THE ART OF USING COLOR | MILANO’S CHEESE | CONVEYORS & PALLETIZERS
September 2011
Innovative Ideas for Dairy Processors
Allure of Frozen Desserts The
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September 2011 Vol. 112, No. 9
S P E C I A L F E AT U R E S
From Push Cart To Scoop Shop Artisan ice cream is one of the most exciting dairy food categories of this young decade. Ice cream makers start with a push cart and progress to a store. They agree that consumers understand that handmade and local sourcing equates to a higher cost. Credit the specialty cheese market, which in the 1990s showed that independent makers could survive — and thrive. p. 36
On our cover: Annual sales of frozen sweet goods (excluding cheesecake) were nearly $200 million, according to Chicagobased SymphonyIRI Group. (See more data on page 24.) This month, we also celebrate another frozen dairy dessert: ice cream. Artisan ice cream makers seem to be in a good position to weather rising ingredient costs because they can ask more for their products. For more, see “From Push Cart To Scoop Shop” on page 36.
Coloring Dairy Foods Color plays an important role in food product development. Colorants are typically used to enhance or improve the color that consumers expect of butter, ice cream or yogurt, rather than allure or shock, as they do in beverages and confections. p. 44
Features News & Trends 10 Newsline Overseas markets hold promise for dairy; IDFA supports trade deals
Products & Marketing 24 Dairy Market Trends
30
New Product Review The latest buzz around coffee drinks
Departments Editorial People Supplier News Pumps and Valves Buyers Mart Inside Perspective Aurora Organic Dairy’s Sonja Tuitele shares the company’s sustainability practices.
Lab Talk
REPORTS
Prime time for probiotics
Sales of frozen desserts
26
8 14 20 86 92 98
Ingredient Technology
32
34
Culturally Speaking
63 Milano’s Cheese Co. 74
Behind The Scenes
Give cultured dairy its due
76
Conveyors and Palletizers
Tharp and Young
80 Sayler on Safety
Formulating “better-foryou” desserts
82 Packaging Points 84 Global Insights
More features at Dairyfoods.com Dairyfoods.com reaches beyond the pages of our monthly print content. For Web-exclusive content, great interactive features and recent articles from Dairy Foods, visit www.dairyfoods.com.
DAIRY FOODS Volume 112, Issue 9 (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
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From the Editor’s Desk
Dazzle Them with Dairy Science Jim Carper
A
s children headed back to classrooms over the last four weeks, the annual (and predictable) chorus of “no flavored milk in schools” was heard across the land. Every year, a few more school districts take the bait dangled by the anti-sugar crowd and ban the sale of flavored milk with added sugars while allowing orange juice (which contains even more sugar). The key words and hot buttons in this debate include: children, government intrusion, parental rights, personal responsibility, sugar, obesity and nutrition. Individual dairy processors and trade and marketing associations join the battle, but even they can’t always win. You would think that having science on your side would turn decisions in your favor, but that is not always the case, especially when the issue is this emotionally charged. Hard facts provided by scientific inquiry are vital to the health of dairy processors and producers. Peer-reviewed scientific studies show that nutrient-dense flavored milk is not associated with adverse effects on body weight. Moreover, flavored (and plain) milk contributes to positive nutrient intake in children. Among the institutions promulgating scientific inquiry is the Dairy Research Institute, Rosemont, Ill., which observed its first anniversary in July. Established under the leadership of America’s dairy farmers through Dairy Management Inc. (the organization that manages the producer checkoff program), DRI has a raft of accomplishments to celebrate. Among them: • Studies of milk fat showing it does not increase the risk of heart disease • Creating the scientific support for marketing claims about dairy and whey protein • Identifying best practices in sodium reduction in cheese • Developing nutritionally enhanced yogurt and other cultured dairy foods • Showing the true carbon footprint of the U.S. dairy industry (as opposed to the cattle industry) Greg Miller, president of the Dairy Research Institute and a Dairy Foods nutrition columnist, told me that the non-profit DRI manages the investment in dairy research by coordi8
Dairy Foods | September 2011
nating and focusing the activities of other research outfits, such as the six nations in the International Dairy Research Consortium for Nutrition and Health. Other partners are the Center for Advanced Energy Studies and the National Dairy Foods Research Center Program. By avoiding duplication, you don’t have five separate studies about milk fat and heart health, for example. This way, research dollars are used more effectively. DRI works with organizations you might not think of as dairy customers. NASA, for instance, seeks protein solutions to the loss of bone mass in its astronauts in space. The U.S. Department of Defense is concerned about obesity, body mass and traveler’s diarrhea among its personnel. DRI seeks a dairy solution. DRI’s research efforts confirmed the importance of dairy in a healthy diet. When the 2010 Dietary Guidelines for Americans were released in January, the recommendations for children ages 4-8 were to increase their daily dairy intake from 2 to 2.5 servings. The new DGA also recognized dairy as an important source of nutrients for those with lactose intolerance. The guidelines reported “moderate evidence indicates that intake of milk and milk products are associated with a reduced risk for cardiovascular disease and type 2 diabetes.” You can thank DRI. These conclusions are ones that dairy processors can take to the bank, or at least to their advertising agencies who can then develop relevant marketing messages. Dairy processors might also be interested in an Institute for Ingredient Processing project at South Dakota State University, Brookings, S.D. An industrial-size dryer was installed that will filter out whey before it’s processed. This is a big deal because previous research has been conducted only with bench-size dryers. The industrial dryer will provide “real world” data. DRI is funding the staffing and research at SDSU. Other dairy ingredient research activities found that whey protein, not soy protein, leads to lower body weight, body fat and waist circumference compared to carbohydrates. DRI is involved in whey protein sensory and application research that seeks to expand the use of whey ingredients by improving quality and performance and to facilitate increased
use of co-products by providing economically viable opportunities. By improving whey quality and performance, processors can develop new food and beverage products. For example, meal replacement beverages can now be formulated with 10% protein due to improved heat stability, compared to the previous formula of up to 5%. The impact of improved whey flavor can also be seen in the recent launches of new beverages, smoothies and bars formulated with higher protein concentrations, Miller says. Greek yogurt is one of the hottest dairy foods in recent years. Dairy centers, with DRI funding, have provided technical insights to various processors on the use of different processes and ingredients toward manufacturing of Greek yogurt, keifer and frozen smoothies with higher proteins. With growing consumer interest in simple and natural ingredient lines, researchers have recently shown that whey protein can be used as a thickener to replace starches and gums. Dairy processors cannot go it alone. They need trade associations to press their interests in Washington. They rely on flavor houses for product development. And they depend on research organizations to do the hard science that results in better ingredients, evidence of nutritional value in dairy foods and better processing techniques. DRI is one of those institutions that assist dairy processors as well as producers. To keep up with the research, subscribe to DRI’s monthly e-newsletter, Dairy Research Insights. It provides the technical insights on key nutrition, product and sustainability research. See its website (www. USDairy.com/DairyResearchInstitute) for additional resources, including a guide to nutrition claims, a guide to resources of the National Dairy Foods Research Centers and Application Labs and a resource library. Congratulations to the Dairy Research Institute for not only reaching its first anniversary, but also for furthering the cause of dairy foods. 䡲 Jim Carper is chief editor of Dairy Foods. Phone: 847-405-4009. Email: carperj@dairy foods.com.
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News & Trends
NEWSLINE... The Demand for Dairy Is Overseas
T
wo studies released this summer find that demand for dairy foods and dairy ingredients will remain strong for years to come in developing countries, including China and Russia. In the United States, dairy processors need to add value to their brands and bring to market lactose-free milk, organic milk, and fortified and functional milk appeal to niche markets. The results of both studies were disseminated in webinars attended by Dairy Foods. While U.S. dairy processors can find eager buyers abroad, there is work to do at home to develop products and marketing messages to appeal to the American consumer. As a follow-up to a study conducted in 2008 of the export market, Boston-based Bain & Co. stated that its recent analysis “showed that long-term demand for dairy products will remain strong, driven primarily by emerging markets.” “At the same time, traditional sources of supply are constrained and will fall short of expected needs,” says Clinton Anderson, a partner with Bain & Co. “In fact, the demand gap is likely wider than anticipated a few years ago, and the window of opportunity remains open, with the United States well-positioned as a supplier to take advantage.” A second study, this one by a Swiss-based equipment and packaging firm, concluded that “the world is set for a decade-long boom
in milk consumption, with demand for liquid dairy products set to surge by around 30% from 2010 to 2020, driven by economic growth, urbanization and the rising purchasing power of Asia’s middle class.” The forecast, by Tetra Pak, Vernon Hills, Ill., also states that by 2014, packaged milk will outsell “loose” (unpackaged) milk in the developing world for the first time. Where the exports are going The Innovation Center for U.S. Dairy, Rosemont, Ill., worked with the consulting firm Bain & Co. and concluded that growth prospects remain intact. The IC sought to update the research to determine if fast-changing international dairy market conditions since the 2008 global financial crisis altered the initial findings, conclusions and recommendations to the dairy industry. Over the last three years, China, India, Southeast Asia and the Middle East/North Africa have shown continued demand growth, the report noted. More than 75% of the projected increase in world non-fluid dairy consumption from 201015 is expected to come from these four regions. The Tetra Pak research stated that by the end of the decade, India and China are expected to account for more than a third of the world’s total liquid dairy products consumption, with the Asia-Pacific region
Taiwanese, Americans Order Dairy ‘To Go’ 70 60 50 40 30 20 10
䡲 Percentange of those age 15 or older who say they “sip a drink while walking or driving” or “eat on the go” weekly or more often Source: Roper Reports Worldwide 2009 and 2010, reported by Tetra Pak 10
Dairy Foods | September 2011
India
Indonesia
Brazil
China
Turkey
Sweden
Russia
Czech Republic
Poland
Egypt
Thailand
Spain
South Africa
France
Mexico
Argentina
Germany
UK
Japan
Italy
Canada
Korea
Australia
USA
Taiwan
Global
0
News & Trends
Italy Leads The Growth In ‘On The Go’ 12
The World, At a Glance Taken region by region, Tetra Pak forecasts that: • Asia-Pacific’s consumption of liquid dairy products (LDP) will
10
climb by almost 45%, from slightly below 140 billion liters in
8
2010 to almost 200 billion liters by 2020. 6
• Asia-Pacific’s total global market share will grow by at least 5% between 2010 and 2020 to above 55%.
