Dairy Foods March 2011

DCI CHEESE | CHEESE SHOW PREVIEW | TEA & COFFEE

March 2011

Innovative Ideas for Dairy Processors

Outlook

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March 2011 Vol. 112, No. 3

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

Ice Cream Is Naturally Simple For many of today’s ice cream processors, less is more, and that means fewer complex ingredients. Consumers read nutrition labels, remain abreast of food safety issues and vote with their wallets. p. 46 On our cover: Few desserts take to customization like ice cream. He likes hot fudge with walnuts and whipped cream while she prefers butterscotch, crushed pecans and marshmallow topping. Processors develop new flavors to keep the category fresh. They consider current trends and look to foods of the past. For example, Yarnell’s recreates Lemon Ice Box Pie with graham cracker inclusions, lemon flavor and a creamy whipped topping. Our special report about ice cream begins on page 46.

Cheese Trends, Cheese Conference The new dietary guidelines encourage cheesemakers to formulate lower-sodium and lower-fat options. Marketers, including Tillamook, find creative ways to sell their brands. Use our preview of the Wisconsin Industry Cheese Conference to schedule seminars and booth visits. p. 54

Features News & Trends 10 Newsline Dietary guidelines promote dairy; Greek yogurt is on the menu; reports from Dairy Forum; MilkPEP pours one more glass

New Products & Marketing 28 New Product Review Honey milk, calciumenriched milk

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Departments 8 18 22 92 98 101 105 106

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

Dairy Market Trends Yogurt sales are a bright spot in the dairy case.

Ingredient Technology 34

Ingredients Formulating with superfruits

38

REPORTS

71

The Ambassadors of Cheese DCI Cheese Co. president Tim Omer and senior vp of sales Dominique Delugeau head a company that has become the leading provider of specialty cheese to America’s Top 20 retailers. The firm caught the eye of Saputo Inc., which just acquired the Wisconsin-based cheese marketer.

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Everything’s Under Control

Lab Talk The health benefits of tea and coffee

42

Dairy Detective Whey permeate is a superstar

44

Dairy & Nutrition Understanding probiotics

86 Behind The Scenes 88 Quality on the Line 90 Global Insights

Raw milk? No thanks, writes John T. Umhoefer of the Wisconsin Cheese Makers Association. DAIRY FOODS Volume 112, Issue 3 (ISSN 0888-0050) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: DAIRY FOODS, P.O. Box 2144, Skokie, IL 60076. Change of address: Send old address label along with new address to DAIRY FOODS, P.O. Box 2144, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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March 2011 Vol. 112, No. 3 www.dairyfoods.com A Publication of BNP Media II, L.L.C. Editorial and sales offices 155 N. Pfingsten Road, Suite 205 Deerfield, IL 60015 Phone: 847-405-4000 • Fax: 847-405-4100 Publisher Thomas S. Imbordino 773-755-8990; 248-502-2093 (fax) [email protected] Editorial Chief Editor Jim Carper 847-405-4009; [email protected] Executive Editor Marina Mayer 847-405-4008; [email protected] Product Development Editor Donna Berry Field Editor Cathy Sivak Art & Production Art Director Lindsay Leusby Production Manager Lisa Webb [email protected] Sales Amy Vodraska 973-970-9000 [email protected] Wayne Wiggins Jr. 415-387-7784 [email protected] Catherine Wynn 847-405-4010 [email protected] Gabriele Fahlbusch 49-(0)202-271690-15 [email protected] Classifieds Suzanne Sarkesian 248-786-1692 [email protected] Marketing Marketing Manager Elizabeth Wright [email protected] Editorial Reprints Jill DeVries 248-244-1726; [email protected] List Rental Postal: List Rental Manager Robert Liska 800-223-2194 x726; [email protected] Email: Account Manager Shawn Kingston 800-409-4443 x828; [email protected] Audience Development Audience Development Manager Kourtney Bell Multimedia Specialist Katie Jabour Audience Audit Coordinator Carolyn M. Alexander For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected]

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

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Dairy Foods | March 2011

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From the Editor’s Desk

Dairy Goes Clubbing o you think healthy people want messages about healthy foods in a place where they are practicing being healthy? I think so, and so do dairy processors. Farmland Dairies of Wallington, N.J., and Stonyfield Farm, Londonderry, N.H., are the latest dairy processors to place their ad messages through an advertising network that reaches into health clubs. The network connects with nearly 4,000 clubs in 49 states. “While consumers are at the gym, they are focused on their health and wellness, and therefore, are a highly captive audience for products that fit their healthy lifestyles,” says Richard Hirsch, executive vp of the Los Angeles-based Health Club Media Network. Forget about reaching this audience through traditional channels. Health club members don’t watch much television and don’t read the top health and fitness magazines, according to HCMN data. Hirsch tells me that a majority of health club members, particularly women, go on a regular shopping trip after leaving the club and before returning home for the day. “We think this makes for an even more robust messaging environment for health and wellness-related brands, including our many dairy brand clients,” he says. Hirsch points to the high coupon redemption rates on tear pads that are affixed to media (like posters) displayed in the clubs. The rates are 10-20 times greater than redemptions of coupons from free-standing inserts, he says. A two-month campaign at health clubs in the New York metropolitan area for Farmland Dairies’ Skim Plus Fat Free Milk kicked off March 1. The tagline “Mouthwatering (not watery)” appears on HCMN panels with tear-off, instant redeemable $1 coupons. New Jersey-based Linett and Harrison created the campaign. The ads also feature a QR, or quick response, code that allows consumers to scan the image with their mobile phones for instant product information and details about how to receive free samples of Skim Plus Fiber or Skim Plus with Omega-3. Farmland Dairies is a division of Grupo Lala/Lala USA. Stonyfield Farm’s Oikos Organic 0%-fat Greek yogurt brand also includes tear-off, instant redeemable coupons valued at $1. The ads promote the organic yogurt as having 0% fat and two times the protein of ordinary yogurts and feature the campaign’s tagline, “Possibly the best yogurt in the world.” Anne-Sophie Schmitt, brand manager of Stonyfield Farm, says the company turned to HCMN to enhance awareness, drive trial and influence the opinions and purchasing behavior of Oikos among active adults. “HCMN also allowed us to geotarget our consumer outreach to select gym locations that were near key retailers that sell our products,” she says. Other dairy brand campaigns in health clubs have used more than posters and coupons. Marketers have used digital media, branded giveaways (like water bottles and workout towels), mirror clings and sampling.

Jim Carper

D

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Dairy Foods | March 2011

 Stonyfield Farm puts its Oikos ads in health clubs near retailers carrying its brand.

 A “super panel” for Farmland Dairies’ Skim Plus fat-free milk includes a quick-response code. Besides marketing efforts, dairy processors need to gain distribution in health clubs whether in vending machines or in club’s foodservice outlets. Speakers at the January Dairy Forum made that point as well as noting the well-documented restorative powers of chocolate milk after a workout. Dairy processors are finding niche markets to supplement their mass marketing efforts. By doing so, brands tone up their sales and customer loyalty.  Jim Carper is chief editor of Dairy Foods. Phone: 847-405-4009. Email: [email protected].

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News & Trends

NEWSLINE... Uncle Sam Sports A Low-fat Milk Moustache Low-fat and low-sodium dairy foods fare favorably in the 2010 Dietary Guidelines for Americans (DGA) released jointly on Jan. 31 by the Department of Health and Human Services (HHS) and the United States Department of Agriculture (USDA), Washington, D.C. The guidelines are designed to help Americans make healthier food choices and confront the obesity epidemic. The federal government recommends that Americans increase their intake of low-fat and fat-free dairy products to reach three servings of dairy for adults, two and one-half servings of dairy for children between the ages of four and eight (an increase from two servings a day) and two servings for children ages two and three. The DGA recommends consumers switch to fat-free or lowfat milk, avoid oversized portions, fill half the dinner plate with fruits and vegetables, be mindful of sodium intake and drink water instead of sugary sodas and juices. The revised guidelines also advise Americans to balance calories to manage weight, build healthy-eating patterns, monitor calorie and fat intake, incorporate more exercise and encourage retailers, schools and employers to provide a healthy-eating environment and create nutrition-related programs, among other topics. Guidelines recognize nutrients in dairy Dairy foods are some of the top sources of calcium, vitamin D and potassium, which are identified by the DGA as nutrients of concern in the American diet. HHS and USDA promote nutrient-rich foods, defined as foods without added sugar and with low levels of sodium and solid fat. Fat-free chocolate milk is mentioned as an example of a good way of using added sugar to increase the palatability and consumption of nutrient-rich foods. Another recommendation encourages a gradual switch to lower-fat versions of dairy products, which would include fluid milk, yogurt and cheese. While low-fat fluid milk gets the green light, the guidelines flash a yellow caution flag on cheese because of its sodium, cholesterol and saturated fat content. “Almost half of the milk and milk product intake in the United States comes from cheese, little of which is consumed in a lower-fat form. Choosing fat-free or low-fat milk and milk products provides the same nutrients with less solid fat and thus fewer calories,” the report states. “In addition, selecting more of milk group intake as fat-free or low-fat fluid milk or yogurt rather than as cheese can increase intake of potassium, vitamin A, and vitamin D and decrease intake of sodium, cholesterol and saturated fatty acids.” Dairy industry responds favorably Reaction from the dairy industry has been favorable. Dean Foods Co., the nation’s largest dairy processor, praised the recommendations, specifically the call to “increase intake of fat-free or low-fat milk and milk products, such as milk, yogurt, cheese or fortified soy beverages.”

“Mother Nature got it right. Nutritionally speaking, dairy is a cornerstone of healthy eating with nine essential nutrients,” says Andrea Carrothers, a registered dietitian who is the nutrition communications manager for Dean Foods, Dallas. “Consumers who prefer non-dairy beverages can still benefit nutritionally by choosing soymilk or other plant-based beverages that are fortified to supply nutrients like calcium and vitamin D.” “The recommendation that individuals should increase intake of fat-free or low-fat milk and milk products, such as milk, yogurt and cheese, as part of a healthy eating plan is a very positive message for the dairy industry,” says Cary Frye, vice president for regulatory and scientific affairs at the International Dairy Foods Association, Washington, D.C. “The new guidance provides a framework for healthy eating that limits sodium, saturated fat and added sugars in the daily diet, but still provides for many dairy products options.” “The new guidelines did an excellent job addressing ways to improve weight while still helping Americans realize the importance of getting vital nutrients through a variety of foods,” writes Ashley Rosales, a registered dietitian, on the Dairy Council of California blog. “The 2010 Dietary Guidelines are being released at a time when the majority of adults and one in three children are overweight or obese, and this is a crisis that we can no longer ignore,” says agriculture secretary Tom Vilsack. “These new and improved dietary recommendations give individuals the information to make thoughtful choices of healthier foods in the right portions and to complement those choices with physical activity.” The DGA outlines how consumers should put the principles for healthy eating into action in a variety of meal patterns, which include dairy foods as part of the vegetarian diet that includes milk and eggs and the Dietary Approach for Stopping Hypertension (DASH) diet, which is promoted by the National Heart, Lung

Eat This, Not That The “Dietary Guidelines for Americans 2010” recommends: • Drinking low-fat or non-fat milk • Drinking water instead of sugary sodas • Limiting the intake of sodium, solid fats, added sugars and refined grains • Eating nutrient-dense foods and beverages, which include vegetables, fruits, whole grains, fat-free or low-fat milk and milk products, seafood, lean meats and poultry, eggs, beans and peas, and nuts and seeds. Source: 2010 Dietary Guidelines for Americans Continued on page 12

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Dairy Foods | March 2011

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News & Trends

Women Prefer To Eat Right, Not Diet American women have a great interest in healthy eating and healthy foods, according to the Better Homes and Gardens Food Factor 2010 survey, which found that 62% pay more attention to nutrition information on food packages and recipes than two years ago. The magazine surveyed 3,607 women age 18 and older. It released the results on Jan. 31, the same day as the new Dietary Guidelines for Americans. Almost all (91%) of those surveyed are interested in learning how to eat right rather than how to diet and nearly three-quarters (73%) believe dieting is more mental than physical. The biggest challenges to healthy eating, women say, include drinking enough water, the availability of junk food, overeating/portion size, budget and emotional eating. The magazine found that compared to two years ago, women are eating more fresh fruits and vegetables. They say they will pay a 27% premium for an organic product. Health (73%) and safety (66%) considerations are the primary reasons U.S. women buy organic food. Their main reasons for eating locally grown/produced foods include freshness, taste, support of local/small businesses and knowing where the food came from. Despite their stated interest in local foods, the percentage of U.S. women who regularly buy local foods decreased 10 percentage points (51% vs. 61%). Given a choice, 60% would prefer to eat only healthy foods and live longer compared to 35% who say they would rather eat whatever they want and live until they are 70. And 73% of U.S. women would rather win $20,000 than lose 20 pounds.

and Blood Institute, Bethesda, Md. For Americans who need to avoid lactose, the guidelines also recommend reduced-lactose and lactose-free dairy products as the first choice for consuming the wide variety of nutrients provided by dairy. The USDA’s food patterns define milk and milk products (also referred to as dairy products) to include all milks, lactose-free and lactose-reduced products yogurts, frozen yogurts, dairy desserts, cheeses and fortified soy beverages. However, cream, sour cream and cream cheese were not included as part of the dairy group due to their low calcium content. Although the guidelines state that most choices should be fat-free or low-fat, practical strategies for implementing the recommendations acknowledge that when selecting cheese, reduced-fat versions are included. The 2010 Dietary Guidelines were composed by a committee of scientific experts who reviewed and analyzed the most current information on diet and health and compiled their findings into a scientific, evidence-based report. The goal of the Dietary Guidelines is to put this knowledge to work by facilitating and promoting healthy eating and physical activity choices, with the ultimate purpose of improving the health of all Americans. To learn more about the Dietary Guidelines or to read the report, go to www.dietaryguidelines.gov. —By Dairy Foods editors Marina Mayer and Jim Carper.

Photograph this image with your smart phone to read more about the guidelines on the USDA website.

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Dairy Foods | March 2011

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News & Trends

Greek Yogurt. It’s What’s For Breakfast Americans associate yogurt and feta cheese, among other foods, with what Greeks eat for breakfast. U.S. consumers expect a Greek breakfast to consist of bread (mainly pita), eggs, cheese (mainly feta), fruits, yogurt, various vegetables and fruits (tomatoes, spinach, olives and figs) and olive oil, according to research by Kairos Consumers. While the research was intended for out-bound tourism to Greece, the findings have relevance to yogurt (Greek and otherwise) processors in the United States. In January, the Chicago-based B2B research firm conducted a pilot study among U.S. consumers with the aim of exploring perceptions and attitudes toward “Greek breakfast” to go along with promotional efforts by Greece to boost tourism. The Hellenic Chamber of Hotels, an Athens-based trade group, says Greek cuisine should be considered a tourism “ambassador” and that the idea of the

“Greek breakfast” should become part of a Greek “culinary diplomacy” strategy to add value to the country’s hospitality industry. Kairos Consumers undertook its study to understand: • The importance of the local/national cuisine as a criterion when booking a holiday • Willingness to try new flavors/local specialities when on vacation • Consumer perception toward a Greek-style breakfast • Willingness to prepare a Greek-style breakfast Kairos Consumers analyzed reports in U.S. and international trade magazines, conducted an online survey of 52 U.S. consumers and reviewed social media for attitudes about Greek-style breakfasts. According to Kairos Consumers cofounder Katerina Makatouni, “Research through social media found ‘Greek breakfast’ to be associated mainly with a meal that includes Greek-style yogurt as

the main ingredient, topped with items such as fruit, nuts and/or cereal/granola. An association was also made with feta and omelets.” She said an untapped opportunity exists for toppings for Greek yogurt. Co-founder Betsy Hoag says the “Greek breakfast” concept can be expanded further to various eating occasions such as snacks, on-the-go foods, lunch (home, restaurant and office settings) and dinners. Restricting such an initiative only to “Greek Breakfast” is somewhat limiting over the long term, she says. “Food companies are well-served to identify the untapped opportunities in retailing and foodservice channels that could equate to lucrative exports,” Hoag says. “Consumer research is the first step in understanding what type of potential a new product or concept could have in a new market.” The survey is available at www.kairosconsumers.com. Continued on page 14

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WA S H I N G TO N WATC H

News & Trends

Tipton’s Keynote Speech: Promote Profitability, Not Protection In her keynote speech at Dairy Forum 2011, which took place Jan. 23-26 in Miami, Connie Tipton, president and CEO of the International Dairy Foods Association (IDFA), said the dairy industry has many opportunities for achieving its greatest potential, noting that industry participants are closer than ever to finding agreement on policy reforms that will promote growth and profitability rather than protection and limitations. Calling price volatility the “elephant in the room,” Tipton explained that every agricultural commodity has price volatility, but, unlike dairy, the others have tools and programs in place to help navigate the ups and downs. Unfortunately for dairy, current government policies actually exacerbate the volatility, which was painfully evident during what Tipton called the “Great Depression of 2009” for dairy farmers. Tipton commended the strategic leadership of Tom Gallagher, chief executive

officer of Dairy Management Inc., Rosemont, Ill., and his vision for creating the Innovation Center for U.S. Dairy. Shortly after its inception, the Center commissioned a comprehensive study of dairy supply and demand around the globe by Bain & Co., a global business and strategy consulting firm in Boston that identified a clear path forward for the dairy industry, provided that U.S. dairy policies could be streamlined to promote market growth. “There’s a love affair with dairy around the globe,” Tipton added, detailing growing opportunities in China, Japan, South Korea, New Zealand, Argentina, Chile, Ecuador and the United States. “We must have the guts to move in the right direction.” Tipton also applauded the National Milk Producers Federation, Washington, D.C., and its chief executive officer Jerry Kozak for promoting new policies and programs that help encourage growth. But she

warned against programs that would bring more government intervention. “Government controls may sound tempting, but they’re like the siren song promising to take away risk that eventually leaves you dashed against the rocks,” Tipton said. “The reality is that market factors are pretty darn hard to control, and politicians steering those controls are even more unpredictable.” Instead, Tipton advised that IDFA support an improved margin insurance program to replace programs that no longer function properly, such as the Dairy Product Price Support Program. IDFA also believes that the antiquated Federal Milk Marketing Order system is holding producers back from using modern risk management tools. Tipton called for simplifying the federal orders into a two-class system and urged all industry participants to support a streamlined system that would allow growing markets to thrive.

Moving millions of pounds of dairy products efficiently from the West Coast to the East and everywhere in between is no small task. It takes the largest fleet of refrigerated rail cars in America, moving in expedited lanes across a synchronized, multi-modal transportation network. It takes Union Pacific. Find out more at UnionPacific.com or call (800) 877– 0513.

News & Trends

Dairy Processors Honored During Dairy Forum Dairy processors and dairy farmers received awards for excellence at the International Dairy Foods Association’s 2011 Dairy Forum in Miami in January. Dairy Foods recognized the recipients of its Plant of the Year (Michigan Milk Producers Association) and Processor of the Year (Organic Valley). The National Cheese Institute gave its Laureate Award to Emanuele (Lino) Saputo, chairman of Saputo Inc., Quebec. Dave Fuhrmann, president and CEO of Foremost Farms USA, Cooperative and IDFA treasur- Dave Fuhrmann presents the National Cheese Institute Laureate Award to Lino Saputo. er, made the presentation. Fuhrmann awarded the 2011 Innovative Dairy Farmer of the Year award to Luke, Mike and Tony Brubaker of Brubaker Farms, Mount Joy, Pa. The award is co-sponsored by IDFA and Dairy Today magazine. George Siemon (second from left) of Organic Valley accepts the Dairy Foods 2010 Processor of the year award from Dairy Foods chief editor Jim Carper, associate publisher Amy Vodraska and publisher Tom Imbordino.

Continued on page 16

Wherever you find business, you’ll find us.

Dave Fuhrmann presents the 2011 Innovative Dairy Farmer of the Year award to Luke (from left), Michael and Tony Brubakers.

Dairy Foods chief editor Jim Carper presents the magazine’s 2010 Plant of the Year award to Clay Galarneau of the Michigan Milk Producers Association.

News & Trends

Another Glass of Milk Can Plug Nutrition Gap In the wake of a study finding that eight out of 10 Americans fall short on the recommended amount of milk in their daily diets, the Milk Processor Education Program (MilkPEP), Washington, D.C., created the “Pour One More” educational campaign. The year-long campaign launched in January and aims to educate mothers of young children and teens about the importance of finding ways to introduce one more serving of milk a day. MilkPEP is

using national television and print advertising, public relations, social media and retail point-of-sale materials. Processors can also customize a national print advertisement for use in their markets. MilkPEP’s “What America’s Missing” report found that on average, Americans drink only about one of three recommended servings of milk each day and that nine out of 10 Americans fall short of key nutrients in their diets. Download the report at www.milkpep.org.

PEOPLE MCT Dairies, Millburn, N.J. Niall Foster has been named vice president of international sales. Previously, he was chief operating officer of Dairy America, and has also been employed at Lactalis and Socius Ingredients. Marin French Cheese, Petaluma, Calif. Maxx Sherman has been named com-

pany president, responsible for sales, marketing, new product development and all operational activities. Sherman maintains 30 years of experience in the specialty food industry. When he joined Marin French in September 2004, he created the national sales and marketing department. Since then, sales have increased more than 50%.

Ciao Bella Gelato Co., New York Tom Delaplane has been named vice chairman of the board. A 40-year veteran in consumer pack aged goods, Delaplane spent a majority of his career as the executive vice president of sales and distribution for Dreyer’s Grand Ice Cream, where he developed more than 20 brand and distributor acquisitions, Continued on page 18

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Dairy Foods | March 2011

Increase plant efficiency 365it PMO Mix Proof Valves

Make your cheese vats more intelligent Cheese making is now easier and smarter when you combine Norit Südmo’s 365it PMO Mix Proof Valve with our new IntelliTop® 2.0. Building on our proven control unit, Norit Südmo’s IntelliTop® 2.0 is specifically designed to further increase plant efficiency by controlling, monitoring and reporting on all valve functions in the process plant. When you use the IntelliTop® 2.0 with our 365it PMO Mix Proof Valve, you have reliable, efficient and complete process control.

s Milk Fill - The 365it PMO Mix Proof Valve eliminates swing connections and waiting time for CIP, and allows fully automated processing and CIP of milk fill. s Pre-draw - The 365it PMO Mix Proof Valve provides 100% cleanability and eliminates burst washing into vats to clean the pre-draw valves. s Curd Discharge Line - The 365it PMO Curd Outlet Valve allows safe separation of curd and CIP with one compact valve arrangement.

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

News & Trends

PEOPLE including overseeing the brand’s merger with Nestlé in 2003. Dr Pepper Snapple Group, Plano, Texas David Thomas has been named executive vice president of research and development, responsible for all aspects of R&D, including product development, sensory science, flavor and ingredient technology, chemistry, nutrition and regulatory, process development, technical services, knowledge management and the pilot plant. Meanwhile, Tina Barry became executive vice president of corporate affairs, responsible for overseeing internal and external communications, corporate and brand public relations, philanthropy, government affairs and sustainability. Sargento Foods Inc., Plymouth, Wis. Dan Riste has been tapped as senior national account sales manager to new and existing accounts in Texas and Colorado, responsible for developing, over-

seeing and executing comprehensive customer business plans, managing and initiating price quotes and sample requests and coordinating consumer culinary shows. He also will manage new product development activity, including cross-functional team development for customer projects. Fortitech Europe ApS, Gadstrup, Denmark Kevin Tshimpamba has been named business development manager for the African market and responsible for managing food, beverage and pharmaceutical sales and customer relationships. RathGibson, LLC, Lincolnshire, Ill. Mark Essig has been named chief executive officer. Previously, Essig was president and CEO of Sangamon Industries. Packaging Solutions Holdings, Inc., New York Jon Solberg has been named vice

president of business development, responsible for leading initiatives in the cheese and meat packaging markets. Previously, he was product applications manager at PCC Industries. Meanwhile, Tim French was appointed chief operating officer. French maintains more than 25 years of experience in the packaging industry, 10 of them as a chief operating officer. Previously, he was vice president and general manager at Pliant Corp. Daymon Worldwide, Stamford, Conn. Ed Wright has been named president and COO of the North American Brokerage division, responsible for creating a fully integrated system to better align the company’s resources and partnerships. Autocrat, Lincoln, R.I. Ann Malinowski as has been appointed chief financial officer, bringing strong financial leadership, extensive planning and management experience to the position. Continued on page 20

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Dairy Foods | March 2011

We have what it takes 1.

