Gold Peg managing director, Simon Donnelly speaks to Food and Beverage Industry News about the company’s role in the Australian market. Read more
Engineered for high volume, spiral ovens are used to cook a multitude of foods. The Heat and Control spiral oven provides maximum baking capacity with a small footprint as an alternate solution to tunnel ovens. Read more
Safety was top of mind for a top Australian manufacturer of bakery products when they approached their long-term product suppliers at BSC seeking recommendation for a suitable chain lubricant. Nick Gunn, the BSC account manager at the time, recommended the ROCOL FOODLUBE Hi Temp Chain Lubricant from ITW Polymers and Fluids, which resulted in a long-term supply program, covering not just the ISO-certified oven chain lubricants, but also a wide range of other oils and greases in the FOODLUBE family.
According to Nick, the ROCOL FOODLUBE portfolio adds an invaluable safety dimension that not only ensures food industry requirements are met, but additionally works to optimise the production in food plants and simplify the overall cleaning process.
“FOODLUBE’s reputation as a globally recognised lubricant for food and beverage manufacturing means that our customer could use the products with complete peace of mind, with no concerns regarding contamination or machinery performance,” he says. “Due to the wide operating temperatures, FOODLUBE Hi-Temp Chain Oil can operate at temperatures ranging from minus 25 degrees to 280 degrees Celsius, they use the same product in their ovens, as well as in their freezers.”
Emilio Seballos, Channel Manager for Heavy Industry at ITW Polymers and Fluids, explains what makes the FOODLUBE proposition attractive for food manufacturers.
“ROCOL FOODLUBE has NSF accreditation, which is globally recognised, and it is also HACCP certified. On top of that, many ROCOL products provide an additional level of safety assurance through their ISO 21469:2006 certification. Like NSF H1, this certification is globally recognised and important for British Retail Consortium audits as it provides credible, independent assurance that products are formulated, manufactured, stored and supplied hygienically and safely.”
Another area where food manufacturers can benefit from the use of ROCOL FOODLUBE products, Emilio explains, is to rationalise and simplify their lubricant inventories.
“The technology behind food grade lubricant products has improved drastically over the last 10 to 15 years. Whereas many food manufacturers still prefer to keep separate inventories for food grade and non-food grade lubricant in their plants, they are increasingly coming to realise the simplifications they can achieve by switching to food-safe products through more of their applications, thus eliminating the risk of cross-contamination in their plants,” he says.
“In the case of the FOODLUBE product range, all the oils and greases are made with a synthetic base oil, which means they don’t break down and carbonise when exposed to high temperatures. This in turn leads to prolonged maintenance intervals as the lubricant does not evaporate from the chain, nor does it cause the chain to drag. The FOODLUBE Hi Temp Chain Spray also has great resistance to water washdowns, so you don’t need to lubricate your chain as frequently in a high water washdown environment. All of this leads to reduced maintenance expenses for the plants and enhances their total reliability and efficiency,” he adds.
As a routine practice, Emilio says the ITW and BSC personnel often perform joint assessments for BSC clients to help them rationalise their inventories.
“The beauty of the ROCOL FOODLUBE portfolio is that many of the products serve multiple purposes. For example, your gearbox oil in one application can be used as chain lubricant in another application. Similarly, your hydraulic lubricant might double up as a chain lubricant, depending on the situation,” he says.
“Where ITW P&F and BSC come into play is to help our customers rationalise their inventories to simplify their management. In one audit we did in conjunction with BSC some years ago, the customer was using 25 different lubricants from 13 different brands. We were able to simplify this down to 12 lubricants from the FOODLUBE range.”
Within this portfolio, Emilio says the FOODLUBE Premier 1 grease has been a “game-changer” in the food industry.
“The FOODLUBE Premier 1 grease is a food grade grease designed for bearings operating at high speeds and high temperatures. Because this grease has a consistency grade of 1, in addition to a wide temperature range of minus 30 to 180 degree Celsius, it can effectively replace multiple types of greases in one application line.
“The FOODLUBE Premier 1 grease is resistant to water washdowns and ISO21469 certified, so you can safely use it where stringent quality control measures are in place.”
The FOODLUBE WD spray is another popular product within the range, Emilio says.
“The FOODLUBE Water Displacement (WD) spray is ideal for use as a general lubricant to protect small components such as linkages, pivots and pins. Having high temperature resistance (up to 120 degree Celsius) and being synthetic based make this a multi-purpose spray that you can use for many applications. The WD Spray is also fortified with PTFE for increased lubricity and like all FOODLUBE products, it is free from colour and odour – which is very important in the food industry.”
As an additional safety measure, all plastic components including the lids and actuators in the ROCOL FOODLUBE products are metal detectable and capable of detection by most metal detection equipment.
Read more articles like this at: www.lets-roll.com.au
“I’ve had some incredibly hard and dark times with this business. Terrible times, when I thought we weren’t going to make it.”
Operators of anaerobic digestion (AD) plants know how important it is to optimise energy use across all stages of the process. That is why many recapture as much heat as possible for reuse elsewhere, including from the hot exhaust gases generated by the combined heat and power (CHP) engines which turn the biogas from the AD plant into useful heat and electricity.
Heat exchangers used for exhaust gas heat recovery need to be particularly robust in order to cope with the physical and chemical stresses imposed on them from the exhaust gases which are both hot and corrosive. HRS Heat Exchangers were recently asked to install just such a unit.
An AD site, belonging to one of the leading waste management companies in the UK, transforms some 45,000 tonnes of food waste from domestic and commercial sources into renewable electricity and high value digestate biofertiliser. From the beginning the plant had been designed to be as efficient as possible and included exhaust gas heat recovery. However, when the original heat exchanger fitted to the exhaust system failed after just a few years of operation, the client approached HRS to provide a more robust and reliable replacement.
The ideal solution was an HRS G Series gas cooling heat exchanger: a complete stainless steel multi-tube heat exchanger specifically designed for exhaust gas cooling and thermal recovery. The hot exhaust gases flows through the interior tubes of the heat exchanger while the service fluid, in this case water, flows though the surrounding shell. The use of stainless steel is a key factor in the longevity of the G Series and rapid corrosion of the original carbon steel unit was one of the reasons for the original’s failure.