4
• Africa will see significant growth in LDP consumption, which
2
will climb by more than 50%, from around 15 billion liters in Global
Turkey
Spain
Argentina
Poland
Japan
Korea
Italy
0
2010 to almost 25 billion liters in 2020. • Latin American consumption will increase by more than 25% during the decade, reaching more than 30 billion liters in 2020 compared with less than 25 billion liters in 2010.
䡲 Percentage point change from 2009 to 2010. Source: Roper Reports Worldwide 2009 and 2010, reported by Tetra Pak
• In North America, consumption will reach approximately 40 bil-
alone continuing to consume more than the rest of the world combined. Asia-Pacific, Latin America and Africa are all forecast to record double-digit growth in demand for liquid dairy products in 2010-2020. The IC said that Russia’s dairy production dipped and potential lowcost producers such as Brazil and Ukraine failed to develop their supply capabilities. Other sources such as Argentina and Belarus have good potential but are relatively small. Despite modest production increases, New Zealand and the European Union will be unable to keep up with emerging market needs, the 2011 report update concludes.
• In Western Europe, consumption over that same period will
lion liters in 2020 compared with about 35 billion liters in 2010. show a modest fall. Western Europe’s share of global LDP consumption will drop from around 12.5% in 2010 to less than 10% in 2020. • Despite its stagnant growth, however, Western Europe will remain the biggest LDP consumer per capita in 2020, followed by North America. Source: Tetra Pak
Continued on page 12
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FULL potential Are your dairy products reaching their FULL potential? Recent studies 80 billion more liters by 2020 demonstrate that foods formulated with Fibersol®-2 digestion Global demand for all forms of liquid dairy resistant maltodextrin can provide an increased feeling of satiety products (LDP) will grow from some 270 billion liters in so consumers felt fuller for a longer period of time. Fibersol®-2 2010 to around 350 billion liters can also be used to replace calories from sugar and fat while by 2020, according to Tetra Pak. LDP includes white milk and other increasing the fiber content to create ice cream and sorbet liquid dairy products, such as flavored milk, drinking yogurt, sweetened contype products under the appropriate labeling standard densed milk, lactic acid drinks and baby and toddler milk. In this decade, global consumpwithout adding any taste, aroma or unwanted tion of other liquid dairy products is set to rise by close to 60%, topping 100 billion liters by 2020. viscosity of it’s own. Fibersol®-2 digestion resistant The demand for LDP will climb in every region of the world between 2010 and 2020, with the exception of maltodextrin is the fiber you want so your Western Europe where demand is likely to remain flat. The consumers and your dairy products can dairy boom will be most pronounced in Asia – led by India and China – where increased prosperity and the rapid growth of reach their FULL potential! the middle class will spur a significant rise in consumption among millions of consumers, according to Tetra Pak. Demographics, economic growth and sustainability are fuelling six fundamental developments or “mega trends,” which will shape the future of the dairy value chain, Tetra Pak forecasts. Demographic change will be characterized by a growing population increasingly living in cities. Economic growth, particularly in emerging markets, will spur development, boost the ranks of the middle class and speed up globalization. Sustainability will become a key issue as demand for resources puts pressure on the environment and increases the need for technological innovation. The six resulting “mega trends” are: 1. Increased demand for packaged food 2. Greater diversification of consumer needs 3. Changing dynamics in food manufacturing and retailing 4. More food safety awareness 5. Rising competitive pressure 6. Acceleration in green solutions as a “must have” for businesses
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Growth spurred by middle class The World Bank expects the global middle class – broadly defined as those earning around $10-$20 a day – to soar from 430 million in 2000 to 1.15 billion by 2030. These new consumers are expected to show more interest in issues related to food safety, healthy living and the environment. In addition, they are likely to be more brand conscious and interested in products that meet the needs of their busy, urban, “on-the-go” lifestyles. “The emergence of the middle class, urbanization and the expansion of modern shopping habits by busy, health conscious and well-informed consumers have raised both the consumption and distribution of packaged milk. Consumers are looking for greater convenience without compromising on quality and safety,” says Charles Brand, Tetra Pak vice president, marketing and product management. The U.S. forecast Plain white milk remains a big seller in mature markets, but it is value-added products promoting convenience, health and well-being that may offer the best growth opportunities, according to the Tetra Pak report. Although there is rising demand in the emerging markets, Western Europe and North America are set to remain the Top 2 markets for liquid dairy products, in terms of per capita consumption in 12
Dairy Foods | September 2011
News & Trends
2020, according to Tetra Pak. The average Western Europeans and Americans will still be consuming almost 80 liters a year by 2020 compared to the approximately 45 liters consumed by Asians. Still, per capita consumption of dairy products is expected to decrease 3% in North America while rising everywhere else from 2010 to 2020. To compensate for falling volumes, Tetra Pak advises processors to offer more value-added, individualized products to “an increasingly segmented” market. Demand for lactose-free milk, organic milk, fortified and functional milk is expected to grow with consumers increasingly proactive in safeguarding their health, particularly in developed countries where fertility rates are falling and the percentage of the population over 60 is growing. Around two-thirds of milk sold in the United States is private label. The economic downturn in that market sparked a faster drop in branded white milk sales than sales of private label milk from 2007 to 2010. “To recover lost sales, branded companies need to go beyond the logo on their milk: they need to add value – true nutritional benefits that private labels do not offer,” says Sheniqua Little, Tetra Pak’s marketing manager, dairy and dairy alternatives for the United States and Canada.
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Recommendations for staying competitive In the original 2008 report for the IC, researchers identified a number of structural weaknesses that could prevent the United States from capitalizing on the global market opportunity. As a result, the IC board recommended a series of pre-competitive industry initiatives to help the U.S. industry improve its competitiveness and stake a position as a globally consistent supplier. Those recommendations include: • Reform of U.S. pricing and risk management policies • Increased access to international markets • Improved responsiveness to serving product needs of global buyers. The window of opportunity cited in the 2011 report update won’t remain open indefinitely, echoes Tom Suber, president of the U.S. Dairy Export Council, Arlington, Va., which manages the globalization program on behalf of the Innovation Center. Suber is a Dairy Foods contributing writer. “As an industry, we have a limited ability to control the ‘size of the prize,’” he says. “What we can control is time – how quickly we move into this space to build a defensible, sustainable position against the inevitable emergence of new suppliers. “Global buyers see the United States as the natural source of future supply. But they await improved U.S. policies and practices that will permit a greater reliance on the United States as a consistent global supplier rather than as a residual one,” Suber explains. The Globalization IFT BoothOperating #2737 Committee will continue work programs in seven strategic areas: price risk management, quality and traceability, product standards, sales and marketing capabilities, innovation, as well as monitoring of industry efforts in pricing reform and trade treaties.
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joined the Beijing facility as a food technologist.
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Kemin, Des Moines, Iowa
appetizer and non-refrigerated snack product development. Meanwhile, John
technical sales manager for the food technologies division, responsible for
Brody was promoted to senior technology principal.
managing customer accounts and sales in the Southern region.
David Michael & Co.,
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Adam Synoground was named
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Blommer Chocolate Co., Chicago
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countries. Mendoza is bilingual and maintains
Kim Swisher and Caitlin Harvey joined the Union City, Calif., office as R&D
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Autocrat LLC, Lincoln, R.I. Caroline Hennigar-
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try experience.
responsible for generating new products, innovation and technical services.