1 Tetra Pak mix preparation systems and components t


Tetra Almix with Scanima technology, Pumps and Valves t Tetra Alex Homogenizers and Tetra Plex Plate heat exchangers 2

Tetra Hoyer Frigus SF/KF and Tetra Hoyer DeepBlue CK

t
Complete capacity range covering a full diversity of product recipes t
Unique combination of dasher, pumps and easy to understand controls t
Choice of refrigeration system: Freon, NH3 or CO2 2. + 3. 3

Tetra Hoyer Addus Ingredient Feeders

t
Wide capacity range with or without PLC and weighing system t
High accuracy and good distribution of ingredients in final product t
Optional communication and data logging available

Tetra Hoyer Comet Filling Lines t
Wide product range with filling and decoration opportunities

4.

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Tetra Hoyer DeepBlue FM – filling module for low-temperature ice cream 4

Tetra Hoyer Rollo Stick Novelty Lines

t
Tetra Hoyer Rollo RM rotary machines for efficient high-speed production t
Tetra Hoyer Rollo IM in-line machines, lower investment and ideal for multi-layer products 5. 5

Tetra Hoyer Straightline Extrusion Systems

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Flexible small and high capacity systems available t
Efficient single- or multi-lane handling and wrapping equipment 6

Tetra Hoyer Flopac Cartoning Systems

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Tetra Hoyer Flopac 50/100 intermittent or continuous motion cartoners designed for side-loading of ice cream products

Service and spare parts

6.

With more personnel than any other ice cream equipment supplier, we are prepared to meet today’s tight production schedules. Plants depend on our ability to respond within minutes and hours, 24 hours a day, 7 days a week. t
Qualified service engineers for support and training t
Quick response and timely supply of spare parts

Tetra Pak USA Inc. 753 Geneva Parkway Lake Geneva WI53147-0280 USA Telephone +1 262 249 7400 E-mail [email protected] www.tetrapakprocessing.com/hoyer Tetra Pak,

Call our hotline at +1 262 249 7595 and you’ll always speak to a qualified engineer – not an answering service.

, PROTECTS WHAT’S GOOD, Tetra Hoyer are trademarks belonging to the Tetra Pak Group.

INTRODUCING THE MOST ADVANCED MACHINE IN OUR RANGE The human being. We put over 3000 specialists into dedicated teams that work together to get the best out of every processing and packaging machine we make. They also work closely with our customers to eliminate inefficiencies, reduce their operating costs and maintain product quality. Because, despite our engineering heritage, we think it takes more than state-of-the-art technology to make food safe. You need the human touch too. This is the Circle of Protection. tetrapak.com/protection

Tetra Pak,

and PROTECTS WHAT’S GOOD are trademarks belonging to the Tetra Pak Group. www.tetrapak.com

News & Trends

B R I E F LY … Saputo Acquires Wisconsin-based DCI Cheese Co. Saputo Inc., Montreal, will acquire Fairmount Cheese Holdings Inc., the parent company of DCI Cheese Co. Inc., Richfield, Wis., for $270.5 million. The transaction is expected to close in March. Saputo said the acquisition will complement the activities of its U.S.-based dairy products division and increase its presence in the specialty-cheese category in the United States. Saputo is the largest dairy processor in Canada and ranks No. 2 on the Dairy 100, Dairy Foods’ list of the largest U.S. dairy processors. The company calls itself the 12th largest dairy processor in the world. For more on DCI, see “The Ambassadors of Cheese” on page 71.

Dannon Sends 30 Students to National Finals The Dannon Co. completed round one of its second annual TRUST game, which gives students a real-life business challenge to solve as though they were the executive committee of Dannon. One hundred students on 20 teams competed in TRUST Day, and 30 students on six teams advanced to the National Finals, which takes place March 10 at Dannon’s White Plains, N.Y., headquarters. The winning U.S. team will travel to Danone’s Paris corporate office for the TRUST World Final, April 4-5, to share their experiences with other teams from Algeria, China, Czech Republic, Slovakia, Indonesia, Portugal, Romania and Russia. The winning team of students also will receive an internship with Danone.

Johanna Foods Expanding Warehouse Johanna Foods, Inc. contracted Penn Valley Constructors, Inc. to expand its refrigerated warehouse/load-out capabilities at the company’s flagship chilled juice production plant in Flemington, N.J. The expansion and upgrade project includes the addition of 32,000 square feet of cold storage and order assembly space, including 12 new load-out bays. The facility produces Tree Ripe, Ssips and Earth Wise brands as well as private label and national branded products for distribution across the United States.

National DHIA Awards 24 Scholarships The National Dairy Herd Information Association (DH IA) Scholarship Committee selected 24 high school seniors and college students as recipients of $750 scholarships. Judges evaluated applicants on scholastic achievements, leadership in school and community activities and responses to DHI- and career-related questions. To check out the winners, to make a donation or to learn more about the organization, go to www. dhia.org. Continued on page 22

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Dairy Foods | March 2011

Contact Admix today at 800-466-2369 and ask how the Fastfeed can improve your process.

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News & Trends

SUPPLIER NEWS Geliko’s gelatin products are now certified kosher parve for Passover and year-round use by the Orthodox Union. Geliko offers an extended line of kosher-granulated gelatin and kosherhydrolyzed collagen for use in marshmallows, yogurt, protein bars, beverages, gummies, pharmaceuticals and nutraceuticals, including soft and hard capsules and micro encapsulation. G EA Process Engineering France has been selected by Madeta AS to offer a complete turn-key evaporator to process sweet whey in the Czech Republic thanks to its Dairy Evaporation Technical Center. GEA also adopted a “combi” design where the two effects of the evaporator are included in one single body. The idea was to minimize the footprint and associated costs such as those for buildings and platforms. The result is an evaporator that requires very little space and leaves good access for maintenance or for future equipment installation. Oystar USA and the supervisory board of Oystar GmbH agreed to a restructuring that creates Oystar North America, a $250 million company with 650 employees. The new company combines Oystar USA, a Morganville, N.J.-based sales operation representing packaging machinery brands manufactured in Europe, as well as packaging equipment manufacturers Oystar Packaging Technologies, Davenport, Iowa; and Oystar Jones, Covington, Ky.

ALPMA

Ocean Nutrition Canada Ltd. entered into an exclusive longterm strategic agreement with Wilmar International Ltd., a Singapore-based agribusiness and global leader in omega-3 foods. The collaboration resulted in the launch of Wilmar’s new Arawana 3A+ premium cooking oil containing MEG-3 fish oil. The product is widely distributed in China and is available at supermarkets and traditional markets throughout the United States. The R.B. Dwyer Group is printing 3-shrink labels for B.C. Bundt’s “Walk Away Parfaits” with its new infinitely variable cylinder web offset (IVCO) press, manufactured by RDP Marathon. The B.C. Bundt labels are full-sleeve shrink labels made of PVC printed with UV inks in five to six colors. The sleeve comes over the cap of the single-serve clear domed cup to ensure tamper evidence and holds the mini fork to the cup. The sleeve is printed with an indication bar that says “tear here,” so that the sleeve is easily removed from the container. Arla Foods Ingredients launched a three-year joint research project in collaboration with Aarhus University in Denmark to investigate the specific effect of whey protein hydrolysates on muscle growth and recovery after vigorous exercise. Sports science graduate and student Stine Klejs Rahbek will conduct the project. Much of her work will involve designing and impleContinued on page 24

– The new lite

Innovative technology for light and healthy milk products.

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ur whey Make yo fitable! more pro

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Dairy Foods | March 2011

Visit us in La Crosse, WI at the ICTE from April 13th – 14th ALPMA booth 446

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News & Trends

SUPPLIER NEWS menting clinical trials and analyzing the results. Arla Foods also launched a new license package that gives international dairy companies access to patented technology for producing lactose-free dairy products with a real milk taste. The license includes access to Arla Foods’ extensive expertise in developing, producing and marketing lactose-free milk and yogurt. Mettler Toledo developed a cost-effective software solution for statistical quality control and statistical process control. The site, www.freeweigh.net, enables users to prove compliance with average weight and other industry legislation while enjoying the financial benefits of reduced giveaway and an efficient sampling process. This site also integrates third-party measuring equipment with the device integration module, undertakes visual quality checks with the attributes, test plans modules and tracks the performance of individual filling heads with the multi-head analysis module. R MT Robotics received a contract to supply a large-scale robotic case-picking solution for a major North American beer distributor. The system, which has a footprint of less than 40,000 square feet, is designed to pick 300 SKUs at a rate of more than 250,000 cases per day, and will provide 100% picking accuracy, thus reducing product damage and dramatically improving product traceability. The project is scheduled to start in late 2011.

Logistica La Serenisima S.A., the joint venture of Danone and Mastellone in Argentina and a long-time Westfalia customer, upgraded and expanded its automated storage and retrieval system (AS/RS) in Buenos Aires to meet the need for increased speed and throughput in its automated warehouse. In addition, Logistica updated its software and conveyor controls to accommodate dispatch missions to the new machine and added a new safety zone. The entire project also included installing a power bus and the SRM, revising conveyor controls, updating WMS and removing, testing and re-installing the racks. DuPont entered into a definitive agreement for the acquisition of Danisco for $5.8 billion in cash and assumption of $500 million of Danisco net debt. The acquisition is expected to be financed with about $3 billion in existing cash and the remainder in debt. The transaction is expected to close early in the second quarter and be cash and earnings accretive in 2012, the first full year of the combined entity. Silgan Holdings Inc., a supplier of consumer goods packaging products, acquired Ipec Global, Inc., a plastic closure manufacturer primarily serving the North American dairy and juice markets. The purchase was funded through available cash on hand. The transaction is expected to be slightly accretive to earnings in 2011. Continued on page 26

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Dairy Foods | March 2011

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News & Trends

SUPPLIER NEWS Five companies from the Stern-Wywiol Gruppe presented their latest new products at Gulfood/Ingredients Middle East, which took place Feb. 27-Mar. 2 in Dubai. For instance, Hydrosol showcased its customized stabilizing systems for dairy

products, desserts, ice cream, deli foods, ready meals and meat, fish and sausage products. Its sister company, SternVitamin, presented its individual vitamin and mineral premixes designed for fortifying drinks, baked goods, pasta, cereals, dairy

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Dairy Foods | March 2011

With more than 30 years experience in industrial projects, Novasep Process masters all purification technologies that are widely used as either a single-step or combined-within optimized process lines for cost-effective production of various dairy ingredients, including whey and whey permeates. Key expertise includes ion exchange, reverse osmosis, filtration membranes (ceramic and spiral wound) and SSMB chromatography. Also, taking into account project capacity, upstream process and the specificities of the desired ingredient, Novasep Process can propose the best purification process solution. CP Kelco’s Kelcogel Gellan Gum is now listed as an allowable ingredient for use in organic foods and beverages by the USDA National Organic Program under the guidelines established by the National Organic Standards Board. Kelcogel Gellan Gum has unique suspension and versatile gelling performance. Approved products are non- G MO -, kosher- and Halal-certified and can be used in vegetarian applications. Lantech now offers a five-year warranty on its Q-Series semi-automatic stretch wrappers. The warranty is available on the Q-250, Q-300, Q-400, Q-300XT, Q-400XT and Q-300XT Plus stretch wrapping systems.

See us at WCIC, Booth #26

26

products, sweets, baby food, margarine and edible oils. Mühlenchemie, one of the international leaders in flour improvement, showcased novel products that significantly enhance the properties of dough and the baking properties of flour.

Marking its 50th anniversary, Graham Engineering Corp. commercialized its next generation rotary wheel for extrusion blow molding, which has been engineered to run at higher speeds for lighter-weight bottles. Other advantages include reduced maintenance requirements, higher use of pre-manufactured components, improved access inside the spool area for changing hoses, greater flexibility, among others.

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New Products & Marketing

NEW PRODUCT REVIEW

BelGioioso Cheese Inc., Green Bay, Wis., home to this year’s Super Bowl champions — Green Bay Packers — extends its successful Unwrap & Roll line with the Fresh Mozzarella Cheese, Prosciutto & Basil Roll. A sheet of fresh mozzarella (acidified by vinegar) is hand rolled with imported prosciutto and fresh basil leaves. The result is a convenient, unique appetizer that the host simply slices and serves. This distinctive cheese has a 60-day shelf life and comes in 8- and 16-ounce rolls. On the sidelines, BelGioioso constructed a 400pound goalpost to support the Packers in their championship bid. It was displayed at Central Markets in Fort Worth, Texas, near the Cowboys Stadium in Arlington, Texas, where the Packers won Super Bowl Bo XLV.

Just in time for the “big game,” Aldi rolled out a line of frozen dairy-based dips that one simply heats and serves. Resembling a hockey puck (3-inch diameter, but about 2-inches high and weighing 7 ounces), the dips are ready after three minutes in the microwave. Varieties are: Creamy Spinach & Artichoke, Spicy Buffalo Style Chicken and Zesty Queso. The dips are manufactured by Les Plats du Chef Inc., Quebec, Canada. The artichoke variety is also available through Aldi’s sister store Trader Joe’s of Monrovia, Calif.

Private-label discount chain Aldi Inc., Batavia, Ill., introduces Friendly Farms Probiotic Low Fat Smoothie in strawberry and vanilla flavors. Sold in packs of four 7-fluid-ounce recloseable plastic bottles, the beverages are made with traditional yogurt cultures (Lactobacillus bulgaricus and Streptococcus thermophilus) and Lactobacillus acidophilus. The company has not shied away from ingredients that others have started to remove from product formulations, such as high-fructose corn syrup and FD&C Red Dye #40, which are both in the strawberry variety.

NOTEWORTHY I NTROD UCTION S To commemorate its 25th anniversary, Lifeway Foods Inc., Morton Grove, Ill, developed a birthday cake-flavored kefir beverage. Anniversary packaging and a nationwide promotional tour will culminate with company representatives ringing the NASDAQ bell on May 16 in New York City.

28

Dairy Foods | March 2011

Mt Sterling Co - op Creamer y, Mount Sterling, Wis., now offers Raw Goat Milk Mild Cheddar Cheese Slices. Sold in 8-ounce zip-packs, the cheese is aged a minimum of 60 days.

New Products & Marketing

I N T E R N AT I O N A L

In January, Milford, Conn.-based Iskream Inc., introduced the first low-fat, no-sugar-added ice cream made with an all-natural, zero-calorie, stevia-based sweetener. Sold in pints and initially available throughout the Northeast, Iskream comes in three varieties: Berry Good, Chocolate Brownie and Vanilla. A half-cup serving contains 100 to 170 calories, 3 to 6 grams fat and 17 to 25 grams carbohydrate, depending on variety. “It is with great pride and enthusiasm that we announce the launch of the Iskream brand,” says the company’s co-founder, Sandra Lee. Susan Patrick, the other co-founder, adds “We use the finest Madagascar vanilla, Dutch cocoa and whole berries. Honestly, if Iskream didn’t taste great, we couldn’t stand behind it.”

This month, Springfield Creamery Inc., T Eugene, Ore., is launching the country’s first fruit-on-top organic cottage cheese. Nancy’s Organic Lowfat Cottage Cheese Fruit-on-Top comes in peach, pear and strawberry flavors. Like all of Nancy’s dairy and soy products, ucts, this new single-serve ve (8 ounces) productt contains probioticc cultures. The 100% real, organic fruit is lightly sweetened with organic agave and is packaged separate from the cottage cheese in a unique top cup thatt allows customers to o personalize their eat-ing experience. Subscribe to Dairyy Product Innovations ns (www.dairyfoods.com/ m/ dpi), an e-newsletter etter focused on new dairy fo pproducts and new products and services from dairy industry suppliers. SSubscribers receive Dairy Product Innovations Pr monthly with the occamo sional special installation sio or tthemed issue focusing on specific niches such as artispec san cheese or organic and natural foods. To subscribe, natu visit www.dairyfoods.com.

Yogurt has one of the strongest healthful halos in the dairy category, making it a natural choice for extension into drinks, sauces and salad dressings — all segments that have benefitted from the addition of yogurt to product formulations. Now the butter category is welcoming yogurt to its ranks. From Germany’s Meggle AG comes Yogurt Butter, Butter a healthier alternative to traditional tra butter, as it contains 20% 20 less fat. Margarita pizzas and caprese salads may have originated in Italy, but the classic combination of mozzarella, tomato and basil is a favorite around the t world. In Brazil, which boasts b the largest concentration tio of Italians outside of Italy, P o l e n g h i i n t ro d u c e s M o l h o Sabor Sa Marguerita Sauce, a refrigerated, pourable sauce sau based on mozzarelm la cheese ch and dried tomato and basil paste. It is portioned for two in a st and-up pouch for easy opening and pouring.

Contributed by Krista Faron, director of innovation and insights, Mintel Research Consultancy, Global New Products Database (GNPD). For more information call 312-932-0400 or visit www.gnpd.com. Continued on page 30 www.dairyfoods.com

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New Products & Marketing

NEW PRODUCT REVIEW: FOCUS ON MILK Milk is one of the most nutrient-dense foods available to man, making it a great beverage all by itself. Milk also serves as a base for fortified and flavored drinks, ranging from refreshing lattes to nutritionally packed sports drinks. An innovative example of the latter comes from Athletes HoneyMilk LLC, Austin, Texas, a subsidiary of Select Milk Producers, Artesia, N.M., a co-op of 77 family-owned farms located in West Texas and New Mexico. The product starts with fresh milk that goes through a patented cold-filtration process to remove the lactose and concentrate the proteins. This takes place at the company’s Dexter, Texas-based processing facility, and is followed by mixing with honey and other ingredients. The high-protein nutritional drink blend is shipped by tanker trucks to Jasper Products, Joplin, Mo., for aseptic filling into 11.5-ounce plastic bottles. The original honey-flavored product debuted about two years ago in an aseptic box. Honey not only sweetens the milk and provides an appealing flavor profile, but is also said to boost athletic performance and endurance while reducing muscle fatigue. Along with whey and casein to build lean muscle, and minerals and vitamins to balance the body’s cellular and structural systems, Athletes HoneyMilk sports the tagline: Rebuild. Refuel. Recover. Last June, three new varieties (vanilla, light chocolate and light coffee) joined honey when the shelf-stable bottled product debuted. Most recently, light strawberry banana was added to the line. The regular varieties contain 26 grams of protein and 240 calories. The light versions rely on acesulfame potassium to reduce the calorie content to 150; they provide 20 grams of dairy protein. The company is working on stevia-based light versions and hopes to have them in the market before the end of the year. Shamrock Farms, Phoenix, introduces the Calcium Plus milk line, which provides 100% more calcium per 8-ounce serving than regular milk. The product launch coincides with the National Milk Mustache got milk? Campaign encouraging families to “Pour One More.” The new program has pledged to give away one million servings of milk across the coun30

Dairy Foods | March 2011

try to help raise awareness of the importance of milk. Phoenix was one of the main stops in this national tour with a visit to the Phoenix Zoo on Jan. 17, where Shamrock Farms sampled the Calcium Plus milk line. Shamrock Farms’ Calcium Plus milk line comes in many varieties, including whole, 2% reduced-fat and fat-free white milk; 1% low-fat chocolate milk; and 2% reduced-fat and fat-free lactosefree milk. All varieties come in the 96-ounce Smart Fit Bottle, designed by ergonomic experts to be easy to carry, pour and store. Shamrock Farms’ Calcium Plus milk is available regionally at all major retailers.

Target Corp., Minneapolis, introduces a private-label line of Archer Farms ready-to-drink lattes (above) packaged in 9.5-fluidounce glass bottles and sold in packs of four that can be mixed and matched. They start with a base of low-fat milk and are sweetened with a blend of sucralose and acesulfame potassium. This keeps calories down to 100 per serving and fat grams at 2.5. Varieties are: Cinnamon Crème, Pumpkin Spice (seasonal), Raspberry Dark Mocha and Vanilla Caramel. Here’s a private-label innovation from overseas. Coop, an Italian supermarket chain, now offers Milk & Cocoa (below), which is chocolate milk designed to reinforce the concept of simplicity. Although it does include some mouthfeel enhancers (lecithin and carrageenan), this product contains only natural flavors and no added sugar or colors. For sweetness, it relies on agave nectar. 

Enter the MilkPEP Awards online and win great prizes.

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

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

New Products & Marketing

DAIRY MARKET TRENDS

The Rise of Yogurt  Marina Mayer

Executive Editor

or the past few years, yogurt has been touted as a healthy go-to breakfast option, especially since all consumers have to do is add some granola or fruit pieces or drizzle on some honey for a better-for-you on-the-go snack. Regardless of its healthy attributes though, certain yogurt brands have displayed lackluster sales figures, according to SymphonyIRI Group, a Chicago-based market research firm. Although total sales are up 8.3% for the 52 weeks ending Dec. 26, 2010, certain brands showed decreases. For instance, while private label maintained its No. 1 slot with $407.6 million in sales, it also dropped 3.1% in dollar sales since last year. On the other hand, General Mills’ Light snagged the No. 2 spot with $402.1 million in sales with a 5.4% uptick in dollar sales, whereas Yoplait Original claimed the No. 3 position with $390.2 million in sales, thanks to its new offerings with extra calcium, but undertook a 0.8% decline in dollar sales. Other brands also saw sales decrease. Dannon Danactive, for instance, came in at No. 18 with an 18.5% drop in dollar sales, while Dannon Natural dropped 9.2%. Yoplait Light Thick & Creamy took the No. 17 slot with a 16.4% decline in dollar sales, and Yoplait Trix underscored a 10.5% dip.

F

What goes down must come up Regardless of how consumers “dress up” their yogurt, some low sales figures are only temporary, according to sales history from SymphonyIRI. Yogurt sales have been growing every quarter compared to the previous period. In the four 13-week periods of 2010 (beginning with March 28), sales increased 5.6%, 9.2%, 9.9% and 8.5%, according to SymphonyIRI data (see table). Meanwhile, yogurt brands continue to top the charts with an array of new product innovations, flavors and packaging designs to help curdle in more sales. Chobani experienced the largest increase in sales with a 230.3% jump, thanks to its selection of Greek yogurt offerings, available in black cherry, lemon, honey and strawberry, among others. Produced by Agro Farma, Chobani also developed Chobani Champions, which is a line of Greek yogurt targeting kids. “Since day one, our focus has been to make Chobani a priority in the main dairy sets,” says Kyle O’Brien, vice president of sales. “Thanks to our amazing team, avid fan base and retailer support, Chobani is the No. 1 Greek yogurt brand in America. But from our perspective, the yogurt story in this country has yet to be told. We’re excited to be a part of it and to keep climbing.” 32

Dairy Foods | March 2011

Quarterly Sales of Yogurt Reporting Period 13 weeks ended

Dollar Sales (millions)

% change vs. yago

Unit Sales (millions)

% change vs. yago

12/26/10

$976.3

+8.5

926.1

+4.7

9/26/10

$1,096.7

+9.9

1,041.8

+6.2

6/27/10

$1,092.8

+9.2

1,066.8

+7.1

3/28/10

$1,057.1

+5.6

1,074.0

+4.2

12/27/09

$899.6

+5.9

884.4

+7.2

$998.4

+3.5

980.9

+4.8

9/27/09

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

Other chart-toppers include Stonyfield Farm’s Oikos organic Greek yogurt (67.5%) and Yoplait GoGurt (12%). For its part, The Dannon Co. fared well with some healthy sales results from its lineup of better-for-you yogurt brands. For starters, Dannon Activia garnered 20.4%. Another healthy brand is recently introduced Activia Parfait Crunch, a blend of Activia low-fat yogurt, fruit pieces and low-fat granola that delivers 220 calories and 3 grams of fat per 6-ounce container. (Sales figures were not yet available for this new product.) Likewise, Dannon took in 18.6% dollar sales whereas Dannon Activia Light and Dannon Danimals saw 15.2% and 13.2% gains in dollar sales, respectively. Despite the roller-coaster sales results, the health benefits behind a cup of yogurt help this category continue rising to the top.  Editor’s Note: For more on the yogurt category, check out our upcoming Cultured Trends report in the April 2011 issue. Also see the Dairy Detective column about Greek yogurt in the January 2011 and the November 2010 State of the Industry report.