Other design features of the G Series also increase its operational life as Matt Hale, International Sales & Marketing Director at HRS Heat Exchangers, explains: “All HRS tubular heat exchangers include bellows in their design to allow for thermal expansion. The original heat exchanger we replaced was exposed to significant thermal stresses which contributed to its early failure.
“You also need to consider the condensation which can occur when the hot gas meets the tube plate and cooling begins. The resulting condensate is acidic and can be extremely corrosive, so the HRS G Series includes drains in the header to allow this condensate to be removed, as well as a hatch to allow for manual cleaning and inspection.”
As an operational plant, it was important to keep downtime at the plant to a minimum during the installation of the new unit. HRS manufactured the new heat exchanger to the same eternal dimensions and used the same connections as the original. This enabled a straightforward installation in just a few hours without any pipework modifications, with the installation being carried out just eight weeks after design approval.
In operation the new G Series heat exchanger cools the exhaust gas from ~530oC to ~320oC and the heat recaptured from the process is used in the AD facility and to provide hot water around the site. Since installation the HRS G Series heat exchanger has performed so well that HRS has been asked to quote for the replacement of another unit which is used to treat the digested sludge from the plant, with an HRS DTI Series unit.
As the impacts of African swine fever in Asia fade, pork will lead a global animal protein production surge in 2021. Locally, however, production growth will be limited, as Australia’s beef and sheep producers focus firmly on rebuilding stock numbers.
In its just-released Global Animal Protein Outlook 2021, agribusiness specialist Rabobank said China’s initial recovery from African swine fever (ASF) would emerge as the biggest driver of growth in the global animal protein sector in the year ahead – while also representing the greatest risk for global trade.
Rabobank senior animal protein analyst Angus Gidley-Baird said production growth was expected across most key animal protein markets around the world in 2021, and within most species, after a challenging 2020.
“Pork production is expected to grow faster than its protein counterparts in 2021, driven by the ASF recovery in China and Vietnam, while poultry and aquaculture are also expected to grow based on post-COVID-19 improvements to foodservice,” Gidley-Baird said.
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Beef should return to modest growth, he said, led by increased production in North America and Brazil, while wild-catch seafood would go against the growth trend, with a small decline expected due to climatic conditions and reduced quotas.
With the smallest cattle herd in over 25 years, and favourable seasonal conditions, the report said Australia’s beef production would be restricted in 2021, with slaughter numbers to dip slightly from 2020.
Despite this, Gidley-Baird said improved pastoral conditions would increase average carcase weights, leading to a small lift in both production and exports in 2020.
Ongoing competition from producers, feedlotters and processors would also ensure cattle prices remained strong, although prices would ease as numbers build.
“Continued high female slaughter rates in 2020 and high livestock prices suggests a focus by producers on trading cattle rather than retaining them for breeding, and we expect herd rebuilding activities to extend into 2021,” Gidley-Baird said.
Australian lamb slaughter was however expected to increase in 2021, despite the country’s smallest sheep flock in over 75 years.
“Better breeding conditions and an increased focus on lamb production will drive increased lamb slaughter and, while carcase weights are expected to remain steady, production and, in turn, exports should grow,” Gidley-Baird said.
Domestic demand for sheep and flock rebuilding was forecast to remain firm, with export demand key to lamb pricing. And, with softer economic conditions prices –would be lower than in 2020, although remaining good, he said.
African swine fever driving change
Globally, recovery from ASF in China would be the major factor impacting the animal proteins sector in the year ahead, the report said.
China’s pig herd started its recovery in 2020 after nearly halving in size the previous year due to ASF, and would continue to grow strongly in 2021, Gidley-Baird said.
While ASF still threatens many of China’s smaller pork producers – who make up about half of the production – Rabobank expects the ongoing recovery would see the 2021 herd inventory reach above 80 per cent of pre-ASF levels.
ASF still remained active across the globe, with Germany continuing to manage an outbreak detected in September 2020, Mr Gidley-Baird said. And further herd losses were likely in the Philippines and also Vietnam, where, despite sporadic outbreaks in 2020, there was still expected to be an increase in pork production in 2021.
China to dominate global trade
Despite the recovery in China’s domestic pork production, Chinese imports of pork, poultry, beef, and seafood will continue to dominate global trade, the report says.
And, as such, any irregular swings from China could have significant consequences for producers and markets.
“Changes in China’s import policies, shifts in China’s commitment under the Phase One Trade Deal with the US or moves to avoid human or animal health risks could all present trade issues in the coming year,” Gidley-Baird said.
Gidley-Baird said recovery from COVID-19 would also impact the global animal protein market in 2021, with issues surrounding foodservice recovery, labour availability costs, supply chain transformations and food safety creating both opportunity and risk.
In the beef sector, Gidley-Baird said, labour availability and cost would remain the most pressing challenge for global beef processing and production.
“Given the higher cost and reduced opportunities in foodservice, margin squeeze will also be a challenge, however foodservice recovery will help lift these margins, particularly for higher-value beef cuts served in restaurants,” he said.
Reduced global poultry demand due to the economic downturn in some importing countries had impacted trade and created the need for more focus on domestic consumers, but Gidley-Baird said foodservice recovery would help balance out supply and demand.
Similarly the global pork market would shift its focus away from exports towards local consumers, mainly due to ASF but also COVID-19.
“Global seafood trade has been greatly affected by COVID-19, and the market risk will be ongoing pending foodservice recovery and improved demand – sectors such as shrimp are yet to recover from trade disruptions.” he said.
However post COVID-19 opportunities would also emerge, Gidley-Baird said, largely on the back of foodservice recovery and the rise of e-commerce direct-to-consumer trends.
Technology and innovation for a more sustainable sector ‘Tech innovations’ – such as methane-reducing additives which improved feed efficiency, or traceability to mitigate animal disease risk and offer supply chain transparency – exemplified an increasing focus on sustainability and productivity in animal protein, the report said.
These technologies, Gidley-Baird said, would enable and accelerate commercial adoption into 2021 – helping drive environmental, social and economic sustainability.
The increasing role that the market and regulators would play in improving the sustainability of the animal protein supply chain would also become clearer in 2021, Gidley-Baird said, with the number of animal protein, food retail and foodservice companies making commitments to a lower environmental footprint likely to grow.
