtesy of Intralox L.L.C. U.S.A.
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including product recalls, fines and a loss of consumer confidence. “More and more people are paying attention to the whole idea of food safety,” says Don Osborne, team leader at Intralox L.L.C. U.S.A. in Harahan, La., which offers a variety of conveyor belts. “Bakers didn’t use to worry much about it because they have these big ovens that literally kill anything that’s on a product. Now, they’re becoming more aware of the issue.” Intralox recently introduced several products designed for hygienic food-processing applications, including bakery. Its new ThermoDrive belts are made from homogeneous thermoplastic, with a flexible, 100%-closed surface, and are positively driven using sprockets, so they don’t creep or stretch. These tight-transfer belts also allow for smaller radii at the end of conveyors, making it easy for food processors to efficiently transfer small products, such as cupcakes or cookies. Intralox’s modular plastic belting, meanwhile, consists of modules designed to interlock into a brick-like pattern, with full-length hinge rods. The plastic material is easy to clean and helps prevent bacterial growth. “The hygienic design of a conveyor belt is a paramount concern among [food] processors,” says Jamie Card, marketing specialist at Wire Belt Co. of America. The Londonderry, N.H., company offers stainless-steel belts (Flat-Flex, C-CureEdge, TC-327, EYE-Flex, EZSplice and speciality) and CarrySmart conveyors, a made-to-order line of sanitary conveyors (Flex-Turn, Flat-Flex Straight and Flat-Flex Shuttle and Spreader/Converger specialty conveyors). All of the company’s Flat-
Photo courtesy of Wire Belt Co. of America
Flex belting products are accepted by the U.S. Department of Agriculture (USDA) National Sanitation Foundation/ANSI/3-A hygiene standards. So is Wire Belt’s new Compact Grid conveyor belt. Intended for smaller, more delicate products, such as those in the baking and snack industry, the stainlesssteel belt has a 70%-open surface area that makes it easy to clean and keep clean, and it has no concealed spaces in which pathogens and allergens can hide. Compact Grid is suitable for processes in which product coatings, drainage and liquids or air circulation are factors, says Card. The belt’s 10-mm.-sq. openings also provide enough support for doughy products, such as warm cookies, so they don’t deform into the belt during transfer. Wire Belt says all its products are designed for clean-in-place (CIP) applications, and can be cleaned with a food processor’s existing equipment, saving time, money and energy. Dallas-based Triple/S Dynamics Inc., is enhancing its line of all stainless-steel, Continued on page 80
www.snackandbakery.com
Cleaning is hard work.
Steel belts from Berndorf Band make it easy! In the food processing industry the smooth surface of steel belts eliminates ¿bers or fat remnants from lodging within the gaps during processing, helping maintain hygienic requirements. Steel belts from Berndorf Band meet the strictest hygienic requirements and are easy to clean. Due to the smooth surface a limited amount of aggressive chemicals is required and the cleaning area is easily accessible. Comprehensive technical customer service, development of special tools and a wide range of training courses all ensure that our customers receive the very best support.
BERNDORF BELT TECHNOLOGY 2525 Bath Road Elgin, IL 60124 Phone: 847.931.5264 Fax: 847.931.5299
[email protected] www.berndorf-usa.com
Production Technology Conveyors & Belts Beyond sanitation
Photo courtesy of Triple/S Dynamics Inc.
Continued from page 78
sanitary slat conveyors to incorporate such features as CIP belt washing and drying systems and continuously welded lifting flights for elevating applications. The conveyors use a proprietary, overlapping stainless-steel conveyor slat with continuously welded traveling side guides to eliminate crevices in the food stream. The slats are attached to stainless-steel chains that ride on ultra-high-molecularweight (UHMW) guiderails. The conveyors’ formed stainless-steel frames have openings that provide access between the belts for cleaning. According to Blake Svejkovsky, manager of product handling systems at Heat and Control Inc., Hayward, Calif., the company’s FastBack horizontal motion conveyors reduce product breakage by up to 60%, compared with vibratory conveyors, and prevent the loss of product coatings, eliminating unplanned downtime required to clean coatings from the conveyor pan. In addition, Heat and Control’s Revolution distribution conveyors feature rotary gates that eliminate pinch points and product breakage while providing proportional product distribution without the risk of cross contamination and allergen migration.