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Ingredient Technology Photo courtesy of S&P Marketing Inc.

 Prickly pear is available in juice, concentrate and purée forms. The ruby red variety has a bright magenta color and a delicate, slightly sweet, cactus flavor that complements cultured and frozen dairy foods.

 Donna Berry Product Development Editor

he word “supersize” might be long gone from the world’s largest burger joint’s menu board, but there’s a new “super” concept showing up in foodservice and on retail packaged foods. It’s “super-ize,” and the term refers to the addition of powerhouse ingredients ranging from fruits to vitamins, with the former often described as superfruits.

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So, what’s a superfruit? The term superfruit has no legal definition. It is marketing jargon for fruits that offers value beyond basic nutrition, with basic being defined as those nutrients that show up on the Nutrition Facts. The most prominent superfruit attribute is a high Oxygen Radical Absorbance Capacity (ORAC), which is laboratory method of measuring antioxidant capacities of biological samples in vitro. High ORAC values are associated with foods high in antioxidants, molecules that inhibit the oxidation of other molecules. Basically, antioxidants interfere with free radicals (atoms or groups of atoms with an unpaired number of electrons that are formed when oxygen interacts with certain molecules), which can start chain reactions that damage healthy cells. Antioxidants terminate these chain reactions by being oxidized themselves. The blueberry industry pioneered the world of superfruits in the mid-1990s when it began promoting the antioxidant content and high ORAC value of blueberries. The term superfruit came around in 2004 when Superfoods Rx author Steven Pratt highlighted the antioxidant levels and anti-aging properties of blueberries

in his bestseller. And though blueberries are most likely the bestknown superfruit today, the list of superfruits is constantly growing.

Leading Brands Inc., of Vancouver, Canada, offers the Pure line of antioxidant-rich 100% juices, each combining a great-tasting blend of superfruits and premium varietal wine grapes. PureBlue, PureBlack and PureRed pack a whopping 750, 740 and 660 milligrams of polyphenols, respectively, into each 300-milliliter bottle. PureWhite combines the restorative benefits of coconut water with sauvignon wine grapes and lulo, an emerging superfruit harvested in South America.  Continued on page 36

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Dairy Foods | March 2011

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Ingredient Technology

Cocoa: The Next Superfruit?

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Dairy Foods | March 2011

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Research scientists from The Hershey Center for Health & Nutrition, Hershey, Pa., recently compared cocoa powder and various chocolate products with powders and juices derived from fruits commonly considered superfruits. Results from the study were published in the February 2011 issue of Chemistry Central Journal, where the researchers concluded that cocoa seeds provide nutritive value beyond that derived from their macronutrient composition and should also be considered superfruits. This conclusion was based on the fact that cocoa powder and chocolate are made from an extract of the seeds of the fruit of the Theobroma cacao tree. The authors’ findings demonstrated that the antioxidant capacity of cocoa powder was significantly greater than blueberry, cranberry and pomegranate powder, on a per-gram basis, and the total polyphenol (a category of antioxidants) conPhoto courtesy of Rich Products tent of cocoa powder appeared to be greater than açai, blueberry and cranberry powders; however, the latter differences did not reach statistical significance. Further, the Hershey team found that the total flavanol content of cocoa powder was significantly greater than all of the other fruit powders tested. Analysis of fruit products demonstrated that the antioxidant capacity of dark chocolate was not significantly greater, on a per-serving basis, than pomegranate juice but was greater than that of all other products tested. In contrast, the hot cocoa mix had significantly less antioxidant capacity than all of the other products tested. The scientists note that the cocoa powders, cocoa beverages and dark chocolate used in the study all contained natural (or non-alkalized) cocoa but that the hot cocoa mix was made with alkalized cocoa, which explains its low-antioxidant capacity. Separately, a group of Japanese scientists claim to have learned how the polyphenols in cocoa boost the body’s production of highdensity lipoprotein cholesterol (HDL) — the “good” form of cholesterol that protects against heart disease. Their study appeared in the Journal of Agricultural and Food Chemistry, (online, January 2011) and showed that the polyphenols rev up the activity of certain proteins, including proteins that attach to DNA in ways that boost HDL levels. The scientists analyzed the effects of cocoa polyphenols on cholesterol using cultures of human liver and intestinal cells. They focused on the production of apolipoprotein A1 (ApoA1), a protein that is the major component of HDL, and apolipoprotein B (ApoB), the main component of low-density lipoprotein cholesterol (LDL), or “bad” cholesterol. It turns out that cocoa polyphenols increased ApoA1 levels and decreased ApoB levels in both the liver and intestine. Further, the scientists discovered that the polyphenols seem to work by enhancing the activity of so-called sterol regulatory element binding proteins (SREBPs), which attach to the genetic material DNA and activate genes that boost ApoA1 levels, increasing HDL. The scientists also found that polyphenols appear to increase the activity of LDL receptors, proteins that help lower LDL levels. 

Photo courtesy of U.S. Highbush Blueberry Council

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 Blueberries, the fruit behind the term superfruit, along with strawberries, are the fruits of choice for the increasingly common foodservice yogurt parfait.

According to author Paul Gross, a.k.a. the “Berry Doctor,” superfruit status is based on five factors: 1) nutrient diversity and density, 2) phytochemical diversity and density, 3) basic research intensity, 4) clinical research progress and 5) popularity, based on sensory appeal and market demand. He identified 20 fruits as being “super” in his 2010 best-seller: Superfruits. From highest to lowest, Gross named these 20 fruits as being superfruits: mango, fig, orange, strawberry, goji, red grape, cranberry, kiwi, papaya, blueberry, cherry (sweet and tart species), red raspberry, seaberry, guava, blackberry, blackcurrant, date, pomegranate, açai and dried plum. Most of the fruits on his list, as well as a number of emerging exotic fruits — lulu, mangosteen, maqui berry and prickly pear — that will likely soon be added to his list, readily complement the creamy taste and mouthfeel of milk, making them the perfect addition to cultured and frozen dairy products. Not only do they add great flavor, they provide a pleasant color, too. And after all, much of what gives superfruits their super powers is pigmentation, i.e., the antioxidant phytonutrients such as carotenoids and polyphenols. Gross wrote in his book, “In the past few years, the word superfruit has blared into the headlines with alluring fanfare. What began as just a few curious exotic juices in the American market has now evolved into thousands of products in a multibillion-dollar global industry.” And dairy is an ideal delivery vehicle for high-quality superfruit concentrates, juices and purées. 

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Ingredient Technology

LAB TALK

What’s Hot? Iced Tea and Coffee!

Donna Berry

Photo courtesy of Autocrat

ood and beverage trends are said to start in foodservice — at highend restaurants where the final bill for a party of six often totals more than the average family’s monthly mortgage payment. The original innovation gets diluted many times on its way to becoming a retail packaged product. Today’s chefs are telling us that iced tea and coffee beverages are a hot trend. This presents an opportunity for dairy processors to recreate these beverage experiences for at-home and on-the-go consumption.

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Additional descriptors According to the What’s Hot in 2011 report from the National Restaurant Association, Washington, D.C., 57% of the more than 1,500 professional chefs surveyed identified specialty iced tea (e.g., Thai-style, southern/sweet, flavored, etc.) as a hot trend. Green tea — hot or iced — was identified as a hot trend by 35% of the respondents. In the coffee beverage category, 57% of chefs surveyed said organic coffee is hot, while 30% said the same for iced coffee beverages. “Our annual ‘What’s Hot’ chef survey is one of the industry’s most anticipated and quoted culinary forecasts, largely due to the credibility of its respondents — professional chefs that work in some of the nation’s finest dining establishments and educate the next generation of chefs in culinary institutions,” says Hudson Riehle, senior vice president of research and knowledge group for the National Restaurant Association. “The top trends identified by these culinary professionals for 2011 are reflecting larger societal trends, underscoring that American diners are becoming more and more interested in what’s on their plate. Sustainability and nutrition are becoming key themes in our nation’s nearly one million restaurants.” Michael Ty, national president for the American Culinary Federation, St. Augustine, Fla., adds, “Locally sourced

food and a focus on sustainability is not just popular among certain segments of consumers anymore; it has become more mainstream. Diners are requesting to know where their food comes from, and are concerned with how their choices affect the world around us.” This plays right into coffee- and teabased dairy products, where the coffee and tea ingredients can be organic, Fair Trade Certified and even Rainforest Alliance Certified. The milk, too, can be flagged for some sustainable attribute, such as free range, family farmed or locally produced. For example, South Africa’s Fair Cape offers a line of dairy products described as being made from healthy, happy Fair Cape cows fed only natural products with no animal byproducts or added hormones. Packaging for the new line of Fair Cape Free Range Rooibos Yoghurts are able to sport the Cancer Association of South Africa (CANSA) Smart Choice emblem as a result of a 100-gram serving containing the same amount of antioxidants as one cup of brewed rooibos tea. Functional ingredients Ready-to-drink coffee and tea developers are also adding functional ingredients to their formulations. For example, Renewal Laboratories, San Diego, recently introduced the first bottled tea with omega-3 fatty acids. Available in sweetened and unsweetened varieties, the teas are formulated with high-purity fish oil, a source of the heart-healthy omega-3s docosahexaenoic acid (DHA) and eicosapentaenoic acid (EPA). New Marley’s Mellow Mood is a line of relaxation teas and sodas inspired by Bob Marley, the globally recognized musician who, when jammin,’ sang about unity, freedom, peace, empowerment and love. Marley Beverage Co. was created by Marley’s family, paying homage to their father and patriarch, by launching and promoting a wide range

 From mom-and-pop joints to fast-food chains to five-star restaurants, lattes, both hot and cold, have become menu mainstays. Consumers often want to recreate the experience at home, but are not equipped to brew and blend. Dairy processors can help by offering premium products through retail channels.

of drinks that are 100% natural and have ingredients that put people into what they call, “Marley’s Mellow Mood.” Marley Beverage Co. is manufacturing and marketing the new drinks in a joint partnership with ViVa Beverages, Southfield, Mich. The lightly carbonated sodas come in Berry and Citrus flavors, while the ready-to-drink cold teas come in Green Tea with Honey and Black Tea with Raspberry, Passion Fruit and Peach flavors. According to the company, the drinks have been meticulously formulated with an exotic blend of allnatural botanical ingredients sourced from around the world. Chamomile, valerian root, passionflower, melatonin, rose hips and lemon balm are among the time-tested calming and stress-reducing ingredients that the Marley family has expertly crafted into first-of-its-kind relaxation beverages. The cans and bottles are wrapped in signature colors — Continued on page 40

38

Dairy Foods | March 2011

Coffee ExtractQ‚Tea ExtractQ‚Botanicals

We control quality

from plant to plant.

Ingredient Technology

green, yellow and red — and picture the classic Bob Marley image: relaxed, smiling, truly happy. The opposite of relaxing would be pumped up, and that’s what Athletes HoneyMilk is all about. (Read about it in this month’s New Product Review on page 30.) The Light Coffee variety uses coffee extract for flavoring. It also is enhanced with caffeine for stimulation, with each 11.5-ounce bottle containing 150 milligrams of caffeine. Quality beans and leaves Regardless if you are using sustainable raw materials or adding functional ingredients, formulators must remember to design a great-tasting coffee or tea, just like one would be served when dining out. Thus, coffee or tea ingredient selection is of upmost importance. When it comes to choosing coffee ingredients, here are a few things you should know. The least expensive is freeze-dried or powdered coffee. It can be stored at ambient temperature; thus, it has a lengthy shelf life. Unfortunately, such products often deliver an acidic or bitter aftertaste, and a formulator needs to mask this with other flavors, thickeners or sweeteners, which of course, add to the cost. This is why most formulators prefer to simply use a higher-quality ingredient such as concentrate or extract. These are also available in a wide range of qualities, as well as a variety of flavors and strengths to meet a formulator’s desired flavor profile and bottom line. Concentrates and extracts are made by brewing coffee, followed by reducing the water in the resulting brew.  Ready-to-drink coffee and tea marketers are adding value to their beverages in order to create a point of differentiation in what has become an increasingly competitive category. Value comes in the form of premium and seasonal flavors, the addition of functional ingredients and sportsnutrition positioning.

40

Dairy Foods | March 2011

With tea, some dairies actually brew tea leaves for an authentic-tasting beverage. They can also use tea concentrates or extracts, or soluble or instant tea pre-mixes, which contain tea, as well as flavors such as lemon, peach, orange or raspberry. Dairies simply measure how much mix they need, add sweetener and process like fluid milk. In low-calorie or diet formulations, the high-intensity sweetener is part of the pre-mix. Flavor houses also offer coffee and tea flavorants, some of which are based on the real thing. However, tea flavorants typically do not contain the antioxidants one would get from using brewed tea or tea concentrate or extract. Both coffee and tea flavors can be used alone or to enhance the aforementioned coffee or tea ingredients. All of these coffee and tea ingredients have application in other dairy foods, most notably ice cream, but also cultured products. With the latter, it is important to keep in mind that the cultured product base can have a significant impact on final flavor. The level of fat and sweetener, as well as the source of the base (i.e., cows milk or soy) can have an influence on the type of flavor that is chosen.  Donna Berry is the Product Development Editor for Dairy Foods. She can be reached at 773-463-2467 or [email protected].  Lancaster County, Pa.’s Turkey Hill Dairy is the No. 1 refrigerated ated iced tea brand in the nation. From om January to June, the dairy is offering g a limitededition Light Green Tea Wildberry. Available in half-gallon plastic stic jugs, an 8-ounce serving contains a mere 25 calories as a result of being sweetened with aspartame and acesulfame potassium.

Refreshing Teas for Dairy Processors Robertet Teas n

Having supplied billions of units to the industry since first launching the tea-to-dairies category in 1962, Robertet knows tea and a whole lot more – we know how to formulate and process tea to meet your unique processing conditions and flavor requirements.

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A full service, top ten flavor house with core competencies in tea, beverages, and yogurts, Robertet’s flavor ingredients are well represented in a vast range of leading brand consumer products. Robertet’s flavors are fresh, shelf-stable, and blended on-site with quality teas sourced from key global producers.

Black Teas Tea with Lemon Green Teas Oolong Teas Red Teas White Tea Types Flavored Tea Blends Herbal Teas Fortified Teas Optional Sweeteners

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Ingredient Technology

DAIRY DETECTIVE

Food Makers Turn To Whey Permeate ood manufacturers are always looking for a superstar ingredient — one with superb functionality that can help improve the bottom line. Whey permeate fits that bill nicely. It is a functional workhorse that can promote browning, enhance flavor, improve moisture retention and allow manufacturers to reduce sodium levels, all at a very reasonable cost. Whey permeate ingredients vary in composition from supplier to supplier, but their typical composition is lactose (65-85%), ash/minerals (8-20%), protein (3-8%) and fat (1.5% maximum), according to the U.S. Dairy Export Council’s “Reference Manual for U.S. Whey and Lactose Products.” Most of the protein consists of non-protein nitrogen compounds. Good solubility and pleasant dairy flavor make whey permeate formulator-friendly. Whey permeate is found in infant formula and other dry milk formulas, instant drinks, bakery products, confectionery bars, instant soups, milk drinks, sweetened condensed milk, ice cream and dessert products. “U.S. production of sweet whey has decreased dramatically over the past 10 years because of increased filtration of sweet whey into higher-value concentrate for nutritional uses. This shift has resulted in more whey permeate powder production and limited suppliers of high-quality sweet whey powders. In addition, new facilities and equipment have been built and are manufacturing whey permeate that often functions as a 1:1 replacer for sweet whey in applications like compound coatings, biscuit and cracker manufacturing, culture media and meat sausages,” says Peter Gutierrez, vice president, global ingredient sales, Agri-Mark, Onalaska, Wis. From 2005-09, the U.S. production of permeate powder is estimated to have grown by an average of 17% a year, according to a report of various industry sources by 3A Business Consulting, Denmark. The same report projects that while production of lactose may slow, both volume and value

F

42

Dairy Foods | March 2011

of permeate ingredients will continue to grow over the next three years. There are no exact export figures because data for dry sweet whey and whey permeate often are combined in the same trade category. Cost reduction also continues to be a major incentive to use whey permeate. Prices are always changing, but the 3A Business Consulting report noted that the cost of permeate powder was $750 per metric ton, as compared with $900 per metric ton for whey powder, thus affording food manufacturers a substantial incentive to switch to permeate powder. Food manufacturers that switch from sweet whey to whey permeate should first consult local regulations because acceptable uses of permeate may vary from country to country. In the United States, food manufacturers will have to change the ingredient declaration to “dairy product solids,” which is the common or usual name of the ingredient as specified in GRAS Notice No. 37. With more consumers looking for natural ingredients in their food products, this is a consumer-friendly label declaration. Whey permeate as a sodium replacer In 2000, the Wisconsin Center for Dairy Research (WCDR), Madison, began projects using whey permeate. “Initially the focus was on browning, flavor enhancement and cost reduction, but we learned that whey permeate also has salt-enhancement characteristics,” says Kimberlee (KJ) Burrington, WCDR director of dairy ingredient applications. Much of the recent work at the WCDR has focused on sodium reduction in bakery products. “While there is not an extensive amount of research on why whey permeate performs as a sodium replacer, it is believed that these non-protein nitrogen compounds — urea, creatine, creatinine, uric acid, orotic acid and ammonia — may serve as flavor potentiators. The mineral salts (calcium phosphate, magnesium, sodium and potassium) may function as salt enhancers,” says Burrington. Researchers were able

Sharon Gerdes

to achieve sodium reductions of 12-70% in various bakery products. Newer whey permeate ingredients also are appearing on the market. “Delactose permeate has savory flavor characteristics, which can be used alone or in conjunction with other technologies to enable sodium reduction by as much as 30% in some product applications. Leprino Foods’ DLP is differentiated through a proprietary process where some of the lactose is removed, creating a more concentrated flavor that can be dried and ready for use in a variety of food applications,” says Deborah Roberts, category marketing manager, new business development and dairy ingredients of Leprino Foods, Denver. An example of a creative use of whey permeate was demonstrated at the 2010 IFT Food Expo in Chicago. A portable breakfast bite made of cheese and eggs was formulated with roughly 2% permeate in the bread dough to provide 40% less sodium than similar cheesy on-the-go products. One study at North Carolina State University, Raleigh, N.C., by Elizabeth Dixon, also demonstrated how whey permeate could be used as a sodium replacer in cream soups, achieving sodium reductions of 25-50%.  Sharon Gerdes is a food industry consultant who works with the U.S. Dairy Export Council.

To Learn More A symposium during the June 11-14 annual meeting of the Institute of Food Technologists will focus on “Natural Ingredient Opportunities Using Dairy Co-Products.” For a technical paper highlighting the ways to formulate with these natural, cost-effective dairy ingredients, visit www.InnovateWithDairy.com.

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Ingredient Technology

Dairy and Probiotics Are A Good Pair  Contributed by Christopher J. Cifelli, Erin E. Quann and Gregory D. Miller

ore than a century ago, the Nobel Prize-winning Russian immunologist Elie Metchnikoff linked the long, healthy life of Bulgarian peasants to their high intake of fermented dairy products containing lactic acid bacteria. Since this initial observation, scientists have actively examined the health benefits associated with the consumption of probiotics. The most widely accepted definition of probiotics is that they are live microorganisms that, when consumed in appropriate amounts, confer a health benefit to the host. A growing body of scientific evidence indicates that the consumption of specific probiotics can beneficially affect certain aspects of health, including, but not limited to, digestive health. Most probiotics are strains of different species of Lactobacillus and Bifidobacterium. Although the research indicates that probiotics can confer numerous health benefits, it is important to note that the function of a given probiotic is dependent upon strain, the amount consumed and the mode of delivery. Approximately 95 million people in the United States suffer from digestive problems. In 2008, foods and beverages that were marketed for digestive health topped the list of new functional products introduced in the marketplace. UK-based New Nutrition Business predicts that the top food, nutrition and health trend for 2011 will be digestive health, which after energy drinks, represents the largest portion of the functional foods market. New Nutrition Business indicated that “it is also possibly the fastest-growing segment of health, and the evidence is that its growth will continue.” Similarly, an August 2009 report by Chicago-based Mintel stated that U.S. sales of functional dairy products grew by 43% between 2004 and 2009.

M

44

Dairy Foods | March 2011

Further, the report predicted that sales will continue to rise to $6.34 billion in 2014. What to know about labeling and claims Probiotics are available in the market as dietary supplements and in foods. There are no Food and Drug Administration-approved health claims for probiotics in the United States. The most common claims for probiotics on food labels are structure/function claims, which describe the effect of a nutrient or substance on the normal structure or function of the body. Like all other information on a food label, structure/ function claims must be truthful and not misleading, and manufacturers making the claim must have credible scientific evidence to substantiate the specific claim. Examples of structure/function claims for specific probiotic strains in the marketplace include claims about strengthening the body’s defenses, supporting the digestive system, helping naturally regulate the digestive tract and helping to reduce intestinal transit time. Generalized claims about probiotics should not be made since there are thousands of unique strains. Probiotics have been associated with dairy for centuries, and fermented dairy products continue to be predominant in foods and beverages for delivering probiotics. Beyond the natural and historical association between dairy and probiotics, dairy products may be the optimal delivery vehicle for probiotics for several reasons: • Consuming probiotics with food, especially dairy products, may help neutralize stomach and bile acids, increasing the possibility that the probiotics survive digestion and reach the intestine.

• The refrigerated storage and short shelf-life of dairy products promote probiotic stability, helping to ensure that adequate amounts of the probiotic remain viable throughout shelf-life. • Because of the historic link between lactic acid bacteria and dairy products, the presence of live cultures in dairy foods is viewed positively by consumers. • Dairy products are already a substantial contributor of a number of essential nutrients that provide health benefits to consumers. Research continues to investigate potential synergistic interactions between dairy and probiotics to determine if dairy directly enhances the survival and activity of probiotics. Recently, genomic experiments have shown that dairy can increase the expression of genes associated with stress tolerance and cell adhesion, which could possibly allow the probiotic to survive and thrive in the harsh digestive environment. In addition, studies have demonstrated that lactose is a preferred energy source for certain probiotics. The dairy industry has a unique opportunity to leverage the beneficial relationship between dairy and probiotics to develop innovative new products and increase the demand for dairy products. Also, the opportunity exists to continue to educate consumers on the historical association of dairy products and probiotics as well as the healthful properties of probiotics. While additional research is needed on the interplay between dairy and probiotics, the combination of dairy products with probiotics can make for a healthy, functional food package.  Christopher J. Cifelli, Erin E. Quann and Gregory D. Miller are with the National Dairy Council/Dairy Research Institute.