Aleph Farms is heading towards the transfer of its commercial product – thin-cut beef steaks – into proprietary platform suitable for mass cultivation. The steaks, grown directly from non-GMO cells of a living cow, boast nutritional, culinary, and sensory attributes of meat in terms of texture, flavour and aroma, claims the company. The company has developed five proprietary modules for its unique mass production platform, set to bring the product to cost parity with conventional meat at scale.
The prototype of its commercial product will be first introduced at the Asia-Pacific Agri-Food Innovation Summit on November 20th in Singapore as part of a virtual cooking demonstration hosted by Aleph Farms’ resident chef and VisVires New Protein VC.
The company beefed-up its proof-of-concept released in 2018, increased the size of its slaughter-free product, and adapted it to fit controlled, automated bioprocesses to ensure economic viability in large-scale production.
The move marks a major leap in Aleph Farms’ goal of making cultivated meat widely available in the global community. The company is currently transitioning its commercial products to pilot plant (BioFarmT). The pilot launch is planned for the end of 2022.
“One of the big challenges of cultivated meat is the ability to produce large quantities efficiently at a cost that can compete with conventional meat industry pricing, without compromising on quality,” says Didier Toubia, co-founder and CEO of Aleph Farms. “We have developed five technological building blocks unique to Aleph Farms that are put into a large-scale production process, all patented by the company.”
Meat cultivation: process of design that is inspired by nature
Aleph Farms’ platform for cultivating steaks mirrors the natural process of tissue regeneration processes that occur in the animal’s body, but outside of it and under controlled conditions. The process is designed to use a fraction of the resources required for raising an entire animal for meat, and without antibiotics.
To successfully grow whole pieces of meat, compared to minced meat product, the company mimics the extra-cellular matrix found in animals with a plant-based matrix that enables the cells to grow and form structured tissues of meat. Its ‘cell-banks’ yield an unlimited source of pluripotent, non-GMO cow cells’ for growing large quantities of meat without the dependency on living animals.
Aleph Farms has designed patented tissue cultivators to facilitate the biological process occurring in vivo, providing the warmth and basic animal-free elements needed to build tissue in nature. This includes water, proteins, carbohydrates, fats, vitamins, and minerals.
The gastronomical experience of Aleph Farms’ steak
The company has perfected the structure of its product so that it embodies the familiar texture, taste, cooking behavior, as well nutritional qualities of conventional slaughter-based steaks.
“Aleph Farms is establishing a new category of meat, imbued with its own culture and a new world of meaty experiences,” enthuses Amir Ilan, the company’s Resident Chef.
“It’s not enough to just make a protein that will fill the nutritional gap; we need to capture the fullness of the meat-eating experience,” adds Toubia. As a French native with roots in food culture, and having studied food engineering in Dijon, Toubia brings his appreciation of gastronomic tradition to his unique cultivation technology. “Meat can be cultivated from cells isolated from different animal breeds, have different cuts, and it elicits different emotions. We see Aleph Farms as crafters of experiences.” Toubia concludes.
A scorching afternoon in far North Queensland, boiling bitumen and a hand of green cavendish bananas crushed into dust by the wheel of the tractor. This was how Krista and Rob Watkins drove head first into an innovative use for the 500 tonnes of bananas destined for landfill in North Queensland each week.
Krista and Rob Watkins’ company, Natural Evolution is the first company in the world to commercially produce gluten-free flour from bananas. It now has an ever-growing range of highly nutritious food products produced from waste bananas and sweet potatoes. Ranging from its signature Green Banana Baking Flour, through to baking pre-mixes, health supplements, skincare, and now vodka.
According to a recent report published by the Food and Agribusiness Growth Centre, trading as Food Innovation Australia (FIAL), by creating value-added products from food waste, food and beverage businesses such as Natural Evolution could be contributing $18 billion in economic value by 2030.
“Being able to undertake scientific research was essential to our ability to scale up, increase our production capacity and expand our product range. I really encourage other businesses to tap into the collaboration and resource-sharing that FIAL makes possible” said Natural Evolution founder and managing director, Krista Watkins.
FIAL supports businesses such as Natural Evolution to innovate through connecting them with the funding and collaborative research expertise needed to commercialise innovative products and services.
“With the majority of Australian food and beverage businesses being small-to-medium enterprises, providing these businesses with access to the expertise needed to innovate is critical,” said FIAL general manager innovation, Dr. Barry McGookin.
Krista Watkins will be taking part in a live Q&A on collaborative innovation platform, the Food Matrix, on Thursday 19 November. Register via the Food Matrix. Natural Evolution was also featured in the fifth edition of FIAL’s Celebrating Australian Food and Agribusiness Innovations book.
The Godden Food Group is a family-owned and operated wholesale food distribution business located at Ormeau just north of Queensland’s Gold Coast. Godden Foods supplies a range of frozen, chilled, fresh and dry goods to restaurants, caterers and private homes throughout south-east Queensland and northern New South Wales.
In 2019, the lease on the company’s premises came to an end and Jeff Godden, the company’s owner, had to find new premises. Having secured a new home for the business, and also having built a 27,000m3 insulated store, he needed to fit it out with advanced refrigeration equipment, to provide separate rooms for -23°C frozen storage and a chilled area at 2°C-4°C.
For Godden foods, the key requirements were to have a safe, cost-effective refrigeration system that would provide sustainable service well into the future. However, Jeff Godden also had another target in mind – he needed the whole project completed to allow him to be fully operational before his initial rent-free period expired.
The GEA solution
Scantec Refrigeration in Murarrie, Queensland is a refrigeration company with 25 years’ experience in supplying advanced industrial and commercial plants throughout the region. Stefan Jensen, one of the founders of the company, recommended Godden use a centralised low-charge ammonia refrigeration system with four GEA Grasso V300 reciprocating compressors. Although Jensen knew that this would not be the option with the lowest capital expenditure, he was certain that it was the best long-term system for his customer.
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“I knew that this customer would be able to make huge savings on energy costs,” said Jensen. “But when you tell customers that they can reduce their energy usage by two-thirds, sometimes they don’t believe you. But I was able to present evidence from other projects, so the customer went for the idea.”
Jensen explained that the big benefit of a centralised low-charge ammonia refrigeration system is that it contains very little ammonia, around four to five times lower than a conventional liquid overfeed system.
The presence of high-density liquid refrigerant within the wet suction lines and risers is eliminated. Because pressure drops in wet suction lines are up to 60 times higher than in pure vapour lines, the system runs at lower refrigerant pipeline pressure drops, making it very energy efficient.