While cleanability and sanitation are top of mind for bakers and snack producers when purchasing a conveyor system, conveyor manufacturers know that factors such as reconfigurability, improved production throughput and product handling also influence buying decisions. That’s why they also incorporate these capabilities into their product designs. “Our DynaClean system is unique,” says Jill Batka, president of Dynamic Conveyor Corp., Muskegon, Mich. “Most of the [conveyor] options out there for snack and bakery are stainless-steel. Our conveyor is plastic-sided with stainless-steel components. In using plastic sidewalls instead of stainless-steel versions, we’re able to give customers the option to reconfigure or repurpose their conveyors when their needs change. It’s very economical to reconfigure a conveyor they already own.” The custom-designed conveyor is built to meet National Sanitation Foundation (NSF), Food and Drug Administration (FDA) and USDA standards, and is quick and easy to clean and sanitize without using tools. “It’s also blue, which is a favorite color in food processing because most foods are not blue,” says Batka. “From a safety and a cleanliness standpoint, it’s easy to see food product or areas that need to be cleaned.” Batka adds that Dynamic Conveyor has partnered with Intralox for many years, and plans to add Intralox’s ThermoDrive belt to its belt options. Although Wire Belt is very focused on cleanability, Card says the company also is focused on key processing elements like Photo courtesy of Dynamic Conveyor Corp.
product orientation, product placement and improved production throughput. “The conveyors we design now are more focused on adding value to a product as it flows through a process, rather than just moving a product from point A to point B,” she says. “While that trend is becoming more prevalent in the food-processing business today, Wire Belt has been focused on the value proposition for decades.” Intralox’s Activated Roller Belt (ARB)
Photo courtesy of Intralox L.L.C. U.S.A.
technology, which was recently introduced to the baking industry, also offers bakers and snack producers increased throughput, as well as greater product handling flexibility. ARB-equipped conveyors transport products via free-spinning angled rollers that extend above and below the belt surface. Because conveyed products can be moved selectively, ARB conveyors can change the direction, alignment, location and speed of an item independently, without using rails or mechanical controls. Heat and Control says its FastBack product-blending system, meanwhile, lets food processors accurately mix multiple snack, cereal and other ingredients and maintains the blend all the way to packaging. According to Svejkovsky, the horizontal motion conveyor’s gentle slow-forward, Continued on page 83
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www.snackandbakery.com
Increase product yields and Improve your bottom line.
Use Compact Grid™ conveyor belting… only from Wire Belt. t 70% open area allows for efficient heating and cooling of your product.
t Five times greater flow through than average plastic modular belt.
t Excellent product support for smaller, delicate products such as tortilla chips.
t Belt joining is simple and fast. t Low energy requirement for driving the belt. t Excellent belt tracking. t Easy to retrofit on your conveyor. Wire Belt Companyt)BSWFZ3PBE -POEPOEFSSZ /) 5&-t'"9 &NBJMTBMFT!XJSFCFMUDPNt8FCTJUFXXXXJSFCFMUDPN *403FHJTUFSFE$PNQBOZ
Production Technology Conveyors & Belts Continued from page 80
fast-back motion reduces product damage, coating loss and unscheduled cleaning. ClimbBack, a new version of the FastBack horizontal motion conveyor, has
Photo courtesy of Heat & Control
a unique pan design capable of conveying product uphill as much as 8%, operates more cleanly than belt conveyors and reduces equipment stack-up problems.
Purchasing considerations While experienced food processors know what they need and want in a conveyor system for their operation, industry newcomers often only have a general understanding of such things as sanitation, production throughput and configuration flexibility. Conveyor manufacturers can provide useful information about these issues and others that can help bakers and snack producers in their purchasing decision. For instance, a conveyor system that’s easy to clean and inspect is a must for a food-processing company. Knowing how a conveyor must be cleaned (with caustic cleaners, for instance) may dictate the material from which the unit must be constructed (stainless steel rather than plastic or a 316 stainless-steel instead of 304 stainless-steel) and where it can be cleaned. Also, the cleaning process for conveyors having parts that must be soaked in cleanout-of-place (COP) tanks may be costlier,
longer and less ecofriendly. Knowing very specifically how a conveyor will be used and the type and size of the product it will transfer is essential to choosing a unit for maximum production efficiency. Reliability and sustainability also are important purchasing considerations, say the suppliers. Conveyors and belts made by established manufacturers and from durable, high-quality components and materials typically last longer than their less costly counterparts. In addition to being built to last, well-made conveyors are typically designed so that they can be retrofitted to meet a manufacturer’s changing product needs, a less costly and more eco-friendly option. Bakers and snack producers planning to buy a new conveyor system or retrofitting an existing system will find plenty of options for their specific needs, thanks to conveyor manufacturers dedicated to helping their customers move in the right direction. SF&WB
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