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Cover Story

ANNUAL ICE CREAM OUTLOOK

For many off today’s d ’ ice i cream processors, less is more, and that means, fewer complex ingredients blended with simple, yet adaptable creations.  Marina Mayer

Executive Editor

hen it comes to ice cream, consumers know what they want, how they want it and even when they want it. They read nutrition labels, remain abreast of food safety issues and “speak” with their spending dollars. They even follow or connect with ice cream producers via social media outlets to stay on top of contests and new flavor introductions. As complex as this may sound, the processor/consumer relationship is actually anything but. That’s because consumer trends point toward a more simplified outlook, allowing ice cream producers to scale back on unique ingredients and focus on just being unique. “The emerging consumer trends in ice cream is simplicity — the least amount of ingredients listed in a label that are also common such as milk, cream, butter, sugar, etc.,” says Catherine Nobriga Kim, vice president of the frozen division for Roselani Ice Cream (doing business as Maui Soda & Ice Works, Ltd.), Wailuku, Hawaii. “The educated consumer is very much aware of the nutritional label and what value it adds to a product’s claim.”

W

The story under the lid The value of ice cream blended into a litany of enticing flavor profiles are what keep this category in the limelight of shoppers’ 46

Dairy Foods | March 2011

minds and inside household freezers. However, for consumers, it’s about how ice cream makes them feel and what it represents that keeps them coming back for more. Roselani Ice Cream, for example, produces Roselani Tropics, a niche line of flavors that represent the cultural diversity of the Hawaiian islands, Nobriga Kim says. “We serve an experience that wants to be repeated,” she adds. “For example, our signature flavor, Haupia (pronounced howPEE-yah), is the dessert served at Hawaiian luau (feast), which is not reserved for the tourist. A luau celebrates significant milestones in someone’s life (first birthday, high school graduation, wedding, retirement). Our followers have commented that this flavor reminds them of one of these occasions, and through it, they relive that time of their life.” Roselani also distributes national brands under the Unilever label, and is currently reformulating certain lines to include less sugar and more better-for-you ingredients. G.S. Gelato & Desserts, Ft. Walton Beach, Fla., speaks to its consumers by reinventing its portfolio to include innovative flavors while remaining true to its Italian heritage, says Kindra Svendsen, marketing coordinator. “Outside of the health attributes, we are seeing a demand for unique flavors as well as single serving-size portions,” Svendsen

Cover Story

says. “With these trends, consumers have become more ingredient-savvy and m are taking more time and care ar in picking out products, and as a rresult, sales of traditional ice cream are decreasing.” cre For Ben & Jerry’s, it’s not a surprise that its lineup no of ice cream flavors relate to consumers. With flavor names such as Cherry Garcia, nam Mud Pie, Chubby Hubby and Mu Chunky Monkey, the South Chu Burlington, Vt., division of Burl Unilever provides an avalanche of Unilev opportunities for shoppers to feel good opportuniti when digging into a pint full of homemade ice cream. That’s why it introduced a lineup of self-described funky flavors that are developed from simple staples, such as vanilla, chocolate and chocolate chips. For example, the Boston Cream Pie consists of yellow cake pieces, fudge flakes and swirls of pastry cream, whereas Dulce Delish is made of rich caramel ice cream fused with dark caramel swirls. Then there’s Maple Blondie, Milk & Cookies, Mud Pie, Peanut Brittle, Pumpkin Cheesecake and Snickerdoodle Cookie. In addition, Ben & Jerry’s is converting all of its flavors to be fairtrade certified by year-end 2013, says Liz Stewart, public relations. “We believe it’s the right thing to do and it encompasses our company’s three-part mission statement. We’re hoping that other ice cream brands follow our lead,” she adds. “When consumers buy our ice cream, they’re not only getting delicious flavors, but they’re helping support our social mission and values-led sourcing initiatives, including fair trade, which gives farmers fair wages for goods to make healthcare more accessible, develop sustainable farms and contribute to their local communities. It’s the values behind the flavors that we’re looking for consumers to know about and support.” Ben & Jerry’s also thanks its “fans” by hosting Free Cone Day, which will take place April 12 at scoop shops nationwide. To keep its ice cream collection fresh, Turkey Hill Dairy developed two new premium flavors: Homemade Vanilla, which is an old-fashioned ice cream am recipe made with extra vanilla and offers a classic homemade taste; and Double Dunker, mocha ice cream swirled with chewy cookie dough and crunchyy chocolate cookie swirl. The Conestoga, Pa., ice ce cream producer also launched ed Cool White Mint No Sugar gar Added ice cream to its no-sugargaradded line of products, accordording to Colin Wright, trade relaelations coordinator. Cool White Mint is made of dark chocolate olate chips and chocolate fudge and delivers ivers 100 calories per serving.

Top 10 Brands of Ice Cream Dollar Sales (millions)

% change vs. yago

Dollar Share

Private Label

$977.1

-5.5%

24.80

Breyer’s

$422.9

-6.3%

10.80

Blue Bell

302.5

2.2%

.70

Dreyer’s Edy’s Slow Churned

$295.1

-4.8%

7.50

Häagen-Dazs

$252.7

+3.2%

6.40

Ben & Jerry’s

$221.5

+3.6%

5.60

Dreyer’s Edy’s Fun Flavors

$149.0

+46.4%

3.8

Dreyer’s Edy’s Grand

$144.9

-18.4%

3.70

Well’s Blue Bunny

$134.7

+8.3%

3.40

Turkey Hill

$117.8

-6.9%

3.00

Brand

Total category $3,933.5M in Sales (-3.9%), $1,204.5M Units (-3.2%) For the latest 52 weeks ending Jan. 23, 2011 Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Wal-Mart)

This year, Wright says, Turkey Hill also is releasing a limitededition Strawberry Shortcake 26-ounce ice cream cake, available through June. Furthermore, Turkey Hill remains actively involved with its professional sports sponsorships thanks to its Blitzburgh Crunch creation, which was developed in honor of the AFC Champion Pittsburgh Steelers. Blitzburgh Crunch consists of vanilla ice cream with chocolate cake inclusions and a crunchy chocolate cookie swirl. To further simplify its branding initiatives, Hudsonville Creamery & Ice Cream Co. locally sources its raw materials, including milk, cream and fruits, among others. The Holland, Mich., company also offers a flavor profile that caters to both children and adults. Its newest frozen confection, for example, is Lake Affection, which consists of blue mint ice cream swirled with vanilla ice cream to signify lake-effect snow. “Our flavor portfolio is very complete, so that decadent flavors for adult family members (Grand Traverse Bay Cherry Fudge) mesh well with kid flavors (Superscoop) vs. teen flavors (Cake Batter),” says Bruce Kratt, director of sales. “We offer flavors for every mood and every age.” Baskin-Robbins, the owner of “31 Ba Flavors” scoop shops and the F Baskin-Robbins team of frozen yyogurt, ice cream and ice cream cakes, is creating more occassions and reasons for people to shop the ice cream aisles, says Stan sh Frankenthaler, executive chef and Fra vice president of culinary developvic ment for the Canton, Mass., divimen sion of Dunkin’ Brands Inc. That’s why it offers a line of Bright Choices, which includes fat-free, dairy-free, whic no-sugar-added and light treats. no-su It also a hosts a “Flavor of the Month” program, which was designed to constantly introduce new flavors and capture current and Frankenthaler says. emerging trends, Fran Continued on page 48 www.dairyfoods.com

47

Cover Story

“Every month, a new flavor is introduced to consumers for a limited time,” he adds. “To capitalize on the recent red velvet craze, we simultaneously launched a red velvet ice cream that contains a cream cheese ribbon as an in-store flavor along with a limitedtime Red Velvet ice cream cake. Updated packaging keeps it real The ice cream category was impacted greatly

by the poor economy, mainly because many of America’s traditional brands were either traded in for private label counterparts or were deemed a non-essential item and crossed off the grocery list completely. Despite the challenges, several ice cream processors continue to churn out stellar products in refined packaging concepts. For instance, Roselani Ice Cream produces its Roselani Tropics line in 56-ounce

“apex” cartons, Nobriga Kim says. “As a small company, we have put our efforts into efficiencies,” she adds. “In late 2010, we installed a rotary filler that has expanded our production volume from 12 cartons per minute to 18 cartons per minute. Prior to installation, our operation was manual fill. We take pride in what we serve our customers. Rather than diminish that quality with cheaper, lesser ingredients, we continue to review our operational methods to become more productive. With the installation of this piece, we are developing a single-serve component to our line.” G.S. Gelato launched its new pint designs, which better promote brand identity and highlight the flavors and healthy attributes on the face of the package, Svendsen says. “Next to our nutritional information, we have also placed symbols denoting that our product is hormone-free, vegan, cholesterol-free, trans-fat free, etc.,” Svendsen adds. “This helps our consumers in making a quick and efficient choice when choosing a super premium ice cream or our gelato.” Additionally, Turkey Hill Dairy redesigned the packaging for its frozen yogurt line. “The new package includes a ‘Benefits Band’ along the bottom that calls out the health benefits at a glance,” Wright says.  “The cleaner look and colors of the package also help consumers have an easier time finding it on the shelf.” Hudsonville Creamery enhanced its presentation by upgrading to a high-resolution graphic on its 56-ounce cartons, Kratt outlines. “We are all about the consumer’s experience when marketing our brand,” he says. “We don’t take being invited into our consumer’s life experiences lightly, so we make sure that everything we do from recipes to flavorr innovation to consistent qual-ity exceeds con-sumer expecta-tions.”  G.S. Gelato & Desserts introduced ed a King Cake flavor in honor of Mardi Gras.

48

Dairy Foods | March 2011

Continued on page 50

The Ingenious Pursuit Of Flavor

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Cover Story

While the folks at Baskin-Robbins haven’t proposed too many packaging changes, they did recently return to handpacking their quarts in the shops, thus “providing a deeper level of authenticity for our guests,” Frankenthaler says. “We offer hand-packed ice cream in three sizes: small (12 ounces), regular (18 ounces) and large (3 pounds).” Likewise, Ben & Jerry’s tends to update its packaging designs on a yearly basis, Stewart says, whether it be a small tweak or changes in copy. “Last year, we transitioned all our pint packaging to become Forest Stewardship Council (FSC) certified, which makes our packaging much more environmentally sustainable by requiring suppliers to reduce the environmental impact of logging activities,” she adds. “It also calls for the maintenance of areas that need special protection (such as habitats of endangered animals or plants), and the enhancement of the social and economic well-being of forest workers w and local communities.”

The future of ice cream Consumers want it all when it comes to ice cream, says Bruce Ginsberg, president and CEO of MooBella, Inc., Taunton, Mass. That’s why the ice cream industry must find ways to bring their products to countries that don’t have a “cold chain” in place, he adds. “Every day, we get inquiries from individuals and companies from around the globe. They are looking for ways to bring ice cream to places that historically have not had the systems necessary to handle frozen products,” Ginsberg adds. “Because it doesn’t rely on cold transport and storage, MooBella (with its shelf-stable ingredients) has the capacity to drive per capita consumption by bringing the ice cream experience around the world.” The biggest challenge for ice cream producers, however, is staying on the cutting edge of trends. “The ice cream category is highly competitive, so it is important to stay ‘top of mind’ in the minds of our consumers,” Svendsen says. “Ice cream has always, is always and will always be strong. Ice cream makes up a large percentage of the frozen dessert category. As long as manufacturers take consumer trends into consideration, we will remain competitive among other categories within frozen desserts.” Here’s to keeping things simple.  Find more ice cream articles in our archives. Photograph this image with your smart phone. Get the app at http://gettag.mobi. Continued on page 52

50

Dairy Foods | March 2011

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

Cover Story

Need Flavor Ideas? Look To Bars, Delis and Ethnic Restaurants Nowadays, a beer drinker doesn’t have to be in a pub to enjoy a Black and Tan. The classic beer cocktail, made with Guinness and a pale ale, is also an ice cream flavor produced by The Brewer’s Cow. The Old Lyme, Conn.-based company uses Guinness or Sam Adams in its beer-infused ice cream. The company was “mobbed” by foodies when it exhibited at the 2010 New England Dessert Showcase in Boston, says Jason Conroy, who owns the company along with Steve Albert and Larry Blackwell. The event organizer named the product the most unique dessert. Conroy says the first lick of ice cream is sweet, followed by a bitter malt flavor. His variations of the beer-flavored ice cream include a Black and Tan recipe, which contains a fudge weave. Oatmeal Stout, made with a Sam Adams product, has oatmeal clusters. The Brewer’s Cow adds sweet chocolate inclusions to Sam Adams Double Bock to make Double Bock Chocolate. “The real trick” to making beer-infused ice cream, Conroy says, “is how we treat the beer.” The Brewer’s Cow boils off the alcohol to make a syrup and adds brewer’s malt to help the flavor transfer, Conroy says. The ice cream is not simply a vanilla base with added beer, he says. In February, The Brewer’s Cow was talking with Whole Foods, which approached the company after the Boston dessert show. The supermarket chain is interested in the product for its stores in Connecticut and Massachusetts. To service an account that size, The Brewer’s Cow will use a co-packer in Rhode Island, Conroy says. Beer is not the only non-traditional ingredient finding its way into ice cream. Creative chefs are raiding the deli department and ethnic restaurants to create unusual fla-vors. Maple Bacon, Caramelized Honey & Bleu Cheese and Thai Chili Pineapple are on the menu at L.A. Creamery Artisan Ice Cream, a growing scoop shop based in Glendale, Calif. Executive chef Jessica Goryl buys many ingre-dients at local farmers’ markets. The milk is from Straus Family Creamery, an organic dairy in Marshall, Calif. Mochi is a Japanese ice cream dessert that is wrapped in a skin made of rice flour, which allows it to be eaten as a finger food, says Joel Friedman, secretary/treasurer of Mikawaya USA, Los Angeles. The 100-year-old maker of Japanese pastries and desserts started making mochi in 1994. This fall, it will add Pumpkin Spice to go along with its other seven flavors (vanilla, chocolate, strawberry, Kona coffee, mango, red bean and green tea). The new flavor was selected over peppermint and gin-gerbread by Mikawaya’s Facebook fans.

52

Dairy Foods | March 2011

The ice cream is manufactured as a 42-gram ball and sold in packages of two and six. The product is available at all Trader Joe’s stores in the United States. The two-piece pack encourages sampling, Friendman says. He also hopes the two-piece SKU will make inroads at convenience stores with shoppers who are seeking a small bite. While Mikawaya will try a pumpkin-flavored dessert this fall, Yarnell Ice Cream Co. is retiring its Pumpkin Pie ice cream SKU, but not because of slow sales. The Searcy, Ark.-based firm usually sells its limited-edition flavors for no more than two seasons. Replacing Pumpkin Pie is a cinnamon bun flavor named Sticky Bun. Flavors being reprised for a second season are Strawberry Shortcake (spring), Lemon Ice Box Pie (summer) and Santa’s Cookies and Milk (winter). New flavors result from brainstorming sessions. Company president Christina Yarnell says the company asks employees, “What are the pies and desserts we grew up eating?” Then it recreates those flavors in an ice cream format. Lemon Ice Box Pie has graham cracker inclusions, lemon flavor and a creamy whipped topping. Ethnic recipes also provide inspiration for new flavors. Conroy from The Brewer’s Cow also owns The Old Lyme Ice Cream Shoppe, a retail scoop shop in Connecticut. The owner of a local Moroccan restaurant asked Conroy to create an ice cream using oranges, cinnamon, dates and almonds (ingredients found in a popular North African salad). College students propose flavors to be sold by the Berkey Creamery on the campus of Penn State University, University Park, Pa. Several years ago, the food science club revamped Peachy Pate Paterno, named for the university’s foo football coach, Joe Paterno. The re-formulated recipe includes peach schnapps, nectarine pur and peach fruit pieces. ree Creamery manager Tom Palchak s says he brings out one to three new flav flavors every semester, which are develo veloped by students in the university’s food foodservice department, proposed by flavo houses, requested by the public flavor re or result from brainstorming. Recent flavo are Mint Nittany (mint flavor flavors with O Oreo cookies), Palmer Mousseum (choc (chocolate ice cream, butter-roasted almonds and chocolate swirl) and ScholC ar’s Chip (chocolate chips, raspberry an vanilla bean). swirl and Som Sometimes flavors just don’t fly, howPa ever. Palchak owns up to being the cret least-popular ice cream: the ator of the now-disc now-discontinued Carrot Cake. That’s the i way the inclusions crumble. —Jim Carper, Chief Editor

Cheese Trends

 Jim Carper

Chief Editor

he new Dietary Guidelines for Americans contain some good news/bad news for U.S. cheesemakers. Good news: Americans like to eat cheese. The food is among the Top 25 sources of calories for children and adults. Bad news: eat dairy foods other than cheese, the government says. The DGA recommends that Americans “increase intake of fat-free or low-fat milk and milk products, such as milk, yogurt, cheese or fortified soy beverages.” But that suggestion is tempered by the government’s message that Americans should consume “more fat-free or low-fat vitamin D-fortified milk or yogurt than cheese.” While Uncle Sam does encourage the consumption of low-fat cheeses (along with low-fat milk), the DGA comes down hard on full-fat dairy products. That’s because the guidelines recommend that Americans decrease their intake of solid fats and sodium. Both elements are found in full-fat cheeses. Regular cheese accounts for 3.5% and pizza for 6.3% of the sodium in the American diet. The guidelines recommend that an adult consume no more than 2,300 milligrams of sodium daily, meaning adults have their work cut out for them. They already consume more than that quantity on a daily basis. Shoppers do have choices and alternatives. As Dairy Management Inc., Rosemont, Ill., points out, “There are currently reduced- and low-sodium cheeses in the marketplace and some cheeses are naturally lower in sodium like Swiss and fresh mozzarella.” Under the auspices of DMI’s Innovation Center for U.S. Dairy, a best practices group of nearly 20 cheese companies and manufacturers are addressing the opportunities and challenges associated with reducing sodium content in cheese. The group says it has been working “pre-competitively to improve consumers’ health and wellness while maintaining strict expectations for food safety and taste.” The group also is working to maintain taste and functionality in lower-sodium products, update process controls in manufacturing and educate key audiences about the necessary role of sodium in cheese.

T

54

Dairy Foods | March 2011

Calcium in Cheese Stacks Up Favorably With Other Foods Food

Standard portion size

Calories

Calcium (mg)

Fortified ready-to-eat cereals (various)

about 1 ounce

100–210

250–1,000

1 cup

117

500

8 ounces

127

452

1½ ounces

165

452

2 ounces

189

438

Evaporated milk, nonfat

½ cup

100

371

Tofu (regular, prepared with calcium sulfate)

½ cup

94

434

Ricotta cheese, part skim

½ cup

171

337

1½ ounces

162

336

Sardines, canned in oil, drained

3 ounces

177

325

Pasteurized process American cheese food

2 ounces

187

323

Provolone cheese

1½ ounces

149

321

Mozzarella cheese, part-skim

1½ ounces

128

311

Cheddar cheese

1½ ounces

171

307

Low-fat milk (1%)

1 cup

102

305

Muenster cheese

1½ ounces

156

305

Skim milk (nonfat)

1 cup

83

299

Ricotta cheese, whole milk

½ cup

216

257

Orange juice, calcium fortified Plain yogurt, nonfat Romano cheese Pasteurized process Swiss cheese

Swiss cheese

Source: U.S. Department of Agriculture, www.ars.usda.gov/ba/bhnrc/ndl.

Cut down on fats Major sources of solid fats in Americans’ diet are “grain-based desserts (11% of all solid fat intake); pizza (9%); regular (full-fat) Continued on page 56

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Touching Everyday Life

™

Cheese Trends

cheese (8%); sausage, franks, bacon and ribs (7%); and fried white potatoes (5%),” according to the DGA. The DGA sends a mixed signal regarding cheese. On one hand, the guidelines state, “When selecting cheese, choose lowfat or reduced-fat versions.” On the other, there’s this: “Choose fat-free or low-fat milk or yogurt more often than cheese. Milk and yogurt are better sources of

potassium and are lower in sodium than most cheeses. Also, most milk is fortified with vitamin D.” The guidelines do see a companion role for cheese. For example, to encourage the consumption of more vegetables, the government suggests pairing them with reduced-fat cheese sauces. Dairy products rate highly for their calcium content, and cheese fares particularly  Tillamook rolls out its mini-bus, called the Loafster, to groceries and farmers’ markets.

well, compared to other dairy foods (see table). Cheesemakers and cheese marketers need to be creative to ensure that consumption does not drop off in light of the government’s latest recommendations. First Lady Michelle Obama has made it clear that she’s not against eating or serving high-fat foods for herself or her family. The White House served bratwurst, cheeseburgers and deep dish pizza at a Super Bowl party in February, and Mrs. Obama allows her daughters to eat pizza on weekends. Cheesemakers are taking their message about cheese directly to consumers with marketing campaigns and traveling exhibits. Non-traditional pairings Wine and cheese, cheese and crackers and macaroni and cheese are classic pairings. In California, the cheese industry is pushing a new partner. Instead of roses for Valentine’s Day, the California Milk Advisory Board told lovers to “say it with cheese” with a menu of chocolates and California cheeses. The CMAB called the pairing “a savory-sweet love connection sure to stand the test of time and taste.” The state’s 50-plus cheesemakers produce more than 250 varieties and styles of cheese, including bandage-wrapped Cheddar and Brie. The board says foods with similar flavor profiles go well together. Darker chocolates pair best with more complex aged cheese, while sweet milk chocolates complement buttery cheeses like Brie. Fruity chocolates and sharper cheeses go together, as do nuttier chocolates and high butterfat cheeses. The board created a tasting table at its website, RealCaliforniaCheese.com/recipes. A smart phone app called “Pair Savvy” for iPhone and Android devices is available at pairsavvy.realcaliforniamilk.com. 56

Dairy Foods | March 2011

Cheese Trends

Taking it to the streets In February, Tillamook Cheese, the 102-year-old farmerowned dairy brand, embarked on the second annual crosscountry event, which started in Phoenix. A custom-refurbished convertible mini-bus, called the Loafster, is traveling through Arizona, California, Colorado and Utah to “bring tasty cheese to the people,” the company says. The Loafster, created from a 1966 VW Microbus, resembles baby loafs of Tillamook Cheddar cheese. The on-the-road campaign is akin to the Oscar Mayer’s traveling Wienermobile. Product demonstrators set up a 10-foot by 10-foot tent in a supermarket parking lot or at farmers’ markets and distribute cheese samples, coupons and recipe cards. They encourage shoppers to “like” the Tillamook Facebook page and visit the company’s website. The demonstrators are all “marketing professionals” who engage visitors in conversation about how cheese is made, who makes it and how to use it, says Mary Cecchini, the brand communications manager. Tillamook emphasizes its cheeses are made from milk with no artificial growth hormones by a co-operative of family farmers. Cecchini says a goal of the tour is to convert shoppers to Tillamook’s premium-

A CUT ABOVE THE REST! THEIVARSON BCS

priced medium and sharp Cheddars and its newly formulated Monterey Jack (made creamier and milder). Another goal is to cement relationships with its fan base. The company has 100,000 Facebook fans. The bus stops in Los Angeles on April 23, where it is the sponsor of Los Angeles’ Grilled Cheese Invitational. Cheese is on a roll Cheesemakers know how to have fun. At the eighth annual Sonoma Valley Cheese Conference in California (which ended March 2), chefs, cheesemakers and local officials vied for the title of “Big Cheese” as they rolled their favorite cheeses down a custom-built ramp. Rollers of cheeses that rolled the furthest were named winners. Among those scheduled to compete were Ari Weinzweig (Zingerman’s Creamery, Ann Arbor, Mich.), Mariano Gonzalez (Fiscallini Cheese Co., Modesto, Calif.), Marilyn Wilkinson (Wisconsin Milk Marketing Board, Madison, Wis.) and Jacquelyn Buchanan (Laura Chenel Cheese, Sonoma). Artisan cheesemaker Sheana Davis of The Epicurean Connection in Sonoma organized the activity at the city’s MacArthur Place. The conference is open to the public on the first day, when there are cheese, beer and wine tastings. The following days are devoted to business issues related to the artisan cheese industry.   Sonoma residents Rich Lee, Sheana Davis and Rhonda Stallings roll cheeses.