“This is where most of the energy saving comes from,” he said.
The GEA Grasso V300 compressors at the heart of the system were suitable for the job. Scantec chose the GEA machines, partly because they were available quickly, but mainly because of their inherent energy efficiency.
“The V300 is an excellent machine and, in my opinion, more efficient than anything else on the market,” said Jensen. “But it’s also one of the very few that does not require water cooling,” he said. “Water cooling typically adds at least $15,000 to the installation cost and is a drain on energy as the water has to be pumped around the system.”
Not requiring water cooling further reduces energy consumption and makes the installation “plug-and-play”, reducing the time involved and giving the company the flexibility to take the plant with them should they need to move again in the future.
The new plant at Godden Foods was commissioned in May 2020, coinciding with the start of trading from the new premises. According to Jensen, its Specific Energy Consumption (SEC) is better than anything he’s seen on the market.
“With energy savings of around two-thirds compared with an industry-standard, air-cooled HFC-based system, Godden will get the whole cost of the new plant back in eight years well before the expiry of the 15 year lease period,” he explained. “But if you just consider the marginal additional cost, compared with a freon plant, the payback will be three to four years.”
Maintenance costs for the system will be in the region of two per cent of the initial capital cost annually, lower than equivalent freon systems.
It is also safe. The operating inventory within the freezer is only 1.5kg of ammonia so, even if there was a catastrophic leak, the concentration of ammonia within the refrigerated space would be only around 100 ppm. The IDLH (Immediate Danger to Life and Health) threshold is 300ppm as a comparison.
The result is a new refrigeration plant for Godden foods that is more energy efficient than an equivalent freon system, environmentally sustainable, safe, portable if necessary and, if correctly maintained, will provide 30-40 years of faithful service.
For more information on GEA products, click here.
Packaging specialist Tetra Pak has released new research that revealed the carbon footprint of different food and beverage (F&B) packaging formats in Australia and New Zealand, with carton packaging having the lowest climate impact.
Commissioned by Tetra Pak and conducted by environmental consultants thinkstep ANZ, the new report “Life Cycle Assessment of Beverage and Food Packaging in Australia and New Zealand” is a market-first, independently peer reviewed comparison of the environmental impact of common packaging formats, including cartons, PET bottles, rPET (recycled PET) bottles, HDPE bottles, pouches, tin cans, glass bottles and glass jars.
It is important for F&B manufacturers to look at the carbon contribution of packaging across the entire life cycle of a package, in addition to end-of-life. The report revealed that the biggest contributor to carbon emissions is the source of materials used in the packaging.
Based on the amount of carbon dioxide released into the atmosphere per package of 1L fresh milk, the report found that carton packaging has a climate impact of 51 grams – almost 12 times less than glass packaging (605 grams), 5.5 times less than PET (280 grams) and 3 times less than HDPE (164 grams).
Cartons performed the best compared to other forms of packaging because of its material efficiency (using less material) and its mass which is mostly fibre from a renewable plant source.
Packaging formats were analysed across their entire life cycle, including base material production, pack manufacturing, filling, transport, and end-of-life (recycling or landfill) impacts, to offer insight into their overall environmental impact.
Andrew Pooch, Managing Director, Tetra Pak Oceania said: “Food packaging plays a critical role in feeding the world’s population, but it is causing problems for our climate. Today, the global food system accounts for 26% of global greenhouse gas emissions.
Sustainable food packaging can play a strong role in bringing about the harmony between protecting our planet’s ecosystem and meeting the human need for food. As an industry, we need to start talking about minimising packaging impact from cradle-to-grave, if we are serious about sustainability.
It is critical for the F&B industry to explore new ways of producing materials, addressing their embedded carbon, and promoting carbon neutral materials.
Cartons have the potential to become the world’s most sustainable food package. Mostly made of paper, cartons have a far smaller contribution to greenhouse gas emissions compared to other packaging types. If we swapped Australia’s pasteurised milk from formats like HDPE bottles, rPET bottles and PET bottles to cartons, it would be the annual equivalent of taking more than 77,000 cars off the road.
Steven Sischy likes a challenge. The automation and drives business manager for APS Industrial joined the company three months ago with the brief to work together with one of its manufacturing partners – Siemens – to make them the leading automation brand in the country. Siemens already has a great reputation in Europe and Australia, but Sischy is keen to take them one step further.
“My aim is to increase Siemens market share in Australia. Currently, they don’t hold the position of number one. They are definitely a mainstream player in a lot of the sectors where they are active, but they don’t have the dominance they have in Europe.
“My challenge is to see how quickly we can get them up there with Europe and help local industry experience these world-class products and technology. In the short amount of time I’ve been with APS we’ve started to see some returns with having a big focus in particular areas.”
This includes the food and beverage market where over the past two years, the Internet of Things (IoT), Artificial Intelligence (AI) and Industry 4.0 have started to take hold in the processing and manufacturing of goods.
“We also see the packaging industry as a very big market within the Australian and New Zealand markets,” he said. “What we have seen, with COVID, is a lot of people are more interested in knowing where their food is coming from.”
And this is one core principles of how Siemens does business – helping make sure that the food supply is secure, especially when it comes to traceability.
“What is important is cyber security,” he said. “If you look at the food and beverage sector, you will see that Siemens has a cyber security policy within its entire range. When they talk about traceability – especially when you start looking into food and beverage, as well as pharmaceutical – you want to know who has actually put what ingredients where, but they want to now go down to even the operator who packed the product.
“This is part of Siemens core DNA. This technology is already in place and gives manufacturers the capability to say ‘I can show whatever is going into a product has been made with a particular recipe and we will track the entire process from start to finish. We will also note when an operator has changed anything, down to the time and date when it occurred.’”
But there is also a component of the security protocols that is sometimes not taken into consideration, especially when it comes to bespoke manufacturing processes.
“The other side, with the technology – is the intellectual property, which is a massive component,” said Sischy. “Cyber security – because the products are already in place – protects the companies that are investing in these technologies to make sure their knowhow does not fall into foreign hands or any of their competitors’ hands.
“Siemens cyber security is very robust. A lot of the exposure that Siemens has to essential services – whether it be water, wastewater, electricity generation, transport – needs to have robust communication protocols secured end-to-end, so nobody can get in there and potentially harm those processes in any way.”