Vogel was named director of quality assurance
Denali Ingredients, New Berlin, Wis.
Delkor Systems, Minneapolis
and research and development, responsible for
Doug Allen was named business development director of stabilizer systems,
Mike Wilcox joined on as vice president of
working with marketing,
responsible for managing the compa-
sales, marketing and aftermarket services, bringing more than 25 years of domestic and
sales and operations to ensure that QA and R&D objectives are aligned with
ny’s current customer relationships, while overseeing new product develop-
international sales and marketing experience in packaging. Meanwhile, Fred Green was
business needs and external expectations. She will also oversee planning and
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execution of product reviews, technical
D.D. Williamson, Louisville, Ky.
extensive senior management experience in manufacturing and engineering.
investigations, formulations and process improvements, and will spearhead new ingredient/processing technologies.
Mark Larson was named strategic account manager for the dairy sector.
Vogel
Fristam Pumps USA, Middleton, Wis. L u i s M e n d o z a joined as regional sales manager for Mexico and Central America, responsible for the distribu-
Allen Flavors Inc., South Plainfield, N.J. Mike Kelly was added to the sales team, bringing more than 13 years experience in the flavor, beverage and related industries.
Darigold, Seattle, Wash. Jim Wegner was named president and CEO of Northwest Dairy Association and Darigold, replacing John Underwood, who retired. In his 35 years in the dairy industry, Wegner spent 28 as director of dairy operations overseeing plants in both the United States and Canada.
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WAS H I NGTON
WATC H
News & Trends
Tipton’s Video Touts Simple Approach for Dairy Reform, IDFA Submits Letter Urging Congress to Pass FTAs Growing global demand and the business it’s bringing to the United States “is a total success story for the U.S. dairy industry,” says Connie Tipton, president and CEO of the International Dairy Foods Association (IDFA), Washington, D.C. This and other topics are discussed in Tipton’s latest video, “Coffee with IDFA: Dairy Policy with Connie Tipton.” In this 17-minute, 15-second YouTube video, Tipton emphasizes the importance of getting the right policies in place “so we can take full advantage and be a consistent exporter in these markets.” She calls for keeping policies simple, getting rid of the Dairy Product Price Support Program, providing adequate funding for the Livestock Gross Margin for Dairy program, setting up tax-deferred savings accounts for producers and simplifying the milk pricing system. Go to http://www.youtube.com/watch?v=9q_Q33t0ttA to view the video. In addition to Tipton’s push for dairy reform, a coalition of more than 120 agriculture and food organizations, including IDFA, submitted a letter to Congress and President Obama emphasizing the importance of passing the pending free-trade agreements (FTAs) with South Korea, Colombia and Panama. The agreements, which feature strong benefits for dairy exports, appear to be gaining renewed momentum now that the debt-limit deadlock is over.
“It’s difficult to watch years of market development evaporate in a matter of months because we are not able to compete on the basis of price, making the United States the residual supplier where it was once the main supplier,” the coalition letter said. “U.S. agriculture is prepared to work to achieve the full benefits of these agreements but can only do so if the U.S. government moves quickly to pass these agreements.” The agreements previously stalled over renewal of the expanded trade adjustment assistance (TAA) program, which provides financial aid and training to displaced workers. The administration said it will not submit the three agreements to Congress without reaching a deal to renew TAA, but Republicans consistently oppose combining the two. The latest reports say several leading members of Congress are currently working on solving the dispute and may be close to a deal. “While IDFA had hoped that these important agreements would be passed before the August recess, we are optimistic that they will take a high priority when Congress meets in September,” says John Kelly, IDFA manager of international affairs. “It’s important to get these deals passed as quickly as possible because other dairy exporting countries like the European Union already have agreements with important markets, including South Korea. We are already seeing a quota disadvantage of 4,560 tons for cheese in that market.”
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Dairy Foods | September 2011
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News & Trends
MilkPEP Unveils MyPlate Ad in USA Today The Milk Processor Education Program (MilkPEP), Washington, D.C., placed an ad in USA Today to emphasize milk’s important place on the table and its role in overall wellness, as shown through MyPlate. “Positioning dairy choices right next to the plate on America’s table is a great way to remind us of the importance of what we eat and drink,” says Vivien Godfrey, MilkPEP chief executive officer. MyPlate is part of a multi-year, government nutrition communication initiative that provides consumers with easy-to-understand recommendations and a new website, www. ChooseMyPlate.gov, along with other tools and resources.
B R I E F LY … LALA-USA Changes Name to Borden Dairy LALA-USA is changing its company name to Borden Dairy Co., a subsidiary of Group LALA. This name change is designed to
Arla Foods Expands Production
create a single corporate identity for the Dallas-based company, moving it closer
ed cheese production at its Hollandtown facility in Kaukauna, Wis. The enhanced
to becoming more consumer-centered
dairy facility produces havarti, Gouda, Edam, fontina and Muenster cheeses.
in its approach to the market and more effective in its day-to-day operations.
Dairy Foods | September 2011
Arla Foods Inc., Basking Ridge, N.J., expand-
This newly focused business unit will be tasked with all functions, including manu-
C.F. Sauer Sells Dean Foods Margarine Operations
facturing and distribution of the LALA, La Creme, Frusion and Weight Watchers
C.F. Sauer, Richmond, Va., sold its Dean Foods margarine operations, includ-
brands. To support continued growth, the
ing a plant in Sandston, Va., to Bunge North America, St. Louis. The food and
company also created a shared services center to process transactions while freeing up business unit finance and support staff to focus on providing decision support to the business unit leadership. The objective is to have company-wide transaction processing consolidated in the shared services center during 2012. Borden Dairy ranks 16th with 2010 sales
18
of $2 billion on the Dairy 100, Dairy Foods’ annual ranking of processors.
feed ingredient company will immediately begin operating the eastern Henrico County plant, which employs 160 people, and intends to hire most of the employees there. Bunge also bought the margarine production and packaging assets of C.F. Sauer’s New Century, Kansas, facility, which will close at an unspecified date.
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Functional Ingredients in Dairy Foods Date: Thursday, September 22 Time: 2:00 p.m. ET Webinar Duration: 60 minutes Register: webinar.dairyfoods.com Dairy foods — cheese, cultured, fluid and frozen — serve as ideal delivery vehicles for all types of functional ingredients, including specialty fatty acids, fiber, minerals, probiotics, vitamins, whey proteins and more. This is because most dairy products are stored under temperature-controlled (chilled or frozen) temperatures and have a limited shelf life. These conditions ensure that the consumer enjoys the product and reaps the benefits promised. On September 22, 2011, from 2:00 to 3:00 pm ET, Dairy Foods will explore recent innovations in functional dairy foods. This will be complemented by an overview of how nutrition authorities and consumers are educated on the health and wellness benefits that functional ingredients provide, especially when they are delivered in calcium- and protein-dense dairy foods. Webinar attendees will gain insight to what’s new in functional dairy foods, and how industry is educating consumers about the health and wellness attributes associated with these products. They will be able to take this knowledge and get creative in their own R&D and marketing departments.
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Webinar Schedule: Dairy Foods’ Product Development Editor Donna Berry sets the tone for this webinar with a review of some of the most innovative functional dairy foods introduced in the past year.
Lori Hoolihan, Ph.D., R.D., a nutrition research specialist with the Dairy Council of California, will describe the council’s efforts to educate consumers about functional dairy foods.
Wayne Geilman, Ph.D., the chief food scientist at Salt Lake City-based TCBY, The Country’s Best Yogurt, will discuss the company’s most recent innovation: Super Fro-Yo. This product is loaded with ingredients that support digestive health, weight management, bone health and the aging process, without sacrificing great taste.
Can’t attend live? Register and watch ON-DEMAND. Questions? Email
[email protected] or visit www.bnpevents.com
News & Trends
SUPPLIER NEWS G EA Process Engineering acquired
can provide products and services in
Construction at the St. Louis location
Nu-Con Ltd., Auckland, New Zealand. Nu-Con will be integrated into GEA Pro-
Central and South America as well as Caribbean countries.
began last month and will be wrapped up by Jan. 31, 2012. The expansion in India
cess Engineering under the brand name GEA Nu-Con and will be part of the food
Hawk Measurement launched a rede-
drying systems strategic business unit,
signed website, www.hawkmeasure.
Virginia Dare continues its commitment
which also includes GEA Niro, GEA Avapac and GEA Colby. The transaction is
com, which illustrates more than 32 different applications to help compa-
to sustainability and the environment by joining forces with “Hike forkaTREEna,”
expected to be completed in September.
nies make the right decisions about measurement technologies related
a New Orleans-based non-profit organization dedicated to replanting the city’s
PL Thomas, in association with Isocell
to their specific applications. The site
trees lost in Hurricane Katrina’s after-
S.A., Paris, released the results of a new human clinical study using their
also includes company news, upcoming events, press releases, data sheets,
math. A grove of trees was planted along Lake Pontchartrain.
exclusive dietary supplement ingredient, GliSODin in The International Journal of
manuals, brochures, software and market-specific solutions.