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57

Cheese Conference Preview

Cheesemakers, butter makers and whey processors gather April 13-14 in La Crosse, Wis. The two-day event is hosted by the Wisconsin Center for Dairy Research and the Wisconsin Cheese Makers Association. It includes educational seminars, a tabletop expo of hundreds of exhibits, a cheese auction and an awards banquet. Wednesday, April 13 7:00 a.m. Registration opens 7:30-8:15 a.m. Supplier breakfast session: 2012 International Cheese Technology Exposition preview The 2012 International Cheese Technology Exposition is moving to Milwaukee. Be the first to see the new floor-plan layout, learn of new sponsorship opportunities and check out facility photos as details for this new venue are unveiled. 8:30-10:30 a.m. Concurrent sessions “Session A: Dairy Ingredients.” Moderated by KJ Burrington, dairy ingredients applications coordinator, Wisconsin Center for Dairy Research. 58

Dairy Foods | March 2011

• Combined native whey and casein concentrate production. John Lucey, professor of food science, UW-Madison • Conjugation of whey protein for heat stability. Srinivasan Damodaran, professor of food science, UW-Madison • Pro-cream and DLP blends as an ingredient for various food product applications. Rajesh Bund, post doctorate, UW-Madison Food Science “Session B: Cheese.” Moderated by Dean Sommer, cheese and food technologist, Wisconsin Center for Dairy Research. • Health and wellness is still top of mind. Learn about current WCDR and food science research projects. Rani Govindasamy-Lucey, senior scientist, Wisconsin Center for Dairy Research

• Current issues related to cheese defects. Mark Johnson, interim director and senior scientist, Wisconsin Center for Dairy Research • Food safety: What’s ahead and what does it mean for cheesemakers? Marianne Smukowski, dairy safety and quality coordinator, Wisconsin Center for Dairy Research • New technology in cheese manufacturing. John Jaeggi, cheese industry and applications coordinator, Wisconsin Center for Dairy Research 11:00 a.m. Wisconsin Center for Dairy Research joint address The director of the Wisconsin Center for Dairy Research will present elements of a new strategic plan for the Center for Dairy

Cheese Conference Preview

Research, and will update the industry on plans to construct a new dairy plant and CDR technology center at Babcock Hall. 11:30 a.m. Complimentary luncheon and industry achievements program Celebrate the honorees of Wisconsin Cheese Makers Association’s Distinguished Service Award and graduates from WCMA’s Management Skills for Dairy Professionals Certificate Program. 12:30-5:00 p.m. Tabletop Mini-Expo The Mini-Expo is a concise and complete gathering of dairy industry suppliers offering cutting-edge ingredients, technology, equipment, services, software and knowhow to advance your business. 5:00-7:30 p.m. United States Championship cheese auction Bid on gold medal cheeses to support the contest, WCMA’s six student scholarships and WCMA’s Member Education Initiative. Thursday, April 14 8:30-noon Concurrent Sessions 8:30 a.m.-noon Session A: GSFI – A New Marketplace Expectation. Moderated by Matt Mathison, Wisconsin Milk Marketing Board. Recent food safety events involving many products (including dairy products) have increased the need to enhance food safety, ensure consumer protection and strengthen consumer confidence. The Global Food Safety Initiative has become the new food safety standard in the United States. Since 2008, retail and foodservice buyers are asking their suppliers to become certified in either the Safe Quality Food or British Retail Consortium program. Highlighted will be why the marketplace is demanding these programs and how cheese companies have successfully implemented these systems into their overall plant operations. 8:30 a.m.–noon Session B: Sustaining Sustainability: Retailer and Industry Activity. Sustainability is an enduring market opportunity with natural application to the dairy industry. This session will include retail grocer and marketer perspectives on

sustainability as well as proven examples of sustainable practices and the marketing of sustainability from major international dairy manufacturers. Retail Panel • Cathy Strange, global cheese buyer, national procurement and distribution, Whole Foods Market, Austin, Texas • Vicki Decker-Smith, specialty cheese category manager, Schnuck Markets, St. Louis Dairy Processor Panel • Andrea Asch, manager of natural resources, Ben & Jerry’s Ice Cream, South Burlington, Vt. • H. Hulst, president of CONO Cheesemakers, Middenbeemster, Netherlands 8:30-10:00 a.m. Marketplace Expectations • “What’s Happening in Today’s Marketplace.” Allen Sayler, vice president, food safety, technology and regulatory solutions, Randolph Associates, Inc. and Dairy Foods columnist. • “GSFI at Retail – Why SQF?” Payton Pruett, vice president, corporate food technology, The Kroger Co. • “GSFI at Retail – Why BRC?” Bill Schlueter, director of technical services, Swiss Valley Farms 8:30-10:00 a.m. Cheese Company Implementation • The Certification Process. Jim Van

Ells, technical manager, food safety certification systems, NSF International • SQF Certification. Jason Mathis, quality assurance manager, Arla Foods USA • BRC Certification. Speaker to be named. Noon Complimentary luncheon and WCMA Annual Meeting 1:00 p.m. Perspectives from Cheese Marketing-land: Chef Creations, Beverage Pairings and Flavor Tastings Move your Cheese! After your cheese leaves the plant, the marketing begins: Chefs create, magazines gush, salesmen push, samplers demo and tradeshows roar. Expert marketers from the Wisconsin Milk Marketing Board lead this fun, interactive session on popular cheese marketing tools and Wisconsin Center for Dairy Research joins in. This session is available to all attendees, but seating is limited to 100. • “Please Play with Our Cheese!” Chef Seth Bixby Daugherty, president, Real Food Initiatives, will create (and you will taste) cheese-inspired dishes in realtime, while offering a chef ’s perspective on how cheese should perform, store and impact great food. WCDR’s Dean Sommer will join this discussion, translating these end-user requirements to make procedure ideas at the plant. Continued on page 60 www.dairyfoods.com

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Cheese Conference Preview

Marketing Board, will educate participants on cheese and beer pairings and explain why great beer is the best partner for great cheese. Learn to market your cheeses with perfect partners in this fun, interactive session. 4:00 p.m. United States Champions reception Celebrate with cheesemakers and butter makers from around the nation. 5:00-7:30 p.m. United States Champions awards banquet An evening devoted to dedication to craft. You are invited as cheesemakers and butter makers from around the nation are recognized for their achievement. 7:30 p.m. Afterglow reception • “Blue Cheese is Blue Cheese – WRONG! And It’s Aged in a What?” Sara Hill, culinary manager, cheese education, Wisconsin Milk Marketing Board, will lead participants through two “vertical” cheese tastings—Cave Aged Cheese and Blue Cheese. Learn how WMMB

trains chefs and retailers across the United States about how to understand, sell and care for these “masterpieces of microflora.” • “Artisan Cheesemakers and Craft Brewers: Creating a Flavor Phenomenon.” Sara Hill and David Leonhardi, director education and events, Wisconsin Milk

Continued on page 62

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Dairy Foods | March 2011 DFDigitalAd-Horizontal.indd 1

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Leading the food industry in processing and packaging solutions.

Cheese Conference Preview

1 G-M-I.

2 Stoelting

1

3 United 3Salt

2

15 15 D.R. Tech

4 Parker Hannifin 4

12 12 Hydrite Chemical

14 13 14 13 Green Symbiont Bay Pkg. 17 Ecolab

18 Enerquip 18 LLC

17

29

28 28 CMT

29

Wonderware

30

31 CVP Systems 31

Novak’s Cheese of 30 Wisconsin

44 44 Garon Foods

43 Conger Toyotalift

45 Ivarson

46 ALPMA

41 41 Walker

47 Custom Fab&Rpr 47

60 60 Applied Science

59 59 Hayssensandiacre

63 Sepro 63 Membranes.

64 IMAC

65 GEA Niro Soavi 65

GEA Process 66 Engineering

84 DQCI 84 Services

82 82 Tweet Garot

81

Energy Panel 81 Structures

85 86 Dairy Suburban 86 Connection 85 Electrical

105 105 Applied Tech.

104 104 HANNA Instrmnts

103 103 Hart Design

107

108

106

128 Mead & Hunt 128

150 Viking Pkg

151 WEL

150 Technology Companies 151

147 147 Ampco Pumps

36 Danisco

50 Weber Inc. 50

88 Protective 88 Coating

89 USDA/ NASS 89

102 101 101 102 Century PTI Foods Intl Pkg Tape

123 122 122 123 Intrntl Multipond Machinery America 133 Cavitus Pty. 133

145 144 144 The145 Boldt Rubber Company Fab Tech.

169 Advanced Instrmnt 169

170

171

SM Engineering 170

Yamato Corp. 171

184 184

Convenience Food Systems

183 183 Flowtrend Inc.

77

76 76 Exopack

75 75Inc. DCI,

74 74 Sweetener Supply

73 73 Cheese Reporter

90 LOMA SYSTEMS 90

Specialists 91

91 Data

92 Cryovac

93 Kusel 93 Equip

94 Int’l Fiber 94 Corp.

97 97 Johnson Industries

96 96 Nelson Jameson

99 99 MSS

182 182

Herrmann Ultrasonics

181 181 Butler Automatic

92

98

98 VNE Corp.

112 113 114 QLC, Inc. Centerpoint Wetoska 114 Energy 113 112 Pkg

121 121 Fristam Pumps

95 95 DSM Foods

115 116 Page & Nutricepts Pedersen 115 116

120 120 Thomas Technical

119 119 Delkor Systems

118 118 National Utilities

117 117 RELCO

134 135 Bakers Northland Supply Lab 134 Co 135

136 MCT 136 Dairies

137 Main Street 137Ing

138 Norit 138 Südmo

143 142 143 Pkg142 Koss Corp Industrial of America 156 AWI

156 Mfg.

166 165 164 164 166 AGC 165Heat Bulk Watertech Lift of America Transfer Internatnl. 172 Philquip LLC 172

72 Kelley Supply 72

71 R. 71 Mueller

157 Evaporator Dryer Tech.

157

163 163 Cheez Source

173 174 Herbein + Shullsburg Company Trans 173 174

180 180

A&L Labs

141 141 Masters Gallery

Meyer

140

139 139 Oshkosh Chs/Strg

158 ASA The 158Grp Morse

159 Kraemer Brothers 159

160

140 CR

160 APT

162 161 162 161 Excel Filtration Engineering Engineering 175 Brabazon Pump 175

176 H. Derksen 176

179 178 177 178 177 179 Fibosa Badgerland Coating Financial Excellence

Complimentary Refreshments

Complimentary Refreshments

167 167 CEM Corp.

52

Food77 Master Logistics

111 Paul 111 Mueller

152 153 154 155 Plumbing Hydranau- High Track APN - WI 153 155 Creations tics LLC Inc. 152 154

168

52 Diversey

70 Probst Group 70

100 100 C.E. Rogers

110 Extrutech Plastics 110

168 General Machinery Corp

CDR

69 Loos Machine 69

87 Karl Schnell 87

146 146 ALKAR RapidPak

37 37 WI

56 55 54 53 56 53 54 55 Quest J. Millerbernd WI Aging Industrial Rettenmaier & Grading

GEA Westfalia 68 Separator

132 Koch Membrane 132

38 38 WMMB

51

78 78 Printpack

109

36

51 Multivac

79

131 Faith Tech. 131

148

34 35 Jasper Softtrace 35 34 Engineering.

79 Anderson Chem/Sanitation.

129 130 Stuart W. KMC/Indiana Sugars 129 Johnson 130

Corp.

23 23 TetraPak

80

124 124 Werner Electric

148 Henkel

24 24 Allied Blending

80 Anderson Chem/Water Mgmt.

125 125 Scan American

149 149 DeLaval Cleaning

25 25 Zepnick

68

67 GEA

makers

126 126 Aagard

22 WOW 22 Logistics

57 57 Aladdin Label

Tuchenhagen 67

Foreign Type CSK Food R.D. Smith Multi CheeseCon106 veyor Co. 108 107 Enrichmnt 109

127 127 Heritage Mfg.

21 A&B Process 21

Foss North America 49

58 58 Flair Flexible Pkg

66

9 9 Cargill

49

48

8 Chr. Hansen 8

10 10 Cargill Salt

40 39 40 39 Whey Treat Cheese FBC Market News

48 SPX

61 61 Graham Chemical

83 83 Zorn Compressor

33

Engineered Products

62 62 Martin Milk Svc.

64

33 Curwood

32 Deville Technologies 32

Microdyn Tech.

46

45

19 20 Fortress Nu-Con Technology. Equipment 19 20

42 42

43

7 Pro Chemicals 7

6

11 11 Corenco

27 26 26 27 Fromagex Separators Inc

Midwest

6 Reiser

Entrance

16 Membrane Process 16 & Controls

5 Miron Construction 5

Exclusive Sponsors Cargill Chr. Hansen

62

Dairy Foods | March 2011

Danisco Diversey

DSM Millerbernd

Sweetener Supply Corp.

Cheese Conference Preview Dairy Foods advertisers in this issue are shown in red. Their booths are highlighted in yellow on the floor plan (opposite).

Company Name

Booth

A & B Process Systems.......................................... 21 A & L Laboratories, Inc. ........................................ 180 Aagard ........................................................................... 126 AGC Heat Transfer, Inc......................................... 165 Aladdin Label, Inc. ...................................................... 57 ALKAR-RapidPak, Inc. .......................................... 146 Allied Blending & Ingredients, Inc. ................... 24 ALPMA Alpenland Maschinenbau....................46 Ampco Pumps Company Inc. ...........................147 Anderson Chemical Co./ Sanitation Technologies..................................... 79 Anderson Chemical Co./ Water Management ...............................................80 APN WI, Inc.................................................................. 155 Applied Science, Inc. ................................................60 Applied Technologies, Inc. ................................. 105 APT-Advanced Process Technologies Inc......160 ASA - The Morse Group ...................................... 158 AWI Manufacturing................................................. 156 Badgerland Financial .............................................178 Bakers Supply Logistics/ Progressive Warehousing .............................. 134 Brabazon Pump, Compressor and Vacuum...175 Bulk Lift International, Inc. ................................. 164 Butler Automatic, Inc. ........................................... 181 C.E. Rogers Company .......................................... 100 Cargill ...................................................................................9 Cargill Salt ......................................................................10 Cavitus Pty Ltd .......................................................... 133 CEM Corporation .....................................................167 CenterPoint Energy.................................................113 Century Foods International............................. 102 Cheese Market News ..............................................39 Cheese Reporter ........................................................ 73 CheezSorce................................................................ 163 Chr. Hansen, Inc. ............................................................8 CMT- Italian Qualiy Products, Inc...................... 28 Coating Excellence International....................177 Conger Toyotalift ........................................................ 43 Convenience Food Systems ............................ 184 Corenco, Inc. ................................................................. 11 CR Meyer...................................................................... 140 Cryovac/Sealed Air Corp. ..................................... 92 CSK Food Enrichment ......................................... 108 Curwood, Inc................................................................. 33 Custom Fabricating & Repair, Inc. .................... 47 CVP Systems, Inc. ......................................................31 D.R. Tech, Inc. ................................................................15 Dairy Connection Inc................................................86 Danisco USA Inc.........................................................36 Data Specialists, Inc. ................................................91 DCI, Inc. ............................................................................ 75 DeLaval Cleaning Solutions ............................. 149 Delkor Systems, Inc. ............................................. 119 Delta Instruments/Advanced Instruments .. 169 Deville Technologies Inc. ....................................... 32 Diversey ........................................................................... 52 DQCI Services .............................................................84 DSM Food Specialties USA, Inc........................95 Ecolab Inc. ...................................................................... 17 Energy Panel Structures, Inc. ..............................81 Enerquip, LLC................................................................18 Evaporator Dryer Technologies, Inc. ............ 157

Company Name

Booth

Excel Engineering, Inc.......................................... 162 Exopack ........................................................................... 76 Extrutech Plastics Inc. .......................................... 110 Faith Technologies ................................................. 131 Fibosa Foodtech, Inc..............................................179 Filtration Engineering Co., Inc.......................... 161 FLAIR Flexible Packaging Corporation.........58 Flowtrend, Inc. ........................................................... 183 Foodmaster Logistics of Wisconsin ................ 77 Foreign Type Cheesemakers Assn. ..............107 Fortress Technology, Inc. .......................................19 FOSS North America ...............................................49 Fristam Pumps USA.............................................. 121 Fromagex........................................................................ 27 Garon Foods, Inc. .......................................................44 GEA Niro Soavi............................................................65 GEA Process Engineering ....................................66 GEA Tuchenhagen North America .................. 67 GEA Westfalia Separator, Inc. .............................68 General Machinery Corp..................................... 168 G-M-I, Inc............................................................................1 Graham Chemical Corporation .........................61 Green Bay Packaging Inc. .....................................14 H. Derksen & Sons Co. .........................................176 Hanna Instruments ................................................ 104 Hart Design & Mfg., Inc. ....................................... 103 HayssenSandiacre .................................................... 59 Henkel Corporation ............................................... 148 Herbein + Company, Inc. .....................................173 Heritage Manufacturing, Inc. .............................127 Herrmann Ultrasonics, Inc. ................................ 182 HighTrack LLC dba Midwest Refrigerated Services, Inc. ............................. 154 Hydranautics.............................................................. 153 Hydrite Chemical Co. ............................................... 12 International Fiber Corporation .........................94 International Machinery Exchange ............... 123 International Media & Cultures, Inc. ................64 Ivarson Inc. .....................................................................45 J. Rettenmaier USA ...................................................55 Jasper Engineering & Equipment Co. ............34 Johnson Industries International, Inc. ............ 97 Karl Schnell Inc............................................................ 87 Kelley Supply................................................................ 72 KMC/Indiana Sugars............................................ 130 Koch Membrane Systems, Inc. ....................... 132 Koss Industrial, Inc................................................. 143 Kraemer Brothers, LLC ........................................ 159 Kusel Equipment Co. ............................................... 93 LOMA SYSTEMS ........................................................90 Loos Machine & Automation ...............................69 Main Street Ingredients........................................137 Martin Milk Service and Martin Warehousing ... 62 Masters Gallery Foods, Inc. ............................... 141 MCT Dairies Inc. ....................................................... 136 Mead & Hunt, Inc. .................................................... 128 Membrane Process and Controls, Inc. ..........16 Membrane System Specialists, Inc.................99 Microdyn Technologies Inc................................... 42 Millerbernd Systems ................................................54 Miron Construction Co., Inc. ....................................5 Multi-Conveyor LLC ............................................... 106 Multipond America, Inc. ....................................... 122

Company Name

Booth

Multivac, Inc. ..................................................................51 National Utilities Company ............................... 118 Nelson-Jameson, Inc................................................96 Northland Laboratories ....................................... 135 Novak’s Cheese of Wisconsin, Inc. ..................30 Nu-Con Equipment ................................................... 20 Nutricepts, Inc. .......................................................... 116 Oshkosh Cheese Sales & Storage .............. 139 P.T.I. - Packaging Tape Inc. ................................. 101 Packaging Corporation of America.............. 142 Page & Pedersen International, Ltd.............. 115 Parker Hannifin...............................................................4 Paul Mueller Company .........................................111 Philquip LLC ................................................................172 Plumbing Creations Co. ...................................... 152 Printpack, Inc. ............................................................... 78 Pro Chemicals LLC .......................................................7 Protective Coating Specialists, Inc. .................88 QLC, Inc..........................................................................112 Quest Industrial ..........................................................56 R. Mueller Service & Equipment Co. ............... 71 R.D. Smith Co., Inc. ................................................. 109 Reiser ...................................................................................6 RELCO, LLC .................................................................117 Rubber Fab Technologies Group................... 144 Scan American Corporation ............................. 125 Separators, Inc. ........................................................... 26 Sepro Membranes Inc............................................. 63 Shullsburg Transportation LLC ........................174 SM Engineering Co.................................................170 Softtrace, Ltd. ...............................................................35 SPX.....................................................................................48 Stoelting, LLC...................................................................2 Stuart W. Johnson & Company Inc. ............... 129 Suburban Electrical Engineers/Contractors ..85 Südmo North America, Inc. ............................... 138 Sweetener Supply Corporation..........................74 Symbiont ......................................................................... 13 Tetra Pak CPS .............................................................. 23 The Boldt Company............................................... 145 The Probst Group, LLC ............................................ 70 The Whey Treat Co. / FBC Ind. ...........................40 Thomas Technical Services, Inc. .................... 120 Tweet-Garot Mechanical........................................ 82 United Salt Corporation ............................................3 USDA-NASS Wisconsin Office ..........................89 Viking Packaging Technologies, Inc. ........... 150 VNE Corporation ........................................................98 Walker Engineered Products .............................. 41 Watertech of America, Inc. ................................. 166 Weber, Inc. ......................................................................50 WEL Companies ...................................................... 151 Werner Electric Supply......................................... 124 Wetoska Packaging Distributors ................... 114 WI Aging & Grading Cheese Inc. ....................... 53 WI Center for Dairy Research.............................. 37 WI Milk Marketing Board .......................................38 Wonderware Midwest .............................................. 29 WOW Logistics ............................................................. 22 Yamato Corporation ...............................................171 Zepnick Solutions, Inc............................................. 25 Zorn Compressor & Equipment ........................ 83 Source: Wisconsin Cheese Makers Association

www.dairyfoods.com

63

Cheese Conference Preview

EXHIBITORS

Advanced Instruments, Inc.

ALPMA

Delta Instruments, a subsidiary of Advanced Instruments, provides automated systems with the lowest cost of ownership and highest reliability. Presenting this year: The SomaScope Smart™ meets IDF/ISO/FDA/NCIMS standards at low or high somatic-cell levels utilizing proven flow-cytometry technology. Results are produced in 30-seconds. Testing and calibration are fast and easy with the wizard-driven SomaSmart software. The SomaScope Smart is the first somatic cell counter enabled by an LED light source, eliminating HBO lamp hotspots. The LactoScope™ FTIR Advanced (FTA) analyzes both cheese and milk. The FTA measures component levels of raw milk with speed, simplicity, and reliability. In conjunction with its exclusive Cheese Application, the FTA can also analyze a wide range of hard and soft cheeses. One instrument that gives the cheese producer all the information they need.

ALPMA Alpenland Maschinenbau GmbH – System competence from Milk to Packaged Cheese

Contact: Delta Instruments/Advanced Instruments Two Technology Way Norwood, MA 02062 800-225-4034 or +1-781-320-9000 www.aicompanies.com

Contact: U.S. Representation please contact Ivarson Inc. P: 414-351-0700 F: 414-351-4551 Questions: [email protected] Website: www.ivarsoninc.com

ALPMA’s motto “Cheese is our world” illustrates the focus of their business. Dairies all around the world use the advanced technology and knowledge of the traditional Bavarian company. ALPMA offers customized solutions for the complete supply chain such as raw milk reception, cheese production and cutting and packaging technology for both hard and soft cheeses. Its scope of delivery ranges from the mechanization of standardized machines to fully automated line installations. In doing so ALPMA has achieved a great reputation as a worldwide leading supplier of Dairy techniques and technology.

Booth 169

Danisco USA Inc.

Delkor Systems Inc.

Danisco’s roots in the cheese industry reach back more than 100 years to the birth of Marschall Dairy Laboratory in Madison, Wisconsin. Our innovative ingredient solutions help you deliver benefits such as natural food protection, desired taste and texture, digestive and immune health. Visit our booth and learn more about these exciting brands: • CHOOZIT™: an innovative and comprehensive range of ripening and lactic cultures for cheeses • HOWARU®: premium probiotics for immune health and digestive health • Care4U™: the most comprehensive, all-natural range of food protection solutions available in the market Our expertise and broad portfolio are unmatched. Bring us your challenge and let us show you the difference we can make.