Sischy said it is also critical to note that Siemens has got a cyber security team that constantly looks at any of these issues that may arise. In the event of a breach, or a potential attack, they can get in contact with the security division who will act on their behalf to ensure that the processes are still intact. Sischy said it is important to protect your assets and if a company already has the necessary security steps in place at a high level, it is easy to integrate these types of measures down to individual processes.
“When it comes to starting your digital journey, we have already got it down to the Siemens LOGO!, which is a very small micro-based controller for home automation, as well as small pump stations,” he said. “It has already got cloud connectivity, so you can put it to the local cloud, or you can send it something like mindsphere if you choose to do that. But the point is you do have that capability.
“Like AI, as well as vison-based systems, we’ll start seeing the evolution of what we call edge-based processors where you are going to have a fair amount of processing sitting very close to the action and then sending that information, or digitalised image, back to some central-based cloud solution, which will then give you the ability to interrogate the information even further.”
Digital twins are also part of the Siemens’ portfolio. Digital twins have come to the fore over the past 12 months, whereby it is possible to create a virtual twin of a physical item. This gives companies the ability to start developing a process, have a look at what they want to do with the process, how they want to improve it, and put in the diagnostics before they connect any physical device to the network.
“Also, through a process that we call Team Centre, you’ve got the ability to also then work out from a manufacturing side, ‘How do I increase the movability? Do I have the right product for the solution? How do I reduce costs and how do I improve the quality of the system?’” said Sischy.
The end game to all these processes is giving processors and manufacturers the ability to achieve the productivity outputs they want, and streamline global processes.
“If you look at it – it doesn’t matter where you look – where any food and beverage company have global location, how do we see whether or not a certain geographical area is more deficient or even profitable versus other areas?” said Sischy.
“What we find, if you have a progressive company, is that they are always looking to be at the forefront of their competitors, or always be ahead of their competitors, which means the uptake of technology is relatively easy. It is where you have companies that may not have the capacities internally, that it becomes more challenging. Sometimes in those instances it can sometimes be harder.”
He said that APS’s philosophy, and therefore something that they are also trying to bring with the Siemens’ suite of products – and Team Centre in particular – is trying to improve the overall quality but also try and lower costs.
“A big part of this going forward, in the Australian market, is to try and reduce your energy consumption and CO2 emissions,” said Sischy. “It is going to be a massive focus going forward, so we need to look at the end goal and determine the true cost of its implementation. With Team Centre, because of the development and also looking at efficiencies, you can also look at the process flows, and that improves it – the actual physical prototyping reduces the development costs and improves the quality.”
He said that Siemens and APS can provide a complete solution including all the Siemens componentry – the PLCs, the drives, the switchgear, the power supplies, the networking devices, as well as panels and cabling.
“Through the company’s system integration program, end users will have the ability to get an end-solution product for the customer,” said Sischy. “It is not only providing product with the inclusion of the APS system program, but it also gives the customer the ability to understand and deliver their needs.
“To make manufacturers locally more cost effective, they need to adopt these technologies. If they are going to try and do this with their standard ways – ‘this is how we have done it over the years etcetera’ – they might not succeed. They need to adapt to the latest technologies.”
Overall, Sischy is excited about the future of the APS/Siemens relationship. It has been a mutually beneficial relationship for both companies – and of course, Australian industry who is better placed than ever to access these products.
A new training initiative based on the thermometer is about to be introduced to the Australian cold chain industry. It is seen as a practical move to help combat the country’s serious food loss and wastage problem, estimated to cost the country nearly $4 billion a year at farm gate value.
The Australian Food Cold Chain Council (AFCCC), the peak advocacy body comprising concerned industry leaders covering refrigeration assets, transport and food distribution, will release an online education program, Thermometers and the Cold Chain Practitioner this month.
The program is aimed squarely at those the AFCCC regards as the super heroes of the food cold chain process – the people who oversee the movement of food through refrigerated transports, loading docks and cold rooms across the nation.
Industry research convinced the AFCCC that Australia desperately needed a new Cold Food Code that should be adopted by industry to stimulate a nation-wide educational push to bring Australian cold chain practices up to the much higher international standard.
The educational program starting with temperature measurement is the first of a planned five-code series.
The AFCCC has invested in new online education software that will be used to develop training programs to support the release of the actual Code document that will cover temperature technologies and how they should be used for monitoring a variety of foods carried in the cold chain.
The initiative runs alongside the work being done by other authorities, including Food Innovation Australia (FIAL) and the Commonwealth Government, which has signed up to a United Nations treaty to halve food wastage by 2030.
Some of the rising levels of national food wastage is considered to be the result of poor temperature management, and poor understanding of how refrigeration works in a range of storage environments. This includes from cold storage rooms through to trucks and trailers, and even home delivery vans.
Australia has world-class refrigeration and monitoring technologies, but the AFCCC believes industry will have to adopt serious training programs so that those responsible for moving food and pharmaceuticals around the country can get the best out of the available technologies.
Because of the vast distances in this country, food transport is a series of refrigerated events, in the hands of a range of stake holders.
Mangoes picked in the Northern Territory may be handled through stationary and mobile refrigerated spaces as many as 14 times by multiple owners on a 3,400 km journey to Melbourne.
If temperature abuse through poor refrigeration practices occurs in just one of those spaces, the losses at the consumer end are compounded, and shelf life can be either drastically reduced, or result in the whole load being sent to landfill.
People working at the coalface of the industry can sign on independently to do the course, which the AFCCC believes will be an important next phase in their professional journey. Kindred organisations involved in the cold chain will be encouraged to become retailers of the education program. Many industry groups have already signed up to help drive cold chain practitioners to the training program from their own websites.
There will only be modest charges for the course, which will help fund AFCCC’s continuing work on assembling the research and expertise to complete further parts of the overall Code of Practice. This will ultimately be gifted to the cold chain industry for the purposes of universal adoption.
The extent of food wastage in this country should not be under-estimated. It is almost criminal that one quarter of Australia’s production of fruit and vegetables are never eaten and end up in land fill or rotting at the farm gate. This loss alone accounts for almost two million tonnes of otherwise edible food, worth $3 billion.
A government-sponsored study released earlier in 2020 revealed that meat and seafood waste in the cold chain costs the country another $90 million and dairy losses total $70 million.