Buckhorn Inc. acquired tooling assets
Sport Nutrition and Exercise Metabolism . GliSODin supplementation demonstrated positive effects on selected inflammatory markers in a 2,000-meter rowing ergometer test.
Hydrite Chemical purchased Choice Chemical. Choice Chemical’s Visalia, Calif., headquarters expands the
Improvements L.P. for a new reusable plastic container used in producing, shipping, storing and processing bulk
geographical reach so that customers can be better served. It also allows the two companies to expand their product offerings in the dairy, food and beverage industries.
natural cheese. Buckhorn’s new plastic 640 container has a 710-pound fill capacity, reduces waste and improves sanitation and quality by replacing wood boxes, which can splinter and contaminate cheese during the material han-
brands to Portola’s 38-millimeter tamper-evident, drop band, plug closure, known as the DBJ. Also included in the conversion are Kroger’s juice and tea beverages.
CP Kelco’s Keltrol and Kelzan lines of xanthan gum products are registered on the recognized ingredient list for the United States Environmental Protection Agency Design for the Environment (DfE) program. Products and ingredients
dling process.
SensoryEffects established SensoryEffects International, based in Deland, Fla. It will be led by David Lee, director of international sales, and will serve as an international export arm for all divisions of SensoryEffects, including Flavor Systems, Powder Systems and Cereal Systems. With this new arm, SensoryEffects
bearing the DfE logo signify that they help protect the environment and are safer for families.
which launched at Siemens 2011 Automation Summit, June 27-30 in Orlando, is a 53-foot mobile showcase featuring a broad portfolio of process instrumentation, process analyzers and process automation products and solutions. For more information, go to https://blogs. siemens.com/measuringsuccess.
The Kroger Co. awarded Portola Packaging 100% of its milk closure business. Kroger is in the process of converting all of its fresh milk bottle
will be completed by the end of this year.
and intellectual property from Material
ROHA Food Colors invested $5 million to expand the St. Louis location, and is completing a $15 million expansion at its world headquarters in Mumbai, India.
Siemens launched a “Measuring Success” tour designed to connect cust o m e r s w i t h t h e l a t e s t i n p ro c e s s instrumentation and analytics. The tour,
Connect with Dairy Foods Online Dairy Foods maintains a robust online presence. We update our blogs several times a week. On Mondays, the FSI Report reports on dairy-related activity in free-standing inserts. Midweek, executive editor Marina Mayer shares her Marketing Musings about the latest campaigns from milk, cheese, ice cream and yogurt processors. Chief editor Jim Carper ends the week with his Dairy Case, a summary of the week’s news about processors, products and people. Read them all at www.dairyfoods.com/Articles/blog.
20
Dairy Foods | September 2011
Check dairyfoods.com for regular news updates and to view our digital edition and special archived features, like the Dairy 100 ranking of dairy processors and Behind The Scenes, a photo gallery of processing plants. Interact with us on Facebook (www.facebook.com/DairyFoods) where we post photos and links related to dairy foods and beverages. Join the Dairy Foods Magazine Professional Network on LinkedIn where you can share advice about best practices in dairy processing or pose a question to the group.
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New Products & Marketing
DAIRY MARKET TRENDS
Are Frozen Desserts Heading for Hibernation? Marina Mayer Executive Editor
T
he idea of biting down into a frozen dessert on a humid summer day is both refreshing and chilling. Just the mere thought of ice cream melting in your mouth or the imagery of racing to finish it before any chocolate melts is what summertime is all about. But, now that school is back in session and the long days turn into dark nights, it’s safe to say that most frozen desserts also hibernate for the winter. However, according to Chicago-based SymphonyIRI Group, sales of frozen desserts tend to paint a somewhat conflicting picture. Sales of frozen sweet goods (excluding cheesecake) fell 3.8% to $199.8 million in the 52 weeks ended July 10, 2011. Private-label brands snagged the top spot with $35.1 million in sales, which was an 11.8% drop from the previous period. No. 6 Mrs. Smith’s, produced by Schwan’s Consumer Brands, Bloomington, Minn., also saw a drop in sales (11.5%). And sales for No. 9 Duncan Hines Homestyle, produced by Pinnacle Foods Group, LLC, Mountain Lakes, N.J., tumbled 41.2%. Not all frozen sweet goods watched sales melt, however. Delizza, owned by Delizza Inc., Battleboro, N.C., retained its No. 5 slot with a 27.4% uptick in sales, while Weight Watcher’s Smart Ones, a division of Pittsburgh-based H.J. Heinz Co., snagged No. 7 with a 17.6% increase in sales. Cheesecake segment produces roller-coaster results The frozen cheesecake segment also produced some rollercoaster results. Sales increased 25.5% for No. 7 Atlanta Cheesecake, Kennesaw, Ga. Sales of private-label brands, which rank second, rose 19.2% and No. 4 Cheesecake Factory, Calabasas Hills, Calif., watched sales increase 13.6%. No. 1 Sara Lee, from Sara Lee Corp., Downers Grove, Ill., retained its No. 1 spot from last year. Its sales dropped a scant 0.1%. Its sister brand, Sara Lee Bites, fared way worse, plummeting 60%. Cheesecake sales also crumbled for others. Chicago-based Eli’s Cheesecake brand, Eli’s, which claimed No. 8, experienced a sales decline of 37.2%; followed by Yoder’s (14.2%); The Father’s Table, by the company of the same name in Sanford, Fla., (13.6%); and Buffalo, N.Y.-based Rich’s Products’ Jon Donaire brand (10.3%).
24
Dairy Foods | September 2011
Top 10 Brands of Frozen Cheesecake Brands
Dollar Sales (millions)
% change vs. yago
Unit Sales (millions)
% change vs. yago
1
Sara Lee
$36.7
-0.1
7.1
-1.0
2
Private Label
$16.5
+19.2
1.8
+15.1
3
Jon Donaire
$4.6
-10.3
0.6
-10.1
4
Cheesecake Factory
$4.3
+13.6
0.2
+13.6
5
Sara Lee Bites
$1.5
-60.0
0.4
-60.0
6
Edward’s
$1.4
-4.9
0.5
-10.0
7
Atlanta Cheesecake
$1.0
+25.2
0.2
+28.6
8
Eli’s
$0.4
-37.2
0.1
-59.0
9
Yoder’s
$0.3
-14.2
0.1
-12.9
10 The Father’s Table
$0.3
-13.6
0.0
-35.4
For the latest 52 weeks ending July 10, 2011 Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com Total U.S. – Supermarkets, drug stores and mass merchandisers (excluding Walmart)
Whip brands fail to whip into shape Unlike other frozen dessert segments, several frozen whip brands cooled off even before the seasons began to change. No. 8 Rich’s Real Whip took the biggest hit, seeing sales dive 27.4%. Northfield, Ill.-based Kraft Foods’ Cool Whip snagged four spots on the chart, coming in first with a 2.2% drop in sales, while Cool Whip Free, Cool Whip Lite and Cool Whip Sugarfree retained their third, fourth and fifth positions with a 3.7%, 12.8% and 17.4% drop in sales, respectively. Even private label (No. 2) experienced a 2.5% decline in sales. On the flip side, Rich’s saw an uptick in sales, reclaiming its No. 9 slot with an 84.4% jump in sales. Similarly, Kineret (No. 10) produced a 28.7% rise in sales, trailed by Truwhip, produced by Peak Foods, Colorado Springs, Colo., with a 22.7% increase in sales. The idea of a frozen dessert may be exhilarating, but sometimes even that isn’t enough to keep certain frozen dessert segments out of an early hibernation.