Delkor Systems offers a broad range of versatile and flexible solutions for the dairy industry: Carton forming, loading, and closing; Case/Tray Packing, Flat Pad Shrink Wrapping; Robotics; and new formats for Retail Ready Packaging. Delkor packaging machines are specifically designed for optimal cleanability within today’s dairy plant environment with many robust features, including – • Tool-less removable change parts, • Sanitary flighted conveyors with tool-less disassembly, • Washdown duty motors and gear boxes with stainless steel hardware, • All stainless steel air cylinders, • Sanitary stainless steel ball-end leveling feet for minimal floor contact, • All mating parts mounted to welded separators to minimize surface contact, • Minimization of horizontal surfaces. Video demonstrations of all product lines will be presented in our exhibit during the 2011 WI Cheese Industry Conference.

Contact: Janelle Crawford, Market Analyst, Dairy Danisco USA Inc. Four New Century Parkway New Century, KS 66031 800-255-6837 x3421 913-738-3421 fax 913-764-9157

Booth 36 64

Booth 46

Dairy Foods | March 2011

Contact: For more information: Ken Sullivan Director of Marketing Delkor Systems, Inc. 8700 Rendova Street NE Minneapolis, MN 55014 [email protected]

Booth 119

Cheese Conference Preview

Exopack

Fortress Technology Inc.

Halo™ films from Exopack are specifically engineered for sliced and chunk cheese products. These films utilize a patented EVOH encapsulation technology for extended shelf life. Available in up to 10-color process print, Halo films provide maximum shelf impact while offering excellent seal integrity and abuse resistance. Dried milk products such as non-fat dried milk are packaged as food ingredients in Exopack’s patented Seal ‘n Vent® dairy bags with removable inner liner. These USDA approved shipping sacks improve pallet stability while eliminating sifting and infestation problems.

Exclusive to Fortress – the dynamic PHANTOM Series metal detection systems. Designed and manufactured by Fortress, these state-of-the-art industrial metal detection systems provide a wide variety of customized solutions for the Dairy industry. Detect ferrous, nonferrous, and stainless steel metals, with exceptionally rugged Phantom metal detectors. Perfect for harsh washdown environments, Phantom stainless steel detectors have an IP69K rating, to maintain cleanliness and prevent contamination. The detector also utilizes the latest Digital Signal Processing (DSP) technology to ensure complete product integrity. With the highest processing power, Phantom systems are renowned for their superior accuracy, highspeed and ease-of-use.

Contact: Exopack 3070 Southport Road Spartanburg, SC 29302 877-447-3539 www.exopack.com

Call Fortress for more information.

Booth 76

Contact: Fortress Technology Inc. 888-220-8737 or 416-754-2898 www.fortresstechnology.com

Booth 19

Fristam Pumps USA

Garon Foods Inc.

Fristam designs and manufactures high performance stainless steel pumps, blenders and mixers. Our new FKL-A positive displacement pump features a clean, rounded exterior; split-style gearbox for easy access to bearings and shafts; and customizable port-to-port dimensions for easy drop-in replacement of other PD pumps. The FKL-A is built for no-disassembly-required “True CIP”. It allows CIP flow to reach all areas of the pump, including the seal. Nothing is ever removed and cleaned “out-of-place”. Balanced rotors and large-diameter shafts make it durable and reliable. An optional stainless steel gearbox is offered for difficult environments. Rated for up to 500 PSI standard on most models.

Garon is a unique company offering food and food ingredients to the Dairy Industry. Garon’s product line includes peppers, tomatoes, salsa, vegetables, fruits, spices, flavors and specialty items. Products are available in infused, aseptic, brined, canned, dehydrated, dehydrofrozen, dried, freeze dried, IQF, kosher certified, natural, organic, GMO-free and irradiated. With over 100 years of combined experience in the food ingredient industry, Garon ardently seeks to surpass the status quo of acceptable quality by providing safe and superior food products combined with premier customer service. Contact us to encounter the exceptional service, expert knowledge, and elite products at Garon. Experience the difference of Garon’s experience.

Contact: Fristam Pumps USA 800-841-5001 www.fristam.com/fkl

Booth 121

Contact: Garon Foods, Inc. 900 Camarato Dr. Herrin, IL 62948 618-942-4810 www.garonfoods.com

Booth 44 www.dairyfoods.com

65

Cheese Conference Preview

GEA Niro Soavi

GEA Process Engineering

GEA Niro Soavi is the global technology and market leader for high pressure pumps and homogenizers. The GEA Niro Soavi homogenizer product line provides leading technology with the widest range of machines that cover all possible application needs for the dairy industry. From pilot to large-scale fully automated units, in either sanitary or aseptic execution, our homogenizers are also in compliance with 3-A standards and USDA guidelines. GEA Niro Soavi maintains its leadership position through product innovation, reliability and local presence in order to satisfy customer expectations. Our international sales and service network allows GEA Niro Soavi to be close to customers with local, competent and professional support.

GEA Process Engineering has installed thousands of environmentally friendly process plants and systems. No other company is better positioned to help processors meet their sustainability goals and objectives. To further emphasize our commitment to green engineering projects, GEA Process Engineering has created a multidisciplined task force to efficiently and effectively handle all facets of your project. Our approach is designed to help you turn sustainability challenges into a competitive business advantages through: • Feasibility studies including site surveys, process audits, utility calculations, etc. • Conceptual designs • Project budgeting and scheduling • Detail engineering • Project management, equipment delivery and commissioning The following are examples of typical sustainability issues that GEA Process Engineering has successfully addressed through our extensive process knowhow and renowned engineering excellence: • Product, chemical and water recovery and reuse systems • Reduced energy consumption and energy optimization o through heat recovery networks o through equipment & high efficiency motors/drives o through efficient pipe and tank insulation o through efficient heat transfer systems • Installation of advanced automation systems to boost production efficiency, product traceability and enable repeatability

Contact: GEA Niro Soavi 10 Commerce Park North, Ste. 7 Bedford, NH 03110 603-606-4060 www.nirosoavi.com

Booth 65

Contact: GEA Process Engineering Inc. 1600 O’Keefe Road Hudson, WI 54016 USA 715-386-9371 [email protected] www.niroinc.com

Booth 66

GEA Tuchenhagen

G-M-I, Inc.

GEA Tuchenhagen is a global leader in the manufacturing of a wide range of sanitary flow components for the dairy industry. Products include mixproof, single-seat, divert, modulating, butterfly, pressure relief and sample valves; valve control technology; inline instrumentation; cleaning devices; vessel protection and cleaning systems; and the revolutionizing mixproof 24/7 PMO Valve and 24/7 PMO Tank Valve. Additional services offered by GEA Tuchenhagen include concept design engineering, manifold prefabrication, preventive maintenance and customer training. Stop by booth #67 to see our latest innovations.

G-M-I, Inc., an ISO 9001:2008 Company, manufactures quality gaskets and gasket materials including materials that are Metal Detectable and X-Ray Detectable. GMI’s materials have been Independently Tested To and Certified Compliant To FDA, USDA, 3-A, USP Class VI Standards and are AH/ TSE Free™ (Animal/Human Derived Ingredient Free). Call us at 440-953-8811 or visit our web site: www.gmigaskets.com.

Contact: GEA Tuchenhagen North America 90 Evergreen Drive Portland, ME 04103 207-797-9500 207-878-7914 [email protected] www.tuchenhagen.us

Booth 67 66

Dairy Foods | March 2011

Booth 1

Cheese Conference Preview

Hydrite Chemical Co.

Ivarson

Hydrite Chemical Co. introduces The Optimax – a system that can simultaneously control both acid and alkaline detergent and sanitizer dispensing on multiple CIP systems. Concentrations can be controlled via conductivity or timed feed and displayed on a digital read-out. Chemical volumes are measured and recorded volumetrically for reporting purposes, and conductivity of rinses are measured and recorded to help eliminate wasted water and time. The Optimax also monitors and records valve functioning to help ensure cleanliness. Proof of Clean reports are easy to download, print and interpret. Hydrite Chemical Co. is a leading manufacturer of dairy sanitation chemicals, process aids, food ingredients, commodity chemicals and wastewater treatment chemistry in the U.S. Hydrite specializes in membrane system optimization and reducing plant sanitation time to increase profits.

Cheese – Ivarson Inc has its’ roots in the cheese industry. From the earliest days in Wisconsin, Cheese was our main business. Ivarson supplies specific equipment for various cheese production and packaging, For the production and packaging of Cheese Ivarson is proud to be a North American partner for Alpma, the leader in cheese technology. Ivarson also offers Kadova cheese moulds and Paramelt Cheese Wax and Coatings. Ivarson also has our own line of cutting equipment, developed specifically for the North American Market and together with our partner company Alpma, can offer cutting lines with throughput up to 8000 pounds per hour!

Contact: Randy Karcz Director of Sales & Marketing - Food Group Hydrite Chemical Co. 300 N. Patrick Blvd. Brookfield, WI 53045 262-792-1450 www.hydrite.com

Contact: 414-351-0700 [email protected] website www.ivarsoninc.com

Booth 12

Booth 45

KARL SCHNELL

Nelson Jameson

Partner to the food industry for over 60 years For more than half a century, KS has combined the german spirit of invention with acknowledged high quality standards. With this winning combination of technical know-how, creativity and innovative boldness, KS has made a lasting mark on the food industry and contributed to establish the “Made in Germany” seal of quality. Leading cheese manufacturer around the world rely on the innovative products of the specialists from Winterbach. The product range of the family business extends from the highly specialised stand-alone machine up to the complex processing line. Flexibility, efficiency and reliability – these values of the company philosophy are also reflected in the various cheese processing systems developed by KS.

Food processors and regulators alike have discovered that colorcoded zones throughout a processing plant can help stop cross contamination. By using brushes, pails and other sanitary tools that are assigned – by color – to a particular zone or task, the risk of bacterial migration can be greatly reduced. Nelson-Jameson now provides the widest selection of color-coded products selected specifically for the food industry. Hundreds of brushes, handles, racks, scrapers, shovels, pails, lids, cutting boards, signs, aprons and more! In addition to the current product offering, we are working closely with our manufacturers to introduce orange to the spectrum of colors already available. For a complete Color-Coded catalog, and more innovative Sanitation Specialty Products, visit booth 96. Or, contact Nelson-Jameson at 800/826-8302.

Typical applications: • Cream Cheese • Cold Pack Spreads • Pizza Cheese • Analogue Mozzarella • SOS- and IWS Cheese The KS machinery program offers the full range of low- and high shear, batch- and continuous processing equipment. Contact: KARL SCHNELL Inc. U S A P. O. Box 49 New London, WI 54961 (920)982-9974 (office) (920)982-0580 (fax) (920)359-0502 (mobile) [email protected] www.karlschnell.com

Booth 87

Booth 96 www.dairyfoods.com

67

Cheese Conference Preview

Reiser

RELCO

Reiser will showcase their line of cheese processing and packaging equipment. Reiser will feature live demonstrations of their versatile Vemag Stuffer, including a Vemag Cheese Block Former which repurposes cheese trim, ends, scraps and other pieces to produce cheese blocks and entirely eliminate waste. Also on display will be the Holac Cheese Dicer which cubes, shreds and flakes cheese into uniform shapes and sizes. Reiser will also showcase Ross Traysealers for MAP packaging for cheese cubes and crumbles, Repak form/fill/seal packaging machines for sliced cheese and cheese logs and balls, and Supervac automatic belt-chamber vacuum packaging machines for large blocks.

RELCO provides dairy and food plants with customized cheese, milk powder, whey, and other food processing equipment, systems and automation. RelTronix® process control engineers are recognized as industry leaders because of their application knowledge, understanding of sanitary and regulatory requirements, and focus on customer needs. Automation that puts you in control. RELCO® Cheese Plant Technology provides new innovations for efficient, reliable plant design for total systems and equipment needs. Designed by cheese makers for cheese makers. RELCO® Evaporation and Drying Technology has a dedicated team to design sustainable energy efficient systems for liquid to dry processing. KELLER™ Drying Systems are world leaders for lactose processing technology.

Contact: Reiser 725 Dedham Street Canton, MA 02021 781/821-1290 www.reiser.com

Contact: 2281 3rd Ave. SW Willmar, MN 56201 320-231-2210 www.relco.net

Booth 117

Booth 6

Separators Inc.

SPX Flow Technology

Centrifuge Service, Equipment, and Parts

SPX Flow Technology has gained strong brands and market leadership positions by investing in technology, talent and aftermarket support services. For decades, food & beverage processors have benefited from our innovations in systems technology, automated single seat and mix proof valves, pumps, mixers, homogenizers, and heat exchangers from our world renowned brands. Brands serving the food and beverage market includes APV, Waukesha Cherry-Burrell, Lightnin, Gerstenberg Schröder, Bran+Luebbe, Johnson Pump and Anhydro. For more than a century Waukesha Cherry-Burrell has been a leading supplier of fluid handling and process equipment including pumps, valves, fittings, and heat exchangers. WCB and its network of stocking distributors are dedicated to raising productivity, product quality and profitability for their equipment and systems customers. From this dedication has come advancements in equipment development and applications; advancements that have changed the way process designers solve problems.

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

Contact: Phone: 800/233-9022 [email protected] www.separatorsinc.com

68

Dairy Foods | March 2011

Booth 26

Contact: SPX Flow Technology 611 Sugar Creek Road Delavan, WI 53115 262-728-1900 or 800-252-5200 www.spxft.com

Booth 48

Cheese Conference Preview

Südmo North America, Inc.

GEA Westfalia Separator

Waste to Energy Solution Through its years of experience in providing solutions to cheese and dairy plants, Sudmo North America knows the challenges processors face when dealing with the treatment of high strength wastewater. To meet these needs we draw on the Crossflow MBR technology from our sister company, Norit X-Flow. Using Crossflow MBR in an anaerobic system provides filtration with limited energy consumption, simple and quick access to the membranes for maintenance, and fully automatic operation. The anaerobic process turns waste into water for reuse and produces energy rich biogas. Reduced COD and TSS minimize or eliminate disposal costs and the biogas that results from the anaerobic process is converted into to energy for even greater cost savings.

GEA Westfalia Separator will showcase its broad line of dairy equipment of the 2011 WCMA Conference, including the MSE 85. This separator has a capacity of 2,600 gallons/hr or 22,000 pounds/ hr and features a single flat belt drive with no intermediary clutch. The product feed and discharges are hydrohermetically sealed, keeping the product airfree and guaranteeing the highest possible separation efficiency. As an added benefit, the MSE 85 is available with Westfalia Separator® wewatch®, a preventive maintenance monitoring system.

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

Contact: 100 Fairway Ct. Northvale, NJ 07647 800-722-6622 www.wsus.com [email protected]

Booth 138

Booth 68

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Providing Parts with the Perfect Fit

It’s never been easier. Genuine replacement parts from GEA Westfalia Separator are guaranteed to fit your requirement for optimal performance. Our extensive North American inventory means the right part is available and can be delivered to your facility overnight or, in some cases, the very same day. What’s more, our dedicated parts professionals provide technical service support for all the parts we deliver. To learn more about our replacement parts programs, including inventory management and specially developed service kits, call Klaus Brinkrode at 201-784-4335 or email him at [email protected].

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

1517

GEA Westfalia Separator Division

sneak peek a look inside…

DCI Cheese Co.

REPORTS

n February, Montreal-based cheese giant Saputo announced it is acquiring DCI Cheese Co. of Richfield, Wis. DCI markets Salemville, Black Diamond, Liederkranz, Nikos, Organic Creamery and other brands. The company places a high value on food safety. Dairy Foods reporters sat down with DCI executives to talk strategy (page 71) and toured its Green Bay, Wis., facility (page 78).

I

Columns The new food safety law requires action, writes Henry Randolph in “Quality on the Line.” Page 88 “Global Insights” columnist Tom Suber notices that dairy pricing is moving into a higher orbit. Page 90

Equipment Showcase A focus on mixers and blenders on pages 92 and 94. A look at containers on p page g 96.

DCI Cheese Co. president Tim Omer (left) and Dominique Delugeau, senior vice president of sales, call the company a “one-stop-shop specialty cheese supplier and marketer.”

The Ambassadors of Cheese DCI Cheese Co. manages and markets a stable of brands from Europe and the United States to sophisticated shoppers.  April Miller Contributing Editor

DCI Inc.

fast forward what’s coming in April…  Guida’s Milk & Ice Cream  Allen Sayler on Safety  Mike Richmond on packaging  Clay Detlefsen on sustainability  Products: pumps, valves and fillers

hat began as a consulting firm to provide marketing support for small to medium-sized specialty food suppliers more than 35 years ago, has grown — through strategic acquisitions — to become the United States’ largest importer, marketer and manufacturer of specialty cheeses and other prepared foods. Today, Richfield, Wis.-based DCI Cheese Co. is the leading provider of specialty cheese to America’s Top 20 retailers, says Dominique Delugeau, senior vice president of sales, and “dominates the category with a unique collaboration of global reach and personalized customer attention.”

W

Continued on page 72 www.dairyfoods.com

71

Corporate Profile

“I Stand

Behind All Our Patty Paper and Interleaving Products.” Larry Czaszwicz Jr. President/Owner Interleaving the worlds of meat, poultry, dairy, baking, and specialty products

 The new 5-ounce rounded square-shape package for Mario Batali cheese blends has three flat panels that allow for more product visibility and more contemporary label designs.

s'REATSELECTIONCUSTOMSIZES s/RDERSMATCHEDTOYOURNEEDS s,OWMINIMUMS s7ORLD CLASSCUSTOMERSERVICE sv3UPERIORv'-0CERTIlCATION 4OLL&REE #ALLTODAYANDEXPERIENCETHE Framarx/WaxstarDIFFERENCE 3224 Butler Avenue South Chicago Heights, IL 60411 P 708.755.3530 F 708.755.3617 [email protected] s www.framarx.com ”Our goal is to astonish you with great service. Let me know how we’re doing.” - Larry

framarx ® waxstar ™

Interleaving The World

We’re proud to be part of your quality products

In February, cheese giant Saputo Inc. said it was acquiring DCI parent company Fairmount Cheese Holdings for $270.5 million. The Montreal-based company said its acquisition will complement the activities of its United States dairy products division and increase its presence in the specialty cheese category. DCI’s products (both branded and private label) can be found in grocery and club stores as well as specialty shops and restaurants. “The cheese industry has a fairly small group of power players,” Delugeau adds. “We differentiate ourselves with our unique business model, which has evolved to comprise a portfolio of leading company-owned brands, dedicated supplier partnerships and

consolidation capabilities that enable us to offer full-service specialty cheese programs custom-tailored to meet each customer’s needs. We optimize our global reach and leverage our knowledge, expertise and innovation to serve as our customers’ onestop-shop specialty cheese supplier and marketer.” Rapid growth through acquisitions in the 1990s (see “History”) necessitated “a series of technological upgrades that needed to occur flawlessly to ensure our customers didn’t experience our growing pains,” explains Kristy Klug, marketing communications specialist. “E-mail, order entry and several other essential systems were consolidated under single, uniform structures, allowing DCI to seamlessly integrate five companies into one.” Dedicated to remaining on top of IT trends, Klug says additional technological improvements are planned this year.

History DCI Cheese Co.’s transition from brand-building consulting firm to customer-focused supplier of premium company-owned or exclusively held brands began in the early 1990s. Its first company-owned brand, Salemville Cheese, debuted in 1991 when the company was still known as Dan Carter Inc. (the name was changed in 2003) and headquartered in Mayville, Wis. A year later, the company obtained U.S. agent status for the Black Diamond brand. Of DCI’s entire portfolio, the two brands have the highest consumer recognition and are perennial award winners. The company established its first dedicated supplier/manufacturing partnership with Carter/Meister LLC in 1997. During the following years, DCI continued to grow its portfolio with the addition of such brands as Great Midwest, Organic Creamery and many others. Fairmount Food Group, LLC and its equity sponsor, GTCR Golder Rauner, LLC acquired DCI Cheese Co. in 2005. That same year, to accommodate its growing team, the company moved its headquarters to Richfield, Wis. Since 2006, DCI has continued to grow with strategic acquisitions and partnerships, including Swissrose, Advantage International, Green Bay Cheese and G&G.

Machine And Process Design, Inc.  Black Diamond and Salemville are

Machine And Process Design, Inc. Designers and Builders of Machinery for Automation

among the company’s best-known brands. But they are the tip of an iceberg. DCI offers almost 3,000 SKUs.

Designed and Manufactured in the U.S.A.

Along with its Richfield headquarters, the 450-employee yee company maintains four other er locations: a distribution tion center in Appleton, on, Wis.; a conversion n facility in Green n Bay, Wis. (see related article on page 78); an importing/ distribution centerr in Carlstadt, N.J.; J.; and a specialty food ood manufacturing facility for hummus, dips and spreads in Santa Rosa, sa, Calif. With product safety fety a forefront issue in the cheese industry stry as well as at the company, DCI’s president sident Tim Omer says they have invested heavily in the facilities to ensure customers are provided with the safest products possible. In 2010, they achieved their goal of company-wide Global Food Safety Initiative (GFSI) certification at all production facilities. “We take food safety and quality assurance very seriously and have invested

For Processing Dairy Powders and Cheese

heavily in our facilities to ensure we’re providing our customers the safest Stainless Steel product possible,” adds Omer. “Very few Dual pass Rotor manufacturers GFSI’s initial audit. Crushers We’re proud to say that our production facilities passed with flying colors, achieving ‘A’ rankings — the best you can get.”

For Processing Dairy Powders and Cheese

Stainless Steel Dual Rotor Crushers

New products and innovation Salemville and Black Diamond may be the company’s best-known brands, but DCI Continued on page 74

 A marketing campaign by the Joan of Arc brand of imported French cheeses aims to increase consumption frequency by Stainless Steel RIGIMILLS dispelling the idea that Brie, chevre and Camembert should be served only for special occasions.