It’s not just the wasted food at stake. The impacts on greenhouse emissions, water usage and energy consumption will end up being felt nationwide.
The AFCCC was formed in mid 2017 by a cross section of industry leaders covering manufacturing, food transport, refrigeration and cold chain services.
The Council sees itself as an important part of the solution, encouraging innovation, compliance, waste reduction and safety across the Australian food cold chain.
The new Council is not about promoting an industry – it wants to change the industry for the better. It acknowledges that Australia’s track record in efficient cold food handling, from farm to plate, is far from perfect.
Australia’s food and grocery manufacturers, represented by peak body the Australian Food and Grocery Council (AFGC), will develop Australia’s largest industry-led plastic recycling scheme, which aims to collect and recycle nearly 190,000 tonnes of plastic packaging per annum by 2025.
The Australian Government has announced the AFGC will develop the National Plastics Recycling Scheme (NPRS), supported by funding from the Government’s National Product Stewardship Investment Fund (PSIF).
The scheme will initially focus on increasing the diversion of soft plastics such as bread, cereal and frozen vegetable bags, confectionery wrappers and toilet paper wrap from landfill and it will move on to support the increased recycling of other plastics that are currently difficult to collect and/ or recycle. As an industry-led and funded scheme, the NPRS will coordinate and focus the efforts of well-known food and grocery brands to increase the recycling and reuse of plastic packaging.
This will build on existing soft plastics recycling initiatives including the industry funded REDcycle program and the soft plastic kerbside collection trial run by Nestlé, as well as projects and research by the Australian Packaging Covenant Organisation.
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“Over many years, brand owners have invested in packaging innovations that reduce food waste and have moved to using lighter-weight plastics that have a lower carbon footprint. Continuing the focus on packaging sustainability, the NPRS will increase the recycling rates of identified plastics and reduce the amount of virgin plastic used in packaging, helping to meet Australia’s National Packaging Targets,” AFGC CEO Tanya Barden said.
The National Packaging Targets include a goal of recycling or composting 70 percent plastic packaging and incorporating an average of 50 percent recycled content across all packaging by 2025.
“We commend the Australian Government’s leadership on waste reduction and recycling matters, including their support for the NPRS.
“We’re excited about developing a circular economy in collaboration with our members, who comprise nearly 80 percent of packaged food and grocery sales, as well as governments, retailers, plastics and packaging companies, and the resource recovery industry,” said Barden
G.Mondini, a name that delivers innovation, quality and experience in providing dynamic tray sealing systems continue to grow with their ground-breaking tray sealer innovation.
With the culmination of over 45 years’ experience in designing and building tray sealing systems, the TRAVE was created to be at the heart of any packaging system. The design and construction mean this tray sealer can handle the demands of all industrial environments, deliver secure packs with every machine cycle, ability to seal any shape and size of packaging materials on the market, and with patented Platform Technology allows for different packaging technologies to be applied in a simple modular way.
The TRAVE range of fully automatic tray sealing systems deliver on reliability, efficiency and can produce a variety of new innovative packaging options including Vacuum Skin, Darfresh On Tray, MAP, Slimfresh, Slicefresh and the Award Winning Paperseal. Attention to design detail means this is the most hygienic tray sealer on the market, guaranteeing customers the best possible solution.
James White, marketing and sales director at Select Equip, a food equipment company which has been in business for over 35 years and the exclusive distributor of G.Mondini, explains, “It isn’t common knowledge that Mondini TRAVE 350 -R & Trave 384 -R tray sealers can be on the water within 4 weeks from order, with the same Trave performance at a more affordable price. Its all about delivering on all levels with no compromise on its functionality with Mondini PLATFORM Technology fully integrated into its construction. It’s all about offering our customers a real competitive advantage to develop and build their business quickly to meet retailer timelines and demands.”
When it comes to making purchasing decisions with food packaging equipment like tray sealing, it needs to be top-of-mind that capital expenditure is a fixed cost, but it is the ongoing cost of ownership that needs to be considered as well. TRAVE is the lowest cost of ownership compared to any other tray sealer currently on the market today.
Select Equip expertise is on delivering a complete system and support service throughout a clients entire growth cycle. The Trave range of tray sealers is the only system on the market that is delivered future proof and ready to adapt to retailers ever changing packaging format requirements. It’s all about thinking about ‘systems’ and the efficiency and reliability that having one supplier for all your food packaging needs can provide (as opposed to having to rely on different suppliers.) You receive your support, service, equipment, spare parts, and advice all from one place,” said White.
G.Mondini and TRAVE are available through Select Equip. To find out more visit selectequip.com.au email email@example.com or call 1800 1010 122.
The global meat sector at present is facing unprecedented level of disruption and competition, due to mounting growth of plant-based meat alternatives across many categories, according to market research company Future Market Insights. Earlier, plant-based meat alternative products warranted limited shelf space and were meant for niche consumers. With increased awareness of “Veganuary” multiple manufacturers have expanded new product line for plant-based products owing to increased vegan or indeed flexitarian diet.
The global food and beverage recent industry changes illustrate the growth in plant-based alternatives that has brought disruption. Companies across the spectrum are investing heavily in creating and acquiring new products and brands which will provide momentum to the surging consumer demand for plant-based beef products.
Key point from the plant-based beef market study
- A latest study by an ESOMAR certified market research and consultancy company, forecasts impressive growth of the Plant Based Beef market at over 22.7% CAGR between 2020 and 2030
- Based on the source, the soy-based protein segment holds the dominance in the market for plant based beef, while wheat-based protein segments are expected to grow prominently in the forecasted period of 2020-2030
- Based on the product type, burger patty segment holds the dominance in the market for plant based beef
- As alternate protein gains traction in the market owing to the increasing awareness about the environmental impact of food choices consumers make, the majority of the population is shifting towards plant based beef and is expected to gain traction in near future
- Companies across the spectrum are investing heavily in creating and acquiring new products and brands which will provide momentum to the surging consumer demand for plant-based beef products
New product development fuelling plant-based products demand
Increasing demand for innovative products has paved the way for product development across frozen, chilled and ambient segments. This innovation helps consumers with a wider choice of brands and products, and allows plant-based beef to advance improved shelf space and recognition.
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UK is the global leader for vegan food launches. In 2019 approximately 18% of new food launches were vegan. Tesco has developed wicked kitchen range of meat-free products.