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New Products & Marketing
NEW PRODUCT REVIEW silky texture. Flavors are blackberry and raspberry, cherry, mango and pineapple. There’s also a version with large and fresh chunks s of fruit on the bottom. Flavors are mixed berry and strawberry. Activia mi Selects Greek is thick and creamy Sel blended nonfat Greek yogurt that is blen high in protein. Flavors are blueberry, pomegranate and berries, strawpo bberry and vanilla. And last, there’s Activia Selects Parfait, which is a blend of creamy loww fat Activia yogurt, fruit pieces and crunchy granola on top. Flavors cru are mixed berry, peach, strawberry and vanilla. All Selects come in 6-ounce cups and have a suggested 6-o retail price of $1.29. retai The Dannon Co., White Plains, N.Y., extends the Activia brand to four new styles of yogurt under the sub-brand of Selects. New Activia Selects offers consumers authentic yogurt recipes with the benefits of the company’s unique probiotic culture Bifidus Regularis (Bifidobacterium lactis DN 173 010), which has been clinically shown to help naturally regulate the digestive system when consumed daily for two weeks as part of a balanced diet and healthy lifestyle. Activia Selects French is whole milk yogurt that comes in two forms. There is a blended European-style with a smooth and
The Coffee-mate brand from Nestlé USA, Glendale, Calif., which is associated with nondairy coffee creamer in powder and liquid form, can now be found on refrigerated dairy creamers named Natural Bliss. Sold in 16-ounce bottles topped with a convenient recloseable pour spout, Natural Bliss is described as being made with only four simple ingredients: milk, cream, sugar and natural flavor. Available in three varieties — caramel, sweet cream and vanilla — the creamer was created to offer dairy lovers the option to add flavor to their coffee, naturally, according to the
company. But its use does not stop with java. The company is further promoting Natural Bliss as a cooking and dessert cream through culinary efforts by Claire Robinson, host of “5 Ingredient Fix,” a Food Network series featuring recipes made with five ingredients or fewer. Natural Bliss counts as one. “Coffee-mate has been the coffee creamer brand of choice for generations, and millions of people around the world can choose from more than 20 flavors to personalize their cup of coffee,” says Vilma Livas, marketing manager. “Now with Natural Bliss we’re giving people who whiten their coffee with dairy an opportunity to experience the delicious flavor that Coffee‐mate is known for in a brand new, all-natural way.” Germantown, Wis.-based Gehl Foods Inc., brings new opportunities to the alternative beverage (ambient) aisle with the introduction of Main St. Café Protein Smoothies. Sold in 11-ounce plastic bottles, the shelf-stable smoothies come in
NOTEWORTHY INTRODUCTIONS KB Treats LLC, Elmwood Park, N.J., expands its Q-Bees frozen novelty line with Brown-ees. The product combines two beloved desserts — premium vanilla ice cream and a rich, chocolate brownie — into one.
26
Dairy Foods | September 2011
G Series Fit Recover 03 is the latest invention from Gatorade, a brand of PepsiCo Inc., Purchase, N.Y. This 120-calorie protein restorative smoothie (11 ounces) contains 12 grams of protein from hydrolyzed whey protein, 14 grams of carbohydrates and an array of vitamins, minerals and electrolytes. It is also enhanced with conjugated linoleic acid (CLA), a fatty acid that has been shown to reduce body fat and increase lean muscle mass.
New Products & Marketing
taste throughout distribution. Through a unique aseptic process, the company u rapidly raises the smoothies to foodrap safe sa temperatures before cooling and packaging them in a sterile environp ment, eliminating the microorganm isms that cause ordinary dairy foods i to t spoil. This enables the drinks to be shipped and sold unrefrigerated — without compromising their fresh dairy taste.
mixed berry, peach and strawberry flavors. They are the only shelf-stable bottled smoothies in the market made with yogurt; however, the sterilization process does inactivate the cultures. “We’re packaging today’s popular dairy trends to fit consumers’ busy lives,” says John Slawny, vice president-sales and marketing. “Main St. Café captures the existing growth in niche protein products and foodservice smoothies, and brings them together in a fresh, simple way for the broader beverage market.” Gehl Foods begins with real yogurt made fresh on site, providing an excellent source of both natural milk protein and calcium. Each smoothie has 10 grams of dairy protein and 30% of the daily value for calcium. Most important for Gehl Foods, however, is maintaining the beverage’s fresh, creamy
The Kalona SuperNatural brand was launched in 2010, but its origins began five years earlier as the brainb child of owner Bill Evans. In 2005, c Evans started Kalona, Iowa-based E Kalona Organics, distributing K Farmer’s All Natural Creamery dairy products and Cultural Revolution yogurt. In 2010, these brands were consolidated under the new family brand name Kalona SuperNatural. Recently the company added organic sour cream and organic cottage cheese to the brand. The latter comes in two varieties: regular (full fat) and reduced fat. Both cottage cheeses are cream-on-top formulations, which add to their natural richness that is also based on being nonhomogenized and void of stabilizers and emulsifiers. The lack of such additives provides for an ultra-clean mouthfeel. The sour cream, too, has a simple ingredient legend: organic milk and cream and cultures. Subscribe to Dairy Product Innovations (www.dairyfoods.com/dpi), an e-newsletter focused on new dairy products and new products and services from dairy industry suppliers.
I N T E R N AT I O N A L Coconut water has emerged as the “it” beverage among Americans who seek out the latest in health and wellness foods and drinks. Not only have majorr multinationals invested in coconut water brands, but this is ingredient is showing up in everything from makeup to iced tea. Now coconut is taking center stage in a new yogurt from Group Danone in the Netherlands. Coconut & Lime Yogurt includes coconut pieces and coconut milk, as well as real lime juice. Although it doesn’t actually include coconut water, it is reasonable to assume that a North American version of this product could highlight this trendy ingredient. Further, tropical flavors readily complement the flavor profile of coconut, which aligns with American’s growing interest in Latin and Asian cuisines. Provenance has been a buzzword d in the food industry for the past sev-eral years and momentum behind it continues to build. Connecting ingredients to a particular place of origin has become a mainstream marketing strategy, but in the dairy category, it is usually related to local milk production. In Sweden, Arla Foods shows that it is possible to make provenance have a more global reach. This dairy processor’s Touch of Africa range includes unique ingredients that are native to that continent. The Melon/Lemon/Baobab Drinking Yogurt features the fruit from the baobab tree, which is native to southern Africa and boasts exceptionally high vitamin C content. Another variant, Pomegranate/ Hibiscus/Cardamom, includes flavors that are better-known to European consumers but are far from mainstream.
Contributed by Krista Faron, director of innovation and insights, Mintel Research Consultancy, Global New Products Database (GNPD). For more information call 312-9320400 or visit www.gnpd.com.
Continued on page 28 www.dairyfoods.com
27
New Products & Marketing
NEW PRODUCT REVIEW: FOCUS ON COFFEE DRINKS Back-to-school shopping lists for college coeds often include shelf-stable energy beverages that help with pulling late-nighters to study for a test, write a paper or simply have fun being at college. In recent years, coffee-milk beverages have emerged as a betterfor-you option, compared to Red Bull and its many copy cats, and beverage manufacturers are showing consumers that this category has a lot of room for innovation. These innovations capitalize on the growing trend in iced coffee beverages, which according to the NPD Group, Port Washington, N.Y., account for about 20% of sales in coffeehouses and quick-serve restaurants, with more than 1.2 billion servings in 2010. Just in time for the return to campus, Target Corp., Minneapolis, debuted Archer Farms Coffee Energy Drinks, which come in sleek 11-fluid-ounce cans and are sold individually for $1.99 at Target stores nationwide. The drinks start with a base of coffee and reduced-fat milk and the sweetener is sucralose. This keeps calories down to 100 per serving and fat grams at 1.5. Each can contains 65 milligrams of caffeine from the coffee and added caffeine. Labels indicate that the drink is also infused with vitamins (25% of the daily value for niacin, riboflavin and vitamins C, D and B6) and supplemented with wit calcium (10% of the daily value). Target Tar also adds Hazelnut Biscotti to its Archer Farms Farm ready-to-drink latte line. Packaged in 9.5-fluid-ounce glass bottles and sold in packs of 9.5-f four, fou the drinks start with a base of low-fat milk and an brewed coffee. Sweetness comes from a blend of sucralose and acesulfame potassium, b which keeps calories at 100 per serving. Woodway Beverage Partners LLC, Houston, Texas, teamed up with worldreknowned chef Wolfgang Puck to now offer a line of single-serve, readyto-drink, signature coffee beverages t that carry the tagline: Culinary Iced t Coffee. Certified organic, the drinks C come in four flavors: Café au Lait, c Crème Caramel, Double Blend Mocha C and a Vanilla Fusion. Seattle’s Best Coffee, part of Starbucks Corp., Seattle, introduces a line of iced canned lattes made with the 28
Dairy Foods | September 2011
same premium coffee as the Seattle’s Best Coffee hand-crafted beverages. The line includes: Iced Latte, Iced Vanilla Latte and Iced Mocha Latte. A 9.5-ounce can retails for $1.49 or in a four-pack for $4.99. The product line builds on the company’s 2010 marketing strategy of “Anywhere Great Coffee Is Needed,” “…by bringing a new kind of convenience to iced coffee, which is the fastest-groww ing segment in premium coffee,” says Michelle Gass, president of Seattle’s Best Coffee. “Through our test we confirmed that consumers are looking for a great-tasting iced coffee beverage in an on-the-go format and at only 130 calories per serving, it’s a product they can enjoy at breakfast and throughout the day.” IItaly-based illycaffé recognizes that not everyone has tthe time to sit and savor a cup of its freshly brewed illy espresso coffee, especially busy Americans. So the company teamed up with The CocaCola Co., Atlanta, to form the joint venture Ilko Coffee International, and now its beverages are portable and in the h increasingly popular “chilled” format. The illy issimo Italian Espresso Style Coffee Drink line now comes in five varieties. The line debuted earlier this year with Caffè (a bold, full-bodied, espresso-style coffee drink with a touch of sweetness), Cappuccino (rich espresso blended with low-fat milk and cocoa) and lo Latte Macchiato (a smooth L espresso-style coffee drink e with w a hint of milk and sugar). Most recently Caffè No Sugar (unsweetened and without milk and only 15 calories) and Mochaccino (with cocoa, a hint of milk and sugar, and only 100 calories) joined the line. The c latter is the first coffee made with the Domori brand of cocoa. All illy issimo coffee drinks have a suggested retail price of $2.39 for a single can. Four packs are also available for about $6.99. 䡲
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Ingredient Technology
LAB TALK
It’s Prime Time for Probiotics — Don’t Blow It!
I
’ve been a fan of probiotics for about 20 years, which is around the time Stonyfield yogurt became available in Chicago. Since, numerous dairy foods marketers, mostly yogurt manufacturers, have claimed that their products contain probiotics. Only a handful identify the strain on product packaging and supporting literature, and even fewer cite human studies supporting use of the term probiotic. Most use the term quite liberally, and disappointingly, it’s likely that many have little, if any, documentation that the probiotic provides the claimed health benefit. According to the International Scientific Association for Probiotics and Prebiotics (ISAPP), just because a product says probiotic doesn’t mean it contains probiotics. ISAPP cautions consumers on its website that some products labeled probiotic do not have clinically validated strains or levels in the product. Photo courtesy of Danisco
Dairy foods marketers touting probiotic culture inclusion should be able to identify the culture’s strain and its clinically proven health benefit, in order that consumers are confident in their investment.
The ISAPP definition for probiotics is the same as the one issued in 2001 by the Food and Agriculture Organization of the World Health Organization (FAO/WHO), which is: “live microorganisms, which when administered in adequate amounts, confer a health benefit on the host.” “There are hundreds of products claiming to be probiotic, but many are not,” says ISAPP president Glenn Gibson, a food microbial scientist at the University of Reading in the United Kingdom. “It’s important to remember that different strains of even the same species can have a different effect on the body.” Mary Ellen Sanders, ISAPP’s executive director who is based in Centennial, Colo., adds, “A probiotic is defined by its genus (e.g., 30
Dairy Foods | September 2011
Donna Berry
Lactobacillus), species (e.g., rhamnosus) and strain designation, which is often a combination of letters or numbers. The concept of a bacterial strain is similar to the breed of a dog — all dogs are the same genus and species, but different breeds of dogs have different attributes and different breeds are good for different tasks, so different strains of even the same probiotic species may be different from each other. You cannot assume that different strains of the same species will have the same effects.” Gibson emphasizes some key criteria of the ISAPP definition. “The microorganisms must be consumed live and in quantities that have been clinically proven to have a specific health benefit,” he says. “The studies should be performed in humans and published in peer-reviewed, reputable journals.” With that said, probiotic refrigerated dairy foods experienced more than $1.2 billion in retail sales (tracked at stores with $2 million-plus in annual sales, excluding supercenters) this past year, according to The Nielsen Co., New York. Yogurt controls about 90% share. But probiotic yogurt sales are flat, and probiotic milk and other cultured dairy foods sales are down. Could this be because consumers are confused? Or maybe they did not reap any benefits from consuming what some marketers call probiotic, and as a result stopped purchasing the product. Michael Neuwirth, senior director of public relations at The Dannon Co., White Plains, N.Y., says that the company has never used the word probiotic on Activia, since the brand was introduced to the United States in 2006. “We talk about probiotics on the website, but on the package, we promote the benefit of the particular strain we use, which is proprietary,” he says. Activia’s claim, which includes that the strain is alive and in sufficient quantities in each serving, is that it “contributes to the improvement of digestion discomfort as proven in clinical human trials.” “Our customers are purchasing the benefit, not the word probiotic,” says Neuwirth. “Dannon promises a benefit, not just the power of the buzzword ‘probiotics.’ We respect ISAPP’s definition, and are very forthcoming with the specific strain and the clinical data. It’s easy for other marketers to type the word probiotic onto marketing material without having the evidence. We have it…and the brand is thriving.” (Check out this month’s New Product Review on page 26.) The dairy industry needs to unite and do it right when it comes to probiotics. Creating confusion in the marketplace is a disservice to the consumer. If we don’t do it right, others will join us in doing it wrong. They already have. During the past two years, the term probiotic has shown up on everything from breakfast cereal to tea bags. And more are coming. In this country we are innocent until proven guilty, as prime-time live court room drama continues to play out. Let’s take probiotics prime time, with data to prove their efficacy. Donna Berry is the product development editor for Dairy Foods. She can be reached at 773-463-2467 or
[email protected].
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Ingredient Technology
CULTURALLY SPEAKING
Cultured Cream Products Must Live Up to the Name
O
ne of the best known cultured cream products is sour cream. This dairy product contains approximately 18% fat and approximately 7-9.5% solids nonfat. It is typically packaged in 8- to 16-ounce tubs. We put a dollop of it on our tacos or a baked potato, and mix it with onion soup mix or other flavor packets to make a chip dip. We refer to the product as “cultured” because it typically undergoes fermentation with a lactic acid bacterial culture. In contrast, when we refer to a person as being highly cultured, it conjures descriptors such as refined, sophisticated, polished and elegant. Why not position our cultured cream products to fit this image? Excuse me, but we are starting with the “cream” of the original milk after all. A silky smooth mouthfeel This cream fraction from milk has a lipid system unparalleled in taste and functionality. When it is standardized, processed and fermented into a cultured cream product, it takes on a silky smooth mouthfeel that is coupled with a lusciously decadent rich creamy taste and has a pleasing tangy finish that does not disappoint the palate. If you are skeptical, sit in a quiet room with a spoonful of a high-quality sour cream, close your eyes and try it. If you make cultured dairy foods, you might ask yourself if the product positioning fits the quality of the product. Is your sour cream package (the first impression of the product the consumer sees) befitting of a sophisticated, elegant product with a silky smooth texture and a luscious creamy taste? Or, is the package a predominantly white 16- to 24-ounce tub that could be easily labeled “generic sour cream”? Does the product messaging (print and other media advertising) remind you of this premium quality or does it sound ho-hum? Some might say their more generic product positioning supports mainstream 32
Dairy Foods | September 2011
mass marketing at a competitive price point. Today, with increased sophistication of the consumer, even the masses are seeking to have something special, and they are willing to pay a premium price. Producers of crème fraiche (a cultured cream product with up to twice the fat content of typical sour cream) saw this opportunity to redefine this fermented cream product with a little more “culture.” In today’s market, ingredient simplicity helps to define it as high quality. Some dairy brands market their crème fraiche as the only product that goes with caviar, and it only contains one or two ingredients. Products can easily sell for as much as $4-$5 a pint, which reinforces the positioning as the crème de la crème. Dairy processors market cultured dairy products as food ingredients, and they are teaching chefs how to use them effectively to further create demand in fine dining (see www.kendallfarmscremefraiche.com). Processing cultured dairy foods Now, being truly cultured cannot just be about the window dressing (packaging and marketing). The product must meet the message of sophisticated elegance to gain repeat purchase. Hence, the dairy processor must be well-versed in bacterial culture selection, cream processing, fermentation and quality assurance. Attention to cream handling, processing and related technology details can ensure that products do not have defects such as weak body, grainy texture, harsh acid flavor, whey separation, yeast and molds or package bulging associated with excessive carbon dioxide production. Weak body and/or grainy texture can be attributed to several factors, including incorrect formulation, excessive heat treatments, incorrect homogenization, incorrect culture use and lack of precision on fermentation conditions. Whey separation occurs when cream is low in
Phillip Tong
milk protein, there is insufficient acid development or the heat treatment of the cream was incorrect. The common flavor defect of harsh acid taste occurs when diacetyl production is low (insufficient citrate in cream), incorrect cultures are used or incorrect incubation temperatures are used that do not optimize a balance of acid and flavor compound production during fermentation. (For additional information on how to troubleshoot defects in cultured cream products, check out Cultured/Sour Cream, Chapter 18 in “Manufacturing Yogurt and Fermented Milks: by Ramesh Chandan, Ed., 2006; Blackwell Publishing). Because cultured cream products are used predominantly as a condiment or as an ingredient, they must have the proper ingredient functionality (for example, heat and acid stability for sauces and soups, proper viscosity and mouthfeel for dips and thickening and emulsification for other food applications). New cultures and other ingredients are also being made available that give processors additional tools to enhance existing product functionality, flavor, texture and shelf life or launch new cultured cream product lines to meet today’s more complex consumer expectations. Recognition of and effective communication to highlight the “true culture” of cultured cream products can create new opportunities and reawaken consumers to the excellent quality and versatility of cultured cream products in fine dining for meals at home or away from the home. When the dairy industry uses the best technology to put out great cultured cream products, they need to proudly dress them up and showcase them. 䡲 Phillip S. Tong is professor of dairy science and director of the Dairy Products Technology Center at California Polytechnic State University.