Proudly Celebrating over 25 Years Specializing In Sanitary Designs Complying with USDA Guidelines for Sanitary Design and Fabrication of Dairy Processing Equipment

Contact Us: Toll Free Within the U.S. at: 877-224-0653 On the Web: www.mpd-inc.com

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Contact Us: Toll Free Within the U.S. at: 877-224-0653 On the Web: www.mpd-inc.com

Corporate Profile

Inside The DCI Cheese Trophy Case Five DCI Cheese Co. products were honored at the 2010 American Cheese Society’s annual cheese competition in Seattle: • Black Diamond Chardonnay & Extra Sharp Cheddar Cold Pack Cheese Food (third place, Cheese Spreads: Cold Pack Cheese Food and Cheese Spreads with Flavor Added - Spices, Herbs, Seasonings, Fruits - All Milks) • Black Diamond Extra Sharp Cheddar Cold Pack Cheese Food (first place, Open Category Made from Cow’s Milk) • Great Midwest Morel & Leek Jack (second place, Flavored Cheeses: Flavor Added Monterey Jack - Made from Cow’s Milk)

offers almost 3,000 SKUs. With fluid and responsive procurement and supply chain teams, the company is able to respond quickly to clients’ demands and category trends. For the 2010 holiday season, DCI rolled out Roquefort Templiers for Sam’s Club. Aged in the Société Roquefort Caves, this was the first time the milkwhite cheese with emerald green veins was available in the United States. Earlier in the year when DCI relaunched Liederkranz (it had been out

• Liederkranz (third place, American Originals: Liederkranz) • Salemville Smokehaus Blue (third place, Smoked Cheeses: Open Category Made from Cow’s Milk) A t t h e 2 0 1 0 Wo r l d Cheese Awards in the United Kingdom, Black River Gorgonzola and El Cortijo Murcia al Vino received Bronze awards.

of production since 1985), the company relied on its relationship with Myron Olson of Chalet Cheese Co-op in Monroe, Wis., to produce the American replication of Germany’s Limburger. It is currently DCI’s top-selling product in its online store. New packaging for several products in the company’s Il Giardino line as well as for the Mario Batali cheese blends debuted this past summer. The 5-ounce rounded square-shape package has three

flat panels that allow for more product visibility and more contemporary label designs. Made of FDA-approved recyclable plastic resins, the new containers include a tamper-resistant inner heat seal film to ensure freshness. “We were so excited by the distinctive labeling capabilities and product visibility the ‘squa-round’ cup offers,” says Delugeau, “we invested in a custom line at our packaging facility in Green Bay.” While details aren’t yet available, Klug says there are “several major product launches” planned for this year as well as a re-launch of DCI’s Great Midwest brand. “Consumers have become better educated and more passionate about the food they eat,” explains Klug of the impetus behind the changes to the Great Midwest line. “They’re also becoming a lot more adventurous in their kitchens. Because of this, they’re seeking bolder flavors as well as a more intimate knowledge of where their products are produced.” A line of flavor-infused Monterey Jacks will expand in April to include new varieties of flavored jacks and “cutting-edge flavored Cheddars.” The artisanal products, produced by award-winning Wisconsin cheesemakers, are being developed to specifically hit the flavor profiles that today’s customers seek, adds Klug. Social and mobile marketing To promote its award-winning portfolio, DCI implements a variety of promotional methods, including use of social media tools as well as mobile marketing. “Social media has connected us more directly to our customers and has given us a great outlet to provide recipes and serving suggestions, cheese descriptions, links to our other social media posts and, in Continued on page 76

74

Dairy Foods | March 2011

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Corporate Profile

A Quick Scan of Promotions DCI Cheese Co. has used quick response codes with the King’s Choice, Il Giardino, Black Diamond and Joan of Arc brands. Currently shoppers can obtain promotional materials, wine pairings and coupons for Joan of Arc cheese when they photograph a QR code on in-store promotional materials or by visiting the Joan of Arc website. On Feb. 1, Joan of Arc launched the “Give Yourself the Royal Treatment” promotion, which runs to March 31. Shoppers enter online to win the grand prize of free maid services for one year (delivered as a $2,000 Visa gift card). The promotion is intended to make high-quality cheeses “much more approachable to the average consumer,” says Katie Jury, marketing manager. “Brie is such a great cheese, but Americans tend to view it as a food meant for special occasions.”

Jury said the company hopes shoppers “treat themselves like royalty by consuming Joan of Arc’s authentic French cheeses with greater frequency.”

 Cheese kits have become so popular that DCI Cheese created a “kitting” area at its Green Bay, Wis., facility.

asked,” Omer explains. as Although the company is privately held and doesn’t share sales data, according to BizTimes Milwaukee, which aawarded Omer with a Bravo! Entrepreneur Award in 2010, it has averaged 20% comA pound growth during the last 15 years. p Poised to continue its expansion, Omer ssays, “DCI is actively seeking continued vvertical integration and synergistic acquisitions to enhance our positioning as the leadti ing solution-based provider in the industry. in Thanks to DCI’s ingenuity, single-source T positioning and first-to-market speed, we are po primed for long-term growth.” DFR pr general a welcoming environment to talk cheese, general, cheese”” Klug explains. explains “We’ve found that consumers appreciate having another way to reach out to us on their terms, and we’re happy to accommodate them.” In addition to its blog, The Cheese Post (thecheesepost.com), which features all of the company’s major brands, DCI has a YouTube channel and several branded Facebook pages. The video-sharing site includes clips on Liederkranz, Organic Creamery, Nikos and an instructional video showing how to cut a 25-pound ball-shaped Mario Batali Mandarini Provolone. On Facebook, fans can find a company page plus those for Black Diamond, Liederkranz, Nikos, Organic Creamery and Salemville. Just last year, DCI Cheese began utilizing QR (quick response) codes on in-store signage. Shoppers with smart phones are able to take a photo of the code and are then redirected to a corresponding product or promotion website where they’ll find beverage pairings, serving suggestions, recipes, coupons and more. In addition to its marketing efforts, the company also believes in corporate citizenship. Following the 2010 earthquake in Haiti, DCI made a donation of $45,000 to the American Red Cross (representing $100 in honor of each of the company’s 450 employees). “The company’s employees were so inspired by the donation they contributed an additional $1,425 of their own money without being 76

Dairy Foods | March 2011

April Miller is a business writer based in Lakewood, Ohio.  A specialty food manufacturing facility in Santa Rosa, Calif., produces hummus, dips and spreads.

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Plant P lant C Close-up lose-up

 General manager Chris Sandretti (from left), quality assurance manager Christine Helminger and plant manager Bruce Duevel stand with the fruits of their labors at the DCI Cheese Co. facility in Green Bay, Wis.

Photos by Vito Palmisano

Everything’s Under Control Last year’s GFSI certification capped a barrage of investments that gives DCI Cheese Co. precise command over the varied and voluminous output of its Green Bay converting plant.  Paul Rogers Contributing Editor n October 2010, DCI Cheese Co.’s Green Bay, Wis., converting facility reached a staggering 1 million hours without a lost-time accident. For the 275-employee plant, that meant about two years of safe operation — quite an achievement in any manufacturing industry. For DCI, though, it comes as little surprise. Since the company acquired the plant in 2006 (when it purchased Green Bay Cheese Co.), management has spared little expense pursuing a three-point plan to expand capacity, boost operating efficiency and overhaul product and personnel safety procedures. The last five years have seen a rapid-fire succession

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78

Dairy Foods | March 2011

of upgrades in a quest to implement exacting standards that leave nothing to chance. “We believe that our plant needs to operate as a best-in-class facility, and we prioritize our projects with that goal in mind,” says Chris Sandretti, general manager. Some of the most notable changes are: • 2007 — Increased the size of the plant from 80,000 square feet to 150,000 square feet, increased the number of production lines from five to 13 and expanded warehouse storage by 50,000 square feet. • 2008 — Upgraded the warehouse management system

Plant Close-up

 Above: Forty-pound blocks of pepper Jack are run through a cutter prior to going to a vacuum-sealing line. Right: Ten-pound loaves of pepper Jack are weighed on the line.

(WMS), adding radio frequency (RF) capability. • 2009 — Installed a fully integrated demand forecasting and replenishment planning software package that allows the company to tightly manage inventory and production scheduling. “We’ve seen significant gains from that tool,” says Sandretti. • 2010 — Upgraded the enterprise resource planning (ERP) software and integrated it with the company’s other operating divisions. Perhaps the biggest achievement came last July, when the facility earned Global Food Safety Initiative (GFSI) certification. “GFSI took us to a whole different level of control and was a pretty significant investment,” says Sandretti. GFSI is a non-profit benchmarking organization that seeks to continuously improve food production and manufacturing systems to ensure the integrity of the global supply chain. Its standards are stricter than federal, state and international standards. “Every line was affected. It entailed major construction, including erecting new walls. We had to completely separate portions of production and create ‘high-care areas’ with controlled atmospheres,” says Sandretti.

The process also meant remapping workflows, including how people and product moved through the plant and strengthening sanitation procedures to minimize cross contamination. DCI accomplished the tasks and earned the GFSI rating in less than a year — an impressive feat under any circumstances but stunning when you consider that it was accomplished only on weekends. It was a “high-wire act” of planning, says Sandretti. In addition, the GFSI changes required more than physical alterations. They demanded review, re-evaluation and codification of all procedures to wring out any inconsistencies. To achieve the GFSI rating necessitated “a tremendous amount of training for management and floor personnel,” says Christine Helminger, quality assurance manager. Such work is already paying off. DCI picked up a major customer who couldn’t find a GFSI supplier elsewhere. “GFSI really provides the difference between us and any other cheese converter,” says Helminger. And the differential could grow. Every year, GFSI sets the bar a bit higher, looking to further tighten requirements and bolster documentation. DCI has another audit coming this May. Continued on page 80 www.dairyfoods.com

79

Plant Close-up  Shredded cheese from the tumbler is transported on an incline belt to scales prior to going into 5-pound bags.

The more the merrier One reason for the need for control has to do with the plant’s diverse output. “We have the ability to slice, chunk, cube, shred and smoke cheese in retail, deli and foodservice sizes (anything from 0.75ounce snack packs to 5-pound bags of shredded product) and have a growing ‘kitting’ area for cheese trays,” says Sandretti. The plant turns out up to 130 million pounds of cheese a year and packages and distributes most of DCI’s major brands, including Black Diamond, Kings Choice, Salemville, Nikos, County Line, Great Midwest and Party Express as well as private-label products for several customers. With such a breadth of products, pinpoint control over raw materials, scheduling, manufacturing and warehousing is critical. Cheese shipments in all varieties and forms (from 6-pound loaves to 640-pound blocks) from 20-30 manufacturing sites are delivered in a constant stream and are immediately placed in a raw materials cooler. Product is picked from the cold-storage area depending on orders and taken to staging areas at the start of one of 14 converting lines or DCI’s smoking room. “We have a unique capability to add natural wood flavors such as hickory or mesquite to enhance a product’s flavor profile and distinguish it in the marketplace,” says Sandretti. Flavor is based on wood type, duration (the longer the time in the smoker, the stronger the smoke flavor) and temperature. Continued on page 82

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

Dairy Foods | March 2011

Microbiological Testing

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• Fat, protein, lactose and solid analysis by FTIR spectroscopy

80

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Plant Close-up  Shredded cheese falls from an incline belt onto a scale system. “We work with the customer to develop the characteristics they want,” Sandretti says. “We try to be as collaborative as we can be.” It’s a multistep process, starting with the customer’s taste profile. DCI runs test samples, sends them to the customer for feedback and makes adjustments based on their comments. The process could take two or three passes before hitting on just the right characteristics. During a Dairy Foods visit, DCI was smoking 9-pound slabs of mozzarella and 3-pound bars of cheddar. The products gain brownish tones after about 20 minutes. A 3-hour smoking provides a nice golden hue with a noticeable smoked flavor. After smoking, the cheese is wheeled on racks into curing rooms and then to the converting area. Cheeses that are not detoured into smoking have their exterior packaging removed in the staging area. Product then moves by conveyor via a pass-through into separate conversion rooms, where floor personnel direct them into the proper line for blocks, slices, shreds or cubes. After running through the shredder or slicer, conveyors move product to form/fill/seal units, shrink wrappers or cup packagers. Shrinkwrapped cheeses are gas flushed with a carbon-dioxidenitrogen mixture that varies depending in part on the look a customer desires in the finished product. Because the product absorbs Continued on page 84

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Dairy Foods | March 2011

Liquids to Value

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Plant Close-up

AT A GLANCE DCI Cheese Co. Location: Green Bay, Wis. Size: 150,000 square feet History: In 2007, DCI Cheese increased the size of the plant from 80,000 square feet to 150,000 square feet, increased the number of production lines from five to 13 and expanded warehouse storage by 50,000 square feet. It upgraded the warehouse management system in 2008, and in 2009, installed a fully integrated demand forecasting and replenishment planning software package. Last year, the company upgraded the enterprise resource planning software and integrated it with the company’s other operating divisions. Number of employees: 275 Safety record: 1 million hours without a lost-time accident Operations performed: Fourteen converting lines that slice, chunk, cube, shred and smoke cheese in retail, deli and foodservice sizes, plus kitting of cheese trays. The annual output is 130 million pounds. Warehouse: The 8,000-pallet warehouse is capable of holding 12 million pounds.

 On the vacuum-sealing line, 1½- pound pieces of Swiss cheese are placed into bags.

CO2 more than nitrogen, a higher carbon dioxide ratio would be used for customers looking for a tight airless look. Higher CO2 is also used to prevent condensation typically caused by temperature issues within the supply chain. All product runs past a weigher, metal detector, date coder and an auto labeler. Computer assistance in the warehouse Product emerges from the conversion rooms packaged and ready for the 8,000-pallet warehouse, capable of holding 12 million pounds. The WMS controls both warehouse placement and picking. It directs the picker to the position (even specifying the most efficient path) using “first expiring, first out” principles. Warehouse personnel can pull full pallets or single cases, and the system even tracks random weight by package, allowing the customer to order by pound instead of unit. “Our WMS increased efficiency and allowed us to make the leap from a make-to-order operation to distribution center operation,” says Sandretti. The WMS is only one portion of DCI’s computerized control system, albeit a key cog in the structure. “The entire company is managed on a single system, where production is integrated with demand planning software and 84

Dairy Foods | March 2011

the warehouse,” says Sandretti. “Previously, the three activities were separated.” Linking them provided a huge efficiency upgrade, reducing order turnaround and allowing managers to know where all production is at all times. Plus, it provides complete traceability of products and components throughout the process. DCI continues to look for strong-payback investments today. In the first quarter of this year, the company is spending $1 million on a new slicing line to boost throughput, reviewing options for end-of-line automation, planning a warehouse upgrade and continuing to invest in quality and food safety initiatives. “We are working extremely hard on automation to increase efficiency,” says Sandretti. “We are extremely flexible, strive to work with customers and are willing to do whatever out-ofthe-box concept the customer requests to bring unique items to market. We want to be able to provide everything. We are truly a one-stop shop for customers.” DFR Paul Rogers is a Madison, Wis.-based writer who specializes in the dairy and food industries. He wrote about United Dairymen of Arizona in the November 2010 issue.

SQF Level 2 Certified

Plant Close-up

Behind the Scenes A photo gallery of DCI Cheese Co., Green Bay, Wis. Photos by Vito Palmisano

 Above: Plant manager Bruce Duevel (front row, center) and some of the staff celebrate the company's safety record. Right: Blocks of Cheddar, Colby Jack and pepper Jack, weighing 640 pounds, are held in the warehouse prior to production.

Photograph this mobile tag with your smart phone to see more photos online.

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Dairy Foods | March 2011

Plant Close-up

 Eight-ounce pieces of cheese are run down a vertical seal line (above) and then through an auto-labeler (right) prior to being placed into a case.

PLUS For more photos, visit www.dairyfoods.com/ behindthescenes. Or, take a picture of the mobile tag (opposite) with your smart phone to go online now.

 Swiss cheese is check-weighed before it is placed on the vacuum-sealing line.

www.dairyfoods.com

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Processing & Operations Quality on the Line

The New Food Safety Law Requires Action n general, prior to the mid-1980s, the sanitation of non-product contact surfaces on the environment was not a high priority. Bacteriological monitoring of non-product contact surfaces was rarely performed. These surfaces were thought to have little effect on the quality or safety of finished products. In 1985-86, the food and dairy industries were shaken to their core when it came to light that pathogens such as Listeria and Salmonella were capable of establishing residence in plant environments and eventually finding a way to contaminate product contact surfaces and finished products. The discovery that pathogens seem to “grow legs” and move through the environment sparked a revolution in the dairy industry’s food-safety defenses. Since some pathogens are “mobile,” swabbing or testing of environmental surfaces was adopted as a standard practice for minimizing the potential for contamination of dairy products. This practice has now been taken up with the new Food and Drug Administration’s Food Safety Modernization Act (FSMA), signed by President Obama in early January. One of the many new provisions required of dairy plants will be a mandatory environmental sampling and testing program. The new FSMA program, expected to be enforced no later than mid-2012, will require test results be available to FDA investigators. Effective environmental sampling programs require a plant manager to make a number of key decisions: Sampling protocol. Decide kit selection, testing specifics and the number of samples to be tested. Testing protocol. Decide whether to use an in-house or third-party laboratory and which pathogens (species or genera?) to target. Follow-up action and responsibility. Swabbing and testing will not elimi-

I

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Swab remote equipment surfaces

Place swab in whirl-Pak bag until tested

nate pathogens from the environment, but will tell you where they are hiding. A robust cleaning and sanitizing program is required for the control or elimination of pathogens from the plant environment.   The recommended environmental sampling and testing program requires the plant facility to be divided into three zones: Zone 1. Areas in the facility that are very close to product contact surfaces, but not product contact surfaces, including under surface of filler bowl exteriors, filler piston exteriors, novelty mold surfaces, star wheels, in-line conveyor chains, etc. Zone 2. Areas within close proximity to the finished product/packaging area, including control panels, phones, framework or sides of equipment. Zone 3. Includes floors, floor drains, catwalks, underside of filling machines, wheels on dollies, forklifts, trash disposal areas, etc.

Henry Randolph

Once the zones have been categorized, it is recommended that at least 100 specific environmental sampling sites be established according to the potential for contamination of finished products with 50 in Zone 1, 30 in Zone 2 and 20 in Zone 3. Depending upon prior test results and the potential for product contamination, 10 to 30 sites should be swabbed and tested monthly. Use random numbers to select the sites to be tested. Remember: The primary objective is to find “hot spots” so they can be eliminated. Follow-up. You must put in place a plan of action to deal with positive test results. This plan must involve a thorough understanding and application of basic sanitation procedures. All dairy plants need to have a robust environmental sampling and testing program in place. The program should define the basic sampling and testing protocol, establish staff responsibilities and a plan for follow-up when positive results are indicated. If implemented effectively, it will serve as a necessary early-warning system that can reduce or eliminate microbiological contamination of ingredients, packaging and finished dairy products. DFR Henry E. Randolph is the founder of Randolph Associates Inc., which advises dairy processors about improving quality and operations.

Go In-Depth Learn more about food safety at Randolph Associates Inc.’s training courses. The Pasteurization Workshop is May 2-5 and the Sanitation Workshop is May 17-19. Contact Kristy Clark at 205-5956455 or [email protected].

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Global Insights

Dairy Pricing Moves Into A Higher Orbit ike Halley’s Comet, milk pricing “paradigm shifts” come along every so often and make us sit up and take notice. The last sighting was in the 1970s. Over the course of the decade, the farmgate milk price doubled and never looked back — the effect of a new, higher baseline in the cost of production. Here we are again trying to get our bearrings under an altered firmament. At January’s ry’s World Economic Forum in Davos, Switzerland, erland, delegates cited inflation as their No. 1 concern. ncern The daily headlines remind us about the price run-ups of 2008 and resulting food riots. Like three years ago, northern Africa is under siege. Our skeptical nature requires that we assume this trajectory will burn itself out in the atmosphere. And it’s true: economic cycles will always prevail. Rallies will come and go. Supply will overshoot demand for a time and prices will fall back to earth. But there’s a growing consensus that the cost of food, including dairy, has moved into a higher trading orbit. In today’s conversations about food inflation, we may be looking at a structural price increase rather than a cyclical one. The foundational shifts in the global dairy industry over the last four years have been profound, leaving the market with a bias toward undersupply for the foreseeable future. On the demand side, an influx of consumers has joined the middle class in developing countries, led by China. In 2007, the Asian giant accounted for less than 4% of world dairy imports. Today, that share is more than 8% and showing no signs of slowing. On the supply side, the cost structure of “dairying” has been altered (if not permanently, at least for some time) by the linkage of energy and grain prices. At the same time, global grain stocks sit at a 15-year low, leaving prices more vulnerable to weather and policy shocks. All this volatility flows through to world dairy prices, which were once buffered by hefty government inventories but are now fully exposed. The United States has been a clear-cut beneficiary of the new pricing paradigm. The U.S. share of global dairy exports jumped from about 11% in 2006 to 15% (of an expanding pie) last year. Of course, competitive dynamics are in constant motion. An elevated pricing band affects everyone in the dairy supply chain, from farm to fork, across the globe. For the U.S. dairy industry, it affects the policies and strategies we choose. We must decide: • What is our role in a global market of higher average prices? • Where do we fit in? • Where are our opportunities? • Where are our vulnerabilities?

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Tom Suber

Fa Factors that affect supply, demand su A good place to start our situation analysis is Aucksitu land, New Zealand. At the land World Dairy Summit last fall, Rabobank analyst Tim Hunt sugRaboban gested several changes to the face of in the years ahead the global dairy industry indu that should illuminate the th horizon. Hunt agreed that higher high grain costs would have significant impacts for dairy. For one thing, dairy-import demand will rise faster than can be met from pasture-based regions. For another, high grain prices will increase costs to all farmers, thus lifting the returns to dairy required to attract resources to the sector. In addition, it will put even more pressure on dairy farmer margins because the mismatch of movements in grain and dairy prices create constant fluctuations in profitability for producers who rely on grain inputs. That means that pasture-based regions should sustain a milk-production cost advantage, he said. On the other hand, it suggests that countries targeting grain self-sufficiency (think China) face particular challenges. There are implications on the demand side as well. Defending market share for milk products in an inflationary climate will be daunting, Hunt warned. Dairy occupies a premium position, and there are limits to substitution. But necessity is the mother of invention, and much of the potential growth in consumption is taking place in less discerning markets that lack a deeply entrenched history of dairy in the diet. Perhaps the most important strategic consequence is that it appears we’re going to see world prices and domestic prices on par going forward. The long-held conviction that emerging market consumers cannot afford Western products at Western prices hasn’t been accurate for years. In fact, since 2006, world benchmark spot prices have, on average, run 15-20% higher than U.S. benchmark prices. That changes everything. We will continue to endure market peaks and valleys – that law of economics hasn’t been repealed. But if the new dairy-pricing paradigm says the world is flat, that overseas markets bring the same (or better) returns as domestic and that the growth curve in supply has to go through the United States, then U.S. dairy exporters will truly find the sky is the limit. DFR Tom Suber is president of the U.S. Dairy Export Council, Arlington, Va. He can be reached at [email protected].

Dr. Condoleezza Rice Remarks by Condoleezza Rice

Chesley “Sully” Sullenberger Making an Impact

Marcus Buckingham

Guy Fieri

Daytime to Primetime – A Food Passion

Joe Montana

Driving Performance Excellence

Sinbad

Great Leader or Great Manager

Weighty Issues: The World of Sinbad

Jack Li

Dr. Lowell Catlett

John Gerzema

Harold Lloyd

Innovations in Marketing, Merchandising & Technology

Spend Shift: Brands & Post-Crisis Consumers

From Center Stage to Center-of-the-Plate. You’re Going to be a Star when you learn how to build and promote your own Rock Star Foods with the best in the dairy, deli, bakery, and foodservice business. Learn what it takes to have your products Rock-n-Roll off the shelves and out of the cases with the kind of taste, experience, and emotion that connects your brand to ever-changing customers’ needs and expectations. New Releases. IDDBA’s Dairy-Deli-Bake 2011 is the Show of Shows. It stars new products, big ideas, and new marketing and merchandising trends. There are plenty of opportunities to network with 8,000 attendees, while visiting over 1,500 booths, attending special events including the “Wisconsin Brand Stand,” and hearing the best speakers inside and outside the industry.

2020: A Vision for Tomorrow

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Show & Sell Center. Teach and Tell. That’s what the IDDBA Show & Sell Merchandisers do. They seek out new ideas and products, create world-class merchandising programs, and teach retailers how to use these concepts to sell more products and satisfy customers. With how-to instructions, idea sheets, photos, and finished products, the Show & Sell Center offers ideas and strategies for Food That Moves, Cross-Cuisine, Wellthy Eating, Art and Hearth, My Way, and Right-Sized. Sensational Sounds. You’ll be at the edge of your seat listening to great speakers who will share their sensational insights and knowledge to help you and your company stay ahead of the competition. From marketing trends to innovation; from a national economic view to in-store personnel and merchandising topics, we have you covered.