Who is winning?
A few of the leading players operating in the Plant Based Beef market are Impossible Foods, Gardein by Conagra Brands, MorningStar Farms, Archer Daniels Midland Company, Symrise, Roquette Frères S.A., Kellogg’s, Tyson Foods, Sotexpro SA, Crown Soya Protein Group, Puris Proteins, Ingredion, Beneo GmbH, Glanbia, Fuji Oil Co., and other players.
Several leading manufacturers of Plant Based Beef are focusing on partnering with prominent players in the market to increase its business footprints and to increase their production capacity. Leading players of Plant Based Beef are investing in research and development to produce organic, non-GMO ingredients for plant-based beef.
New system capabilities help digitally transform operations by introducing process functionality native to the controller, improving the availability of system assets driving compliance in regulated industries, while enabling the adoption of analytics at all levels of the enterprise. Intuitive workflows and the use of industry-leading cybersecurity standards will help teams design, deploy, and support a DCS infrastructure which reduces time-to-market and helps plants realize profit at a faster rate.
“We’re excited to bring PlantPAx DCS 5.0 to our customers,” said Jim Winter, global process director, Rockwell Automation. “New system features are step changes in helping our customers lower the overall costs to design and commission. The functionality improves the overall effort to integrate the process control layer to the enterprise. By reducing the lifecycle cost of the system and lowering operational risks, we are continuing to find innovative ways to bring more value to end users.”
Process end users desire a system that offers the benefits of a modern experience without the burdens that come with a traditional DCS. The new 5.0 release innovates the modern DCS in the following areas:
- Reduced Footprint
- This release introduces new process controllers and extends the Logix family with cutting-edge processing power and capacity to reduce the complexity of PlantPAx architectures. This action reduces total cost of ownership of the system throughout the lifecycle.
- Project Consistency
- With native process instructions embedded in the controller firmware, project teams can adopt approaches to control strategies that drive consistency for individual projects or multi-site deployments. Consistency simplifies the lifecycle management of deployed systems as teams modernize their automation infrastructure. Consistency lowers total cost of ownership (TCO).
- Streamlined Workflows
- PlantPAx 5.0 provides improved design and operational user experiences. Development teams will realize savings in the configuration of instrumentation, alarms and diagnostic system elements. Operators will have the extended ability to view underlying control logic in a safe and secured manner. Maintenance will have controlled view access for troubleshooting.
- TÜV -Certified for Cybersecurity
- To operate at peak performance and minimize cybersecurity threats, PlantPAx 5.0 system architectures are TÜV certified to the international standard ISA-99/IEC 62443-3-3 which provides guidance on the implementation of an electronically secured system.
- Analytics Enabled
- Process end users recognize the value of analytics as an essential strategy to realize profit in their process operations. The PlantPAx 5.0 release has purpose-built frameworks that easily connect live and historical data from the DCS into reporting and analytical tools.
- Enables extended experiences, such as Augmented Reality, using workflows aligned with process strategies controlling plant operations.
- Allows extensible scalable analytic packages leveraging predictive and prescriptive models for process applications such as soft sensors, anomaly detection, or model predictive control.
As producers continue their digital transformation journey, the advances from this system release will help them unlock value and reduce overall costs at all phases of the plant lifecycle. For more information about PlantPAx DCS 5.0, please visit rok.auto/plantpax.
Nick Sheridan created 99th Monkey in Melbourne in 2013. His aim was to create a nut butter that not only tastes delicious but also that was good for a person’s health and kind to the planet.
“As a former journalist (The Age, Global Coffee Report) living in London and training for my first (and maybe last) marathon in 2012, I became obsessed with peanut butter. When my wife Tracey and I returned to Melbourne, I decided to turn my nut butter obsession into a business,” said Sheridan.
Sheridan started out selling in farmers markets then into local stores and online. At the end of 2017, 99th Monkey was in about 800 independent retailers around Australia.
In 2018, 99th Monkey was one of five Australian businesses that were selected to take part in the Chobani Food Incubator program.
“The program helped me to expand my vision for the business and gave me the contacts and confidence to take the brand to the next level,” said Sheridan
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“2018 was also that year that I finally went all in on the business, leaving my job as editor of a coffee magazine to focus on 99th Monkey full time – it felt like a big leap at the time considering we had a two-year-old daughter and a mortgage.”
The leap paid off and by the end of 2018, 99th Monkey was stocked in Coles’ new format stores, Coles Local. This led to 99th Monkey securing three products stocked in 200 Coles stores in Victoria in 2019.
This past year, 99th Monkey have signed a million dollar deal with Coles. 99th Monkey Natural Almond Butter and Cacao Almond Butter will be stocked in 650 Coles stores nationally.
Knowing that you are able to walk into your local supermarket and buy what you want to feed yourself or your family and stock your pantry is something that we take for granted. Australia is fortunate that we make enough food to feed 75 million people, three times our population and that we have a strong and resilient food, beverage and grocery manufacturing sector in our country.
COVID-19 has taught us all many things about our sense of community, our vulnerability and not to take this $127.1 billion food, beverage and grocery sector for granted. We realise now more than ever how essential it is.
When there was panic buying in early 2020, when shelves were stripped, this was equivalent to three Christmas buying periods all at once, on the same day, with no notice. Retailers and suppliers were caught unprepared, and shelves were emptied.
However, the 274,835 people who work every day to make the food, drinks and grocery items to ensure our shelves are stocked stepped up – they are our essential heroes. This sector went into overdrive straight away to help meet the runaway consumer demand, working 24 hours-a-day, seven-days-a-week to make the products that Australians were wanting. The shelves have not been empty since.
The supply chain was sorely tested. Speciality ingredients not made or found in Australia had to be acquired in other ways, or substitute supplies found, as borders closed.
Movement of goods across such an expansive country is always a challenge but the logistics sector met the challenge to move more products, more often. Workers in the factories, who are the most important asset to our sector, split shifts, implemented COVID-safe plans right away and socially distanced to help ensure transmission of COVID-19 was kept at bay from our essential sector. Everyone met the challenge to keep the supermarket shelves stocked.
Australia’s food, beverage and grocery manufacturing sector works hard, and it has had to. Rising input costs and market challenges have long been an issue for the sector.