Learn more about the what, where and how of PUREFRUIT™ and its appeal with consumers! Download the insight report, “The PUREFRUIT™ Revolution” and visit www.purefruit.com. Tate & Lyle is a leading provider of high-quality sweeteners, texturants, wellness ingredients and innovative solutions for the food and beverage industry. Our passion for food shines through in everything we do, and we are dedicated to helping our customers create cost-effective, better-tasting, healthier and highly successful foods and drinks.
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Ingredient Technology
THARP & YOUNG
The Art and Science of Formulating
W
hat considerations are necessary when formulating “better-for-you” frozen desserts? In many respects, the answers are much the same as for formulating standard ice creams verses general dietary guidelines. These include formulations we already know, such as ice cream modified relative to fat (including reduced, low and fat-free; low/no cholesterol; and low/no trans-fat), carbohydrate (lactose-free, no sugar added, sugarfree, low carbohydrate and low glycemic index) and other nutrition-related hot topics (reduced calories, antioxidants, omega-3 oils, flavoring with “superfruits,” vitamin/mineral supplementation, probiotic-friendly dietary fibers, probiotics and others). Add to these, classic sherbet, water ice, sorbet and hybrid frozen desserts (for example, frozen yogurt and frozen cultured buttermilk), soft serve and other handheld formats (novelties). As with other foods, portion control can play a key role in fitting into any diet plan. Variety can be both good and bad. In doing good, what do you do? It is only possible here to cover a few general aspects of what needs to be taken into account when formulating healthy eating ice creams in the context of an overall wellness eating plan or diet. When formulating “better-for-you” ice cream, key considerations are what you wish to accomplish and what you want to promote about the finished food. These are determined by balancing marketing and other business-related objectives with regulatory limitations and allowances. That is, when considering a specific “better-for-you” claim, it is always good to consider (in addition to the health-related objectives) the practicality of achieving the necessary finished product weight per serving and to be aware of any compositional impact associated with achieving the targeted healthful properties, including their influence on flavor and structure. 34
Dairy Foods | September 2011
Working backward from a target finished weight per serving can help fix levels of certain compositional factors such as total fat, total saturated fat, total sugars, total carbohydrates, calories, etc. Further, if nutritionally efficacious ingredients (that is, “nutraceuticals”) are to be added, their use rates need to be worked into the basic ice cream mix and be at a level compatible with the predominance of scientific peer-reviewed literature for that specific nutrient or ingredient and the physical performance needs of the mix. Nutrient content targets are critical when considering nutrient content claims. Such claims are based on specific nutrients provided in specific amounts by specific serving sizes. In most instances, nutrient content claims can directly affect the nature of the mix composition to be used. They are also critical when health claims are involved. True health claims are claims that associate the intake of a nutrient (or nutrients) with the mitigation of one or more disease conditions. These claims are highly regulated and only allowed when approved by the Food and Drug Administration. Specific wording of such claims are also regulated. Qualified health claims may be allowed but, again, only as pre-approved. Sufficient scientific evidence must be available that supports the claim, and package terminology must be pre-approved by the FDA. Many times, health claims require one or more nutrient content claims or targets and general dietary restrictions in order to apply the claim. Be cautious in making health claims Structure/function claims are nutrition claims associated with some facet of healthfulness. Specific diseases affected may not be referenced and specific nutrient contents required can vary, depending on amount and type of supporting clinical research. Typically, the utility of such claims is up to the manufacturer and the manufacturer’s ability
Tharp & Young
to justify the sound scientific basis of the claim. Approval of FDA is not necessary, but the scientific validity and truthfulness of the structure/function claim must be defensible. Sometimes these type claims fall into the “truth in advertising” type regulatory environment. Thus, structure/function claims are less restrictive than other health claims. As always, it is advisable to seek the council of an appropriate scientific and regulatory authority when considering product claims of any type. Ingredients and nutrition targets Other factors also need to be taken into account. Flavors and flavorings can add significant amounts of total fat and sugars. The addition of particulate and variegated inclusions can make or break any nutrient-content target and, thus, any claim being sought. Economics becomes important as any given “better-for-you” ice cream may or may not meet financial objectives of the business. Direct or indirect claims, such as “natural” (for which no formal definition exists in the United States) or “organic” (which is defined via the United States Department of Agriculture’s National Organic Program), can also effect what can or cannot be done and can or cannot be claimed. How all this fits in to general dietary needs, consumer demands for wellness foods with sensory appeal and the very essence of business remains an evolving art, but certainly an art worth pursuing. 䡲 For more on radically innovative frozen desserts, including “better-for-you” products, attend the “Tharp & Young On Ice Cream: Technical Short Course, Clinics and Workshops,” Nov. 30-Dec. 2 in Las Vegas. Register at www.onicecream.com or call 610-975-4424 or 281-596-9603. Bruce Tharp and Steven Young wrote “Tharp & Young On Ice Cream: An Encyclopedic Guide to Ice Cream Science & Technology,” available this fall from DesTech Publications, www.destechpub.com.
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Cover Story Photo courtesy of Salt & Straw Ice Cream
Artisan
Ice Cream
The high-end sweet treat can take the heat of the economy Donna Berry Product Development Editor
S
ometime between Wall Street crumbling and the nation voting in its first African-American president, artisan ice cream makers sprouted up across the country. Some started selling their goods via a single-standing cart in a major metropolis, while others opened up scoop shops or packaged product for distribution through regional natural and specialty foods stores, as well as farmers’ markets and mail order. And despite challenging economic times, Americans seem to be more than willing to dip into their pockets for what many describe as “an affordable luxury,” positioning artisan ice cream as one of the most exciting dairy foods categories of this decade. Most artisan ice cream marketers agree that consumers understand that handmade and local sourcing equates to a higher cost. Credit the specialty cheese market, which during the 1990s provided a livelihood for numerous cheesemakers who had gone out of business when they were unable to compete with the efficiencies of mega-cheesemaking producers, but showed they could survive — and thrive — when they invested in creating artisan, farmstead and ethnic cheeses. Don’t nickel and dime the pint The difference between artisan cheese and ice cream is that cheese varieties are easily sold at a varying price per pound, which is often determined by ingredients, as well as the time and effort that goes into the making of the cheese. When it comes to ice cream, most marketers line price product, which means that all flavors in the same size package retail for the 36
Dairy Foods | September 2011
same price. This results in some varieties being profitable, others a wash and some sold at a loss. Though many presume that the “additional” ingredients such as candies, flavors, fruits, nuts and other inclusions drive ice cream manufacturing costs, these days it is often the base ingredients. According to the latest figures from the U.S. Department of Agriculture, milk prices have gone up about 40% in the past year, while sugar prices are up almost 20%. And though one would think high-fructose corn syrup suppliers would be giving away this highly functional and economical sweetener that received a ridiculous amount of unwarranted negative publicity the past few years, its price, too, has gone up, in fact, more than 20%. Yet, with all of the major ingredients edients in ice cream costing more, the U.S. Bureau of Labor Statistics says the average price of a half-gallon of ice cream has increased just 7%. Thus, even as the price of icee cream ingredients continues to go up, most marketers are not passing all off the expense onto consumers in fear of consumer backlash, especially in the retail environment. This is where artisan ice cream makers have some leeway, y, as they can charge a premium for their first-class offerings while consumers accept the surcharge. Photo courtesy of KB Treats LLC
Cover Story
Photos courtesy of Watson Inc.
Adding Color One Sparkle at a Time One of the latest crazes in the baked goods category is edible glitter, sparkles that come in a rainbow of colors, as well as metallic hues. Frozen dessert manufacturers can add excitement to their offerings by using the glitter as an inclusion, and scoop shop operators can offer it as a topping. The glitter comes in soluble and insoluble forms, with each version serving a different function. The insoluble form, which is based on sodium alginate, provides color specks dispersed throughout the mix. The glitter can function alone, or enhance the flavor of other inclusions. Edible water-soluble films can even be flavored and cut into shapes. For example, imagine red glitter or strawberry shapes dispersed in strawberry ice cream for an iridescent experience. Soluble glitter, which is based on gum arabic, can be added at the end of the ice
cream-making process right before the hard freeze. These specks will dissolve slightly (providing that freeze-thaw is kept to a minimum), bleeding color into the ice cream and delivering a swirl of color to the finished product. Different glitters with different solubility characteristics will help control the amount of color bleeding and therefore the swirl effect. This is similar to the way colors bleed off candies mixed into ice cream. The glitter can also be applied topically to novelties, in particular the chocolate coating on bars or the exposed ice cream between two sandwich wafers. The pearlescent pigment used in the metallic glitter is limited by FDA to confection applications. Thus candies and coatings with metallic glitter can be topically applied to frozen desserts.
For example, Wholes Foods charges $8.99 for a pint of artisan ice cream manufactured by Chicago-based Nice Cream. The ice cream maker is a big believer in using real foods that promote sustainable and environmentally sound-growing practices and touts the fact that it purchases mostly fresh produce and dairy from farms located within 100 miles of Chicago. This is showcased in Strawberry Cupcake, which starts with cream from Organic Valley Family of Farms Cooperative, LaFarge, Wis., and includes fresh strawberries — handpicked by owner Kris Swanberg — from Susie’s Garden Patch, Garden Prairie, Ill., and butter cream-frosted cupcakes from Southport Grocery & Café, Chicago. Even the pint packages rely on printing from a local design company. “Another summer ‘11 specialty is Chocolate Basil,” says Swanberg. “Think Chocolate Mint, but a little more adventurous. It includes 72% dark chocolate, which is high in antioxidants, and Chicago-grown freshly picked organic basil leaves.” In early August in the Pacific Northwest, artisan ice cream maker — Salt & Straw Ice Cream — opened its first scoop shop in downtown Portland, Ore. Until now, the company has marketed its “farm-to-cone ice cream,” which is made by hand in small best farmbatches using ingredients from some of Oregon’s O ers, producers and restaurateurs, restaurateur as well as a few imported flavors from fro small, known the world, via a sinfarms around th A novelty called Brownees from KB Treats LLC, Elmwood Elmwoo Park, N.J., combines comb premium vanilla van ice cream with a chocolate brownie. See the product packaging in this m month’s New Product Rev Review, page 26.
Kleinpeter Farms Dairy, Baton on Rouge, La., developed a 16% butterfat product named Creme de le Kleinpeter.
gle cart selling scoops and mail order. All ice creams start with high-qualityy cream from Lochmead Dairy, ry, Junction City, Ore., a fourththgeneration dairy whose cows ows were born right on the farm. arm. The hand-churned ice cream eam targets a 17% butterfat, with very little overrun, to ensure a creamy eamy texture and thicker bite, according ording to the company. A single 4-ounce -ounce scoop sells for $3.50. “We opened with our little le push cart just over two months ago and feel so lucky to have had such an incredible response,” says Kim Malek, founder and culinary director. Malek explains that the name Salt & Straw is a nod to making ice cream from scratch in the 18th century with pots of cream in a tin pail surrounded by salt and straws. With the scoop shop opening, customers can watch the ice cream makers hard at work creating each flavor by hand. Signature offerings include Cassia Cinnamon Snickerdoodle, which is made with Red Ape Cinnamon from Eugene, Ore. Three Berry Barbecue is made with Oregon huckleberries, marionberries and raspberries and swirled with a sweet barbecue sauce. Honey Lavender is made with lavender from Red Ridge Farms in the Willamette Valley wine country and honey from Oregon bees. Pear with Blue Cheese uses pears from Truitt Brothers Farms, Salem, Ore., and blue cheese crumbles from Rogue Creamery, Central Point, Ore. Continued on page 38 www.dairyfoods.com
37
Cover Story
“Ice cream is such a great way to celebrate and bring people together,” says Malek. “You can’t help but smile when you’re reminded of your childhood days of simple pleasures like licking an ice cream cone.” And those simple pleasures should not be hindered by location, which is why Salt & Straw debuted a mail order
business earlier this year. A five-pint variety pack commands $65 and can be shipped anywhere in the United States. Americans don’t seem to have a problem splurging on Salt & Straw ice cream, which motivated the company to offer a special holiday mail-order pack for that time of year when everyone digs a little deeper into their pockets to get into the
spirit of the season. The holiday pack includes innovations such as Bourbon Pecan Pie (fresh pecans, molasses, brown sugar and Oregon whiskey from Stone Barn on Portland’s Distillery Row) and Brown-Bread Stuffing (sweet brown bread, savory local herbs, fresh roasted Oregon chestnuts and tart apricots). Big-time players get artsy, too The national, and often at times global leaders, recognize that today’s consumers are drawn to premium ice cream as an affordable luxury. For example, Nestlé Dreyer’s Ice Cream Co., Oakland, Calif., a part of Nestlé USA, which is owned by Nestlé S.A. of Vevey, Switzerland, takes the Häagen-Dazs brand to a higher level of indulgence with the rollout of several “exclusive” and “limited-edition” flavors. True to the tradition of crafting ice creams made like no other, the brand has taken diverse cues from home and abroad to develop one-of-akind creations that delight the senses.
The national, and often at times global leaders, recognize that today’s consumers are drawn to premium ice cream as an affordable luxury. “This year we really focused on flavor experiences when looking for inspiration and ideas,” says Häagen-Dazs brand director Gulbin Hoeberechts. “A slice of holiday pie, a bite of fresh fruit from the orchard, a visit to the ice cream parlor, a trip to India — all of these led to the creation of our 2011 flavors...” These are: Blueberry Crumble (dense blueberry ice cream loaded with rich, buttery cobbler crust crumbles), Caramel Apple Pie (apple ice cream and diced fresh apple swirled with caramel and chunks of flakey pie crust), Cranberry Pumpkin Spice (pumpkin ice cream balanced with swirls of tart cranberry filling and lightly spiced with 38
Dairy Foods | September 2011
Continued on page 40
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Cover Story
Premium and indulgent ice creams are driving dollar sales of the frozen desserts category, which has experienced repeated years of reduced production volumes.
cinnamon and nutmeg) and Sweet Chai Latte (aromatic chai tea blended into a rich, creamy ice cream). The company has one flavor exclusive to Wal-Mart stores, which is Spiced Peach Crumble Ice Cream. It is described as peak-flavor
peaches that are cooked to perfection, lightly spiced and stirred into sweet cream with nuggets of buttery crust. n IIt is such out-of-the-bulkcontainer-thinking that is fuelcon ing frozen dessert growth for Kleinpeter Farms Dairy, L.L.C., Klei Baton Rouge, La., which continues tto grow its mainstream ice cream (12% butterfat) line and is expanding with some indulgence. expan “We are now up to 28 flavors in mainstream line, all of them the ma incorporating locally produced incorpo ingredients,” says Jeff Kleinpeter, ingredie president. “And this summer we debuted Crème de le Kleinpeter, a pint line featuring 16% butterfat ice cream and lots of indulgent, and at times, exotic ingredients. For example, Blanche et Blanche is sweet cream ice cream with white chocolate flakes and macadamia nuts. And we feature Louisiana-grown strawberries in the Strawberry Cheesecake with Dark Chocolate Truffles.” Riding the coattails of the artisanal trend in formulating all types of foods
with sea salt, Talenti Gelato e Sorbetto, Dallas, introduced Sea Salt Caramel gelato this summer. The flavor features rich, golden Argentine caramel (dulce de leche) made exclusively for Talenti, complemented by the finest fleur de sel — the prized sea salt from France — and tiny chocolate-covered sea salt caramel truffles. “The combination of sea salt and caramel has been a favorite amongst top French and American chefs for some time and has become a definite trend,” says Josh Hochschuler, founder and CEO. He points out some added incentives for consumers to buy Talenti. For one, the gelato contains about 30% less fat than regular ice cream. Further, in addition to its commitment to craftsmanship and sourcing quality ingredients, Talenti strives to be eco-friendly and minimize its impact on the environment. “Talenti is committed to embracing green business practices and finding new and innovative ways to minimize our impact on the environment,” says Steve Gill, president. “Our new #2 HDPE (high-density polyethylene) lids are just the latest example of this longstanding dedication to eco-friendly practices.” HDPE resin is easier to recycle than the polypropylene used in the original lids, according to Gill. (Read more about Talenti’s packaging in the June Dairy Foods, page 38.)
Seeing the popularity of sea salt, Talenti Gelato uses the ingredient in a caramelflavored gelato. Continued on page 42 40
Dairy Foods | September 2011
Cover Story
You Say Chocolate…I Say Vanilla Many consumers know that few treats conjure up a summer day memory as much as a dripping ice cream cone or digging into a sundae after a long day at the beach. But which flavor is always the big debate? Who doesn’t remember standing in front of the counter agonizing over that ever important decision? Well, for Americans, chocolate is the way to go as more than one-fourth (28%) say it is one of their two favorite ice cream flavors followed by vanilla (26%) and cookie dough/cookies and cream (22%). These are some of the results of The Harris Poll of 2,183 adults surveyed online between July 11 and 18, by Harris Interactive, New York. Different groups have their different favorite flavors. For example, three in 10 Easterners (31%) and Midwesterners (32%) say chocolate is their favorite while three in 10 Southerners (30%) prefer vanilla. Westerners have a close race for top flavor with 22% saying vanilla, 21% saying chocolate and 19% saying cookie dough/cookies and cream and rocky road. And, of course, there are also political differences in ice cream flavors. One-third of Republicans say chocolate is their favorite flavor (32%), followed by vanilla (28%) and cookie dough/cookies and