Register Now • Educational Seminars • Show Planner • Hotels • Exhibits • Show & Sell Center International Dairy-Deli-Bakery Association P.O. Box 5528 • Madison, WI 53705 • call 608.310.5000 • fax 608.238.6330 • visit www.iddba.org

New Product Showcase

Mixers and Blenders Seydelmann is a worldwide leader in grating, grinding and mixing technology. Seydelmann offers a complete range of bowl cutters that can be used to produce a wide variety of processed cheese. Product structures from coarse chopping to very fine textures can be easily achieved, all with a uniform, homogenous mixing of the ingredients. Seydelmann bowl cutters are ideal for the production of cold pack cheese, cheese tubs, cheese balls and logs, cheese spreads and more. Reiser 781-821-1290 www.reiser.com

SPX has a comprehensive mixer portfolio that offers the flexibility to handle all types of products — quickly and efficiently. With mixing and blending being one of SPX’s core technologies and food safety having paramount importance in today’s plants, all APV-branded mixers are designed to the highest hygiene standards for easy cleanability. The specialized mixing and blending systems fulfill customer requirements in industries as diverse as processed food and beverage, dairy, brewing and personal care. SPX Flow Technology 800-252-5200 www.spxft.com

Reiser

Eliminate daily flushouts due to build up in HTST plate heat exchangers with the DynaShear dual-stage inline, highshear disperser. Installing the DynaShear before the balance tank assures complete dispersion of powders, gums and stabilizers (no more lumps/graininess) and provides longer process runs and reduces water and CIP chemical usage. Plus, the stainless-steel mixing equipment meets or exceeds the strictest sanitary requirements and complies with 3-A third-party verification (TPV) and USDA-dairy standards. Admix, Inc. 603-627-2340 www.admix.com

Admix

Lee Industries offers durable, customized processing equipment to meet the dairy industry needs. Mixer versatility and multibatch capabilities save processing time, and its 3A-approved fluid transfer valves are designed for high sanitary conditions. Lee offers sanitary finishes, ASME uniflow jackets, vacuum-pressure capability, heavy-duty USDA-approved direct drive agitators, double-ribbon, paddle and scrapped-surface combinations and hydralic tilting action. Lee Industries, Inc. 814-342-0461 www.leeind.com The Tetra Almix is a complete mixing solution that handles a range of dairy products such as recombined milk to value-added liquid and cream-based products, with precise control. The high-shear mix unit and mixer tank are both designed to achieve maximum centrifugal force inside the tank. Working together, they literally beat the ingredients to pieces by creating a controlled turbulence that reaches its climax in the perforated stator. The Tetra Almix also puts an end to the air and foaming problem. The basic principle is maximum exposure to liquid in a vacuum environment. Tetra Pak Processing 847-955-6000 www.tetrapakprocessing.com

Lee Industries

Continued on page 94 92

Dairy Foods | March 2011

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

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

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

New Product Showcase PremierTec products from Alfa Laval are designed to advance the liquid mixing process for the food, pharmaceutical and biotechnology industries. Featuring an innovative magnetic mixer, the patented design has a strong magnetic coupling between the impeller and the driving magnets, which causes the impeller to levitate or float with no direct contact with the bearing surfaces. This allows for continued mixing until a tank is empty, and achieves a validated mix to a much lower tank level compared to other mixing products. As a result, the customer saves product, time and ultimately operating costs. The PremierTec portfolio also includes a range of specialty Pharma valves, often bundled together with mixers. All products maintain a 3.1 traceability with USP Class VI-compliant mixing components. Alfa Laval Inc. 801-222-5300 www.alfalaval.com The DCI Dynamixer is designed to mix dry solids, semi-solids or liquids into a slurry or liquid product. This highspeed mixer/blender may also be used to quickly, efficiently and completely Alfa Laval blend, disperse, reconstitute, dissolve, re-hydrate, pre-break or re-run soluble solids, soluble pastes and liquids. Insoluble products are dispersed into liquids to make suspensions and slurries with greater stability and homogeneity. Models are available in a variety of shapes, sizes and motor horsepower to fit a broad range of applications. DCI Inc. 320-252-8200 www.dciinc.com DCI Inc.

Chester-Jensen Chester-Jensen’s Model 70N Cooker-Cooler is a batch-mixing processor designed to cook, cool and super-blend food products all in the same vessel. Made from polished stainless steel, they are fully insulated and offer maximum ratio of heat exchange surface to unit’s volume. The unique dual-agitation configuration, along with heat-exchange jacket on the entire cone bottom, allows the operator to effectively combine and blend ingredients and, in so doing, process the most uniform-finished product possible. Sizes are available up to 1,000 gallons. Typical products include pizza/spaghetti sauce, meat, pastry and pie fillings, beans, pudding, burrito/taco mixes, candies, jellies and jams. Chester-Jensen Co. Inc. 800-685-3750 www.chester-jensen.com The Quadro Ytron Jet Mixer from Quadro Engineering has proven to be successful in bulk tank mixing and gentle handling of shear-sensitive products. The discharge of the Jet Mixer creates a pure axial flow pattern that eliminates vortexing, unwanted air entrainment and the need for hard-to-clean baffles. The Jet Mixer also removes stratification in large storage silos by maintaining complete tank motion of viscous, non-Newtonian fluids and easily suspends/resuspends high-settling rate solids. It comes in five sanitary models. Quadro Engineering Corp. 519-884-9660 www.quadro.com

Quadro Engineering

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Dairy Foods | March 2011

EVERY THING AND EVERYONE YOU NEED IN JUST ONE SHOW. Advanced technology, innovative packaging, green transportation, food safety solutions, expanding markets, sustainability, enhancements in plant operations, new ingredients — all make up the universe of hot trends, education topics and exhibitors that will highlight the 2011 International Dairy Show. Everyone who has a stake in the dairy industry will be on hand to share ideas to streamline processes and improve plant performance.

Don’t miss the premier event of the year for dairy professionals.

PACKAGING, PROCESSING AND TECHNOLOGY SOLUTIONS FOR THE GLOBAL DAIRY INDUSTRY

S E P T E M B E R 1 9 – 2 1 , 2 0 11 • A T L A N T A , G A • W W W . D A I R Y S H O W . C O M Use this code A3DFE when registering at www.dairyshow.com

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Equipment Showcase

Packaging and Containers Fiber-bas Fiber-based packaging solutions from Evergreen Packaging are developed to keep out ligh light, oxygen and vitamins and keep in taste. All of the company’s Tru-Taste barrier board is produced at its own mills. Its patented barrier technologies are designed Evergreen Packaging to extend shelf life and package durability. More than 70% of the carton is made from paper using trees from responsibly managed forests. More than 50% of the energy used to make the paper in the carton comes from biomass. Evergreen Packaging 901-821-2247 www.evergreenpackaging.com The Huhtamaki FM-4000 packageforming machine has quick-change capability. In as short as a shift change, a dairy processor can switch the size aand shape of a package. This speed and flexibility can optimize plant production. Using pre-printed packaging (which is shipped flat) also reduces the costs associated with transportation, warehousing and handling. Huhtamaki Inc. 913-583-8760 www.us.huhtamaki.com The new Multi-seal deli package from Cryovac can be easily and reliably opened and resealed several times, according to the company. The flexible and reclosable package is suitable for sliced and cubed cheeses. The package uses less material than traditional tubs and does not require a zipper or tear-notch feature. The Multi-seal package runs on existing thermoforming equipment. The package design allows for pegboard display at retail. Cryovac 800-845-3456 www.cryovacmultiseal.com Halo films from Exopack are specifically engineered for sliced and chunk cheese products. These films use a patented EVOH encapsulation technology for extended shelf life. Available in up to 10-color process print, the films are said to provide maximum shelf impact while offering excellent seal integrity and abuse resistance. Exopack Exopack 877-447-3539 www.exopack.com

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Dairy Foods | March 2011

Stanpac Inc.

Stanpac’s new 140-milliliter (4.73-ounce) glass yogurt container and heat seal lid complement the company’s line of glass milk bottles and related packaging. Glass containers are suitable for dairy brands marketing a premium product. Glass packaging conveys premium quality and environmental responsibility, the company states. Stanpac Inc. 905-957-3326 www.stanpacnet.com Combibloc EcoPlus is an aseptic carton pack for liquid food from SIG Combibloc Inc., that is said to cut down CO2 emissions by 28% compared to a 1-liter carton pack of the same format. The reason is a new cardboard composite that contains more than 80% wood fiber. SIG Combibloc Inc. 610-546-4200 www.sig.biz/usa Grayling Industries added a reusable, intermediate bulk container to its product offerings. The Caliber 315 IBC is manufactured from FDA-approved materials and features smooth interior and exterior surfaces that allow for easy cleaning. The collapsible design of the tote minimizes storage space requirements and freight costs. The container capacity is 315 gallons or 3,300 pounds. Grayling Industries, Inc. 800-635-1551 www.graylingindustries.com

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

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Buyers Mart

PLANT EQUIPMENT Omega Engineering

Omega Engineering introduces Dilbert Controlcat New Horizons, Version 28. This 150-page, full-color book showcases state-of-the-art products for automation, sanitary, temperature, electric heaters, wireless/data acquisition, pressure/strain/ force and flow/level/environmental. It also includes a user-friendly index for easy product search, economical choices, popular models and accessories, 105 Dilbert cartoons and easy ordering options, including online shopping, technical assistance and fast delivery. Omega Engineering Inc. 203-359-1660 www.omega.com

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OK series from a mixed material trap with a forged steel cover and stainless body to all stainless steel. This trap series does not rust like cast iron or cast steel trap models and is corrosion resistant. With its single-seated mechanism, all models of the FTS series are modulating with 100% turndown ratio on both pressure and flow. The series also has a tight shut-off on no load, resulting in instantaneous response to condensate load changes. All thermostatic air vents operate up to 572°F and remove air rapidly on startup, making it water hammer resistant and capable of withstanding superheat. This series operates with no functional steam loss and does not require a water seal or prime to close. Spirax Sarco Inc. 803-714-2000 www.spirax.com Garlock Sealing

from electrical damage. Plus, the all-inclusive Aegis universal mounting kit (U-Kit) simplifies mounting on virtually any AC motor shaft. The ring’s conductive microfibers are securely embedded in the patented Aegis FiberLock channel and completely surround the motor shaft, providing millions of discharge points for harmful shaft currents. This unique design also creates the path of least resistance that effectively diverts these currents away from bearings to ground. Electro Static Technology 866-738-1857 www.est-aegis.com WCB Ice Cream

Delkor Systems presents a new sanitary case packer that’s designed for optimal cleanability. The case packer ensures minimized horizontal surfaces, incorporates standoff mounting of components for open access and comes with cross members to assist with complete drainage. It also features a quick, tool-less removal of parts for sanitary wash. As for electrical components, the servo motors, gear boxes and pneumatics are all IP-69K rated, which means that these components can receive direct contact from a high-pressure hose. Other features include NEMA 4X electrical enclosures with sloped tops, stainless steel conduit and sanitary ball feet and 100% stainless steel metal components with FDA-compliant plastic components. Delkor Systems Inc. 800-328-5558 www.delkorsystems.com

The new SGi shaft grounding bearing isolator from Garlock Sealing Technologies protects bearings from electrical damage, lubricant loss and contamination. Maintenance-free, the SGi combines the proven technologies of the Garlock Guardian non-sparking bronze labyrinth seal and the Aegis shaft grounding ring in a single unit. It is ideally suited for motors controlled by variable frequency drives, running pumps, fans, high-speed spindles and other equipment in “severe-duty” applications. Designed for long-term total bearing protection, the SGi also provides an IP56 non-contact isolation seal that withstands dust and powerful jetting liquids. It easily replaces contact lip seals and traditional bearing isolators and withstands operating temperatures from –22°F to 300°F. Garlock Sealing Technologies 800-448-6688 www.garlock.com

Spirax Sarco redesigned its 0.5-inch FTS150 and FTS-300 float and thermostatic steam trap series to replace the

The Aegis SGR Bearing Protection Ring from Electro Static Technology protects the bearings of VFD-driven motors

Dairy Foods | March 2011

Electro Static

WCB Ice Cream introduces its upgraded lab ingredient feeder, designed for development and research purposes in laboratories where the demand for small capacities, adjustability of different parameters and repeatability of processes are important. The lab ingredient feeder is ideal for mixing dry and/or liquid ingredients such as nut crumbs, chocolate pieces, fruit syrup and variegates in small capacities into ice cream. The new design features easy start-up with very low raw material requirement and good scalability to full production. Plus, the unit is fully mobile and can fill 18-100 liters of ice cream per hour. WCB Ice Cream 215-425-4320 www.wcbicecream.dk

Buyers Mart

FOX IV

R & D INGREDIENTS SensoryEffects

FOX IV Technologies introduces the Model 5422 next-off print-and-apply labeler for printing and applying 8.5x14inch labels. Designed for 24/7 operation in the most demanding environments, the Model 5422 uses FOX IV’s exclusive Uniwall design that mounts the Zebra 220 Xi4 printer components to a rugged industrial centerwall. Screen-printed label and ribbon paths and user-friendly keypad and menus make the Model 5422 easy to operate and maintain. The Model 5422 print-and-apply system also has print speeds up to 10 ips, print widths from 4 to 8.5 inches, label lengths to 14 inches and print resolutions of 203 dpi or 300 dpi. FOX IV Technologies, Inc. 877-436-2434 www.foxiv.com Cryovac BLX-F2 Automatic Bag Loader from Sealed Air offers configurable packaging options for multiple applications, including Cheddar and Italian cheeses. Users program their in-feed for both in-line and perpendicular product separation and staging, depending on the application. The loader also handles a wider range of product weights, from 8 ounces to 12 pounds, operates at speeds up to 45 cycles per minute and requires minimal time for changeovers. Plus, the touch-screen operator interface saves up to 99 different product settings, and is equipped with sensors and controls to ensure the product is correctly staged for accurate loading. Sealed Air Corp., Cryovac Food Packaging Systems 800-845-3456 www.cryovacequipment.com

SensoryEffects Flavor Systems introduced Choco-Flakes, a line of compound coating inclusions designed to have a melt point around 80°F, making them ideal ingredients for use in ice creams or other frozen dessert systems. They are available in dark, milk and white chocolate, and can be made into other customized chocolate-based flavors such as chocolate cherry or raspberry white chocolate. Plus, Choco-Flakes is said to provide superior mouthfeel, flavor delivery and improved tolerance in application. SensoryEffects Flavor Systems 800-422-5444 www.sensoryeffects.com Ascentra sodium-reducing flavor enhancer from DairiConcepts is a

WeldSeal from Impco is a high-performance brush-on methacrylate compound formulated for sealing porosity in welds containing gases under pressure or liquids. WeldSeal’s low dynamic viscosity enables it to wick deeply into pores and seams and in between close-fitting ferrous metal surfaces. Cured WeldSeal forms a pressure-tight mass that withstands continuous service temperatures of up to 355° F. After WeldSeal cures, excess material on the surface is rinsed away with water, leaving the surface clean and ready for painting or other operations. Impco Inc. 800-779-2491 www.impco-inc.com

convenient, clean-label powdered ingredient that naturally amplifies the perception of salt and other savory nuances as it lowers sodium content. Ascentra enhances existing savory flavors, yielding a richer, more rounded flavor than is available through traditional, all-salt formulations. Ascentra also provides opportunities to lower ingredient costs by replacing higher-cost ingredients with more economical ones. Made from a proprietary, whole milk-based fermentation process, Ascentra does not contain MSG, HVP or yeast extract. Although rich in potassium, it does not contain potassium chloride, eliminating metallic flavor notes. DairiConcepts LP 877-596-4374 www.dairiconcepts.com David Michael & Co. offers a line of Fresh Flavors – non-characterizing flavors that when added to a product using fruit, build back the freshness for a “just picked” sensation. Fresh Flavors also helps to reduce the slightly stale taste that juice products typically develop over the course of their shelf life. Fresh Flavors can also be combined with David Michael’s fruit WONF flavors to produce refreshing results in juices, hard candy and other food items. David Michael & Co. 215-632-3100 www.dmflavors.com

Impco

www.dairyfoods.com

99

Prepared Foods’ 29th annual New Products Conference is the food & beverage industry’s premier event for gaining valuable insights into exciting global new products, culinary advances and emerging consumer trends. The New Products Conference provides R&D, Marketing, Product Developers, and Corporate Management executives like you, a dynamic forum to learn from world-class speakers, capture valuable new product & trend data, participate in an interactive culinary session, taste new products from around the globe, capitalize on incredible networking and ignite your creativity.

Top Reasons To Attend • International New Product Trends

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• Taste 60 New Products From Around the Globe

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• Interactive Culinary Session

• Excellence In Innovation Awards

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“

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”

discover new products

network

Save the Date – September 11-14, 2011

Make a commitment today to invest in your career, revitalize your creativity, and network with the industry’s top new product development leaders, while enjoying the warm weather at The Ritz-Carlton in Naples, Florida

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www.PreparedFoods.com/npc

new product trends

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

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EMPLOYMENT

AUCTION

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A U C T IO

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DF_1010_Classifieds.indd 77

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& COMPAN Y 78

Dairy Foods | Septe mber

or Lease!

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2010

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

DF_1010_Class ifieds.indd 78

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Dairy Foods | March 2011

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A DVERTI S E H ER E 104

CONTINGENCY OR RETAINED SEARCH: VP ENG/MFG/OPERATIONS PLANT/PRODUCTION MGMT PLANT ENG/MAINT MGRS WAREHOUSE/DISTRB MGMT QUALITY/PROCESS IMP. MGMT MAINT/PROD/QC SUPERVISORS

2 4 8 -78 6 -16 9 2

Ad Index *Indicates Regional Advertising

Company Name Admix, Inc. Advanced Instruments ALPMA Amelia Bay, Inc. Autocrat Premium Coffee & Syrup Bentley Instruments Blommer Chocolate Company California Custom Fruits & Flavors Cargill Salt Cognis Nutrition & Health Danisco USA Inc. David Michael & Co. Delkor Systems, Inc. EFCO Products Ins. Eriez Magnetics Exopack Food Tools, Inc. Fortress Technology Framarx/Waxstar Fristam Pumps, Inc. Fruitcrown G-M-I, Inc. Garon Foods, Inc. GEA Niro Soavi NA GEA Process Engineering, Inc. GEA Tuchenhagen North America GEA Westfalia Separator, Inc. Gram Equipment H.S. Crocker Company, Inc. Heat and Control Hydrite Chemical Company

Page No. 20 12, 56 22 3 9 80 53 21 11 33 45 51 BC 18 24 55 82 16 72 4 35 36 36 83 IFC 77 70 50 85 81 23

Company Name International Dairy Deli Bakery Association International Dairy Foods Association IPL Inc. Ivarson, Inc. Karl Schnell USA Machine and Process Design Inc. MilkPEP Mintel International Nelson-Jameson, Inc. Neogen Novasep Polypack, Inc. Relco Robert Reiser & Co. Robertet Flavors, Inc. S&D Coffee SensoryEffects Separators, Inc. Spraying Systems Co. SPX Flow Technology Segment Stanpac Inc. Sudmo North America, Inc. T.D. Sawvel Co. Inc. *Tetra Pak Hoyer Tetra Pak, Inc. TIC Gums Tindall Packaging, Inc. Union Pacific Urschel Laboratories, Inc. U.S. Highbush Blueberry Council Weber Scientific

Page No. 91 95 97 57 82 73 31 105 80 89 26 a-b 48 74 61 41 39 49 26 75 IBC 25 17 6 18 a-b 19 43 93 14, 15 7 37 13

ACCELERATE YOUR

INNOVATION Mintel provides the most relevant, reliable & current market intelligence available. Flavor, ingredient & preparation trends Nationwide restaurant menu tracking Global new product monitoring & analysis

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105

Inside Perspective

A Raw Deal hould dairy farms be allowed to sell jars and bottles of raw (unpasteurized) cow’s milk directly to consumers? It’s an issue that stirs the blood, like a helmet law for motorcycles or a body scan at the airport. When should a state legislate for the interests of the many, and when for the interests of the individual? In Wisconsin last year, politicians coalesced on each side of this question — some supported a bill to allow the sale of raw milk from farms because they supported the rights of the individual; their right to make a choice. Other legislators decided that consumption of raw milk is more than an individual choice — it is a choice that impacts children who are served raw milk and other dairy farms and people in the established dairy industry. The Wisconsin bill (supporting raw milk sales) passed last May and was subsequently vetoed by then Governor Jim Doyle. Another Wisconsin bill, likely similar to the last, is expected in the new legislative session this spring. Supporters of the sale of raw milk in jars or bottles look at this issue without nuance, as if the question of legalizing on-farm sales of raw milk is not complex — as if the rights of the individual versus the rights of the larger populace is the only issue. They make two points: individuals have a right to choose what they put in their body and individual farms should be allowed to enrich themselves. It’s not that simple. Not by a long shot. Consumption of raw milk — milk driven from farms and consumed in urban and suburban homes — can make people ill. According to the Centers for Disease Control and Prevention (CDC), from 1998 through 2008, states reported 86 outbreaks due to consumption of raw milk or raw milk products, resulting in 1,676 illnesses, 191 hospitalizations and two deaths. CDC states that a substantial portion of the rawmilk-associated disease burden falls on children. Among the 86 outbreaks noted

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106

Dairy Foods | March 2011

John T. Umhoefer

above, 79% involved at least one person younger than 20 years old. CDC adds to these facts: “Reported outbreaks represent the tip of the iceberg. For every outbreak and every illness reported, many others occur, and most illnesses are not part of recognized outbreaks.” In Wisconsin last spring, the Wisconsin Medical Society, pediatricians and public health officials joined the dairy industry to ask the governor to veto raw milk legislation. He listened. Raw milk is a highly perishable product. Today, a “hidden market” for raw milk in Wisconsin includes consumers picking up bulk loads of jars and bottles from farms in picnic coolers and holding these jars for pick-up by other consumers in an area. Entire pages — entire chapters — of state and federal regulation control the bottling and distribution of cow’s milk in the United States. And that’s for the pasteurized product. Wisconsin’s raw milk bill allowed for sale at the farm “a sanitary container filled in a sanitary manner” and handed to a consumer. Bypassing all safety hurdles and regulations, the bill assumed the consumer would transport and store these jars with proper refrigeration and consume the product quickly. People pin false hopes on the healing power of raw milk. At a public hearing on Wisconsin’s raw milk bill, some consumers echoed the myriad health benefits claimed by raw milk supporters. But in fact, there’s no scientific research to support claims that drinking unpasteurized milk can cure cancers, allay the impacts of autism or cure allergies or Crohn’s disease. “There’s a dangerous sense of superiority shared by Minnesotans who buy raw milk and serve it to their families,” The Minneapolis Star Tribune noted last June after an outbreak of E Coli 0157:H7 in raw milk was linked to Hartmann Farm, south of Gibbon, Minn., by the Minnesota Department of Health. Eight people became ill, including six children. “Had they visited Hartmann’s Sibley County farm,” the Star Tribune editorial

stated, “they hopefully would have realized they were recklessly jeopardizing their families’ health.” “A June 16 search of his operation by authorities shows it is far from the pastoral utopia they believed it to be,” the editorial added. “Milk was drawn in a filthy or insanitary place,” according to Sibley County court records and photos. Chickens ran free through the milking area. The gutter designed to carry manure out of this area was full of feces. The walls, floor, stanchion dividers, posts and other equipment were “visibly covered with manure.” This farm in Minnesota does not represent modern dairy farming or even other farms that sell raw milk. But this outbreak belies the halo raw milk producers have burnished for their “superior” dairy food: a high-priced niche floated on unproven health claims. No single disease outbreak has shattered American confidence in dairy foods. Yet every outbreak does some damage. In Wisconsin, raw milk advocates argued that “Big Dairy” tried (and succeeded) in stopping their legislation in stopping the “little guy.” Wisconsin has thousands upon thousands of little guys, dairy farmers, who have no intention of selling raw milk directly to consumers — and a handful seeking this niche. And that vast majority wish to protect the safe, wholesome image dairy has earned through decades of advancements in cow care, sanitation, distribution and pristine processing. This spring, Wisconsin will take up another bill to legalize the sale of raw milk. And the voice of the many — health professionals and pediatricians, dairy farmers and scientists, consumers and dairy processors — will be heard again in opposition.  John T. Umhoefer is the executive director of the Wisconsin Cheese Makers Association, Madison, Wis. Dairy Foods seeks essays from dairy processors. Contact [email protected].

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