Companies in Australia want to invest in capital and invest in more jobs. They want to buy the exceptional, high-quality raw commodities from Australian farmers, transform them into products, and then send them around the country for Australians to enjoy. And they also want to export them around the world, capitalising on the international appreciation for the high quality and safe food products made here.
This is how traditional supply chains work but there needs to be certainty for business to invest. Certainty, through a stable economy, a skilled workforce and access to markets.
There also needs to be a responsive domestic market too, which will help foster innovation and business growth. As the world modernises and becomes highly automated, this sector strives to do so as well. This will help ensure the sector remains competitive on the world stage, innovation will flourish and jobs will grow.
To do this, the Australian Food and Grocery Council has called for the Federal Government to implement a Food, Beverage and Grocery Site Modernisation Program that provides short-term incentives for the food, beverage and grocery manufacturing industry. It does so by bringing forward investment in manufacturing plant infrastructure and equipment through an instant asset write off, or grants program for smaller investments, and targeted and efficient investment allowance for larger investments.
Without investing to improve efficiency and innovate, there is a real risk that businesses will either need to reduce the scale of their operations or move offshore.
Taking the jobs offshore would result in job losses at a time when we need to ensure job growth. While nearly 60 per cent of the sector’s jobs are in metropolitan areas, around 40 per cent, or 108,000 jobs, depend directly on this sector in regional Australia.
This sector is the backbone to regional Australia and the bond in so many communities – it is the heart of the community. The jobs and support services in so many country towns and regional centres rely on the economic contribution the sector brings through the wages it pays and the flow on to other businesses servicing the sector or the people who work in it.
In turn, the sector also supports the community through social, environmental and other outreach programs and direct contributions. This might include supporting the construction of local assets being built like a swimming pool, donating to local soup kitchens or getting involved in environmental programs like tree planting. This is happening right across the country with the support of this sector.
At the same time as strengthening our local economies and communities, the sector has seen a growth in exports. In 2020, food and beverage exports have increased 5.8 per cent, led by 7 per cent year-on-year increase in food product manufacturing.
Supply chain dependencies and priorities within countries changed with COVID-19 but recent Australian Bureau of Statistics data proved that COVID-19 hasn’t destroyed
our global trade. So, the trajectory of a growing and strong export market should weather the pandemic, even though it has definitely complicated things due to geopolitical developments.
A strong international trade system is crucial to maintaining global food security while Australia can benefit through local economic stimuli. Trade helps to stabilise food prices and supply volumes, which in turn improves social stability across the globe. During the 2007-08 food price crisis, restrictions by countries on exports of certain commodities led to significant increases in world food prices and intensified the impact on food insecurity and poverty. To date, we have not seen a repeat of this food price crisis and trade flows have continued, albeit with some delays at the start of the COVID-19 pandemic.
While we like to know that we can walk into our supermarket and buy what we want on nearly every occasion, we also need to stop and realise what goes into ensuring we can do just that. Australians should be proud of the food, grocery and manufacturing sector here on our shores, for what it makes, supplies us with and the value it brings to our local economy and communities.
The commitment of Federal and State governments to make infrastructure spending a priority to stimulate the economy through COVID-19, is key to attracting investment into the agriculture sector, according to a new report from MinterEllison called Ahead of the Harvest, 2020-2022.
MinterEllison commissioned Acuris to survey 100 domestic and international investors in agriculture assets to gauge their appetite for investment in the sector and the most favourable conditions that attract investment. The survey was conducted pre-COVID-19, however many of the investors’ observations point to a sector that has strong foundations for attracting investor confidence as Australia rebounds from the economic downturn.
“The fast-tracking of infrastructure projects by State Governments and the Federal Government’s $1 billion Relief and Recovery Fund to support regions, communities and industry sectors (including agriculture) will contribute to a stable climate for future investment,” said MinterEllison partner Matthew Cunningham.
In particular, infrastructure investment will help with agribusiness’s market distribution. Also required is stable, reliable internet. It is encouraging that before those factors came into play, the infrastructure currently in place was considered more than adequate by respondents, with 65 per cent nominating it as a reason to invest.
“Superannuation funds have also expressed an appetite for investing in infrastructure, further demonstrating confidence in infrastructure as an important driver of economic recovery for the economy at large, and specifically the agriculture industry,” Mr Cunningham added.
Australia’s success in negotiating free trade agreements (FTAs) is highly regarded by investors with 72 per cent citing FTAs as Australia’s top advantage when considering agribusiness investment.
Crucial to Australia’s international competitiveness is its 14 FTAs in key markets across the Asia Pacific (including China, Japan and South Korea) and the United States. Australia also has signed and concluded, but not yet put in force the PACER Plus FTA between New Zealand and eight Pacific Island countries (Cook Islands, Kiribati, Nauru, Niue, Samoa, Solomon Islands, Tonga and Tuvalu) and is pursuing a further six (United Kingdom, European Union, India, the Gulf Cooperation Council, Pacific Alliance and the Regional Comprehensive Economic Partnership) that will open Australian agribusiness to export opportunities.
“Short term, these opportunities have been paused as global economies suffer the consequences of the COVID-19 pandemic, however, longer term, Australia’s negotiations to open more markets in the Asia Pacific region will be good news for agribusiness investors and mergers and acquisitions.” said MinterEllison partner, Glen Sauer.
Another key reason to invest in Australia’s agriculture sector is our political stability and legal certainty. Sixty-three per cent of respondents say governance, stability and transparency make Australia attractive for agribusiness investment. The cohesion between Federal and State governments in their response to COVID-19 through the National Cabinet has further emphasised Australia’s political stability during a time of crisis.
“Australia’s strong foundations, sound governance and transparency make it one of the safest places in the world to do business and with the politically bipartisan approach to infrastructure investment, this is unlikely to change in the near term,” said Mr Sauer.
“There is no doubt that COVID-19 has put a pause on the world’s focus on new M&A transactions and while it’s clear there will be significantly-reduced volumes of activity in the agriculture sector for the remainder of 2020, our expectation is that there will be a modest recovery in 2021, with further strengthening in 2022,” said Mr Sauer.
Medicinal cannabis was the sub-sector identified as having the most investment potential (85 per cent). The investment potential of viticulture was favoured by 74 per cent of investors.
Climate change and natural disasters were identified by 82 per cent of respondents as the main barrier to investment, closely followed by wage and other input costs (72 per cent). Australia’s ageing farmer population was identified as a challenge for the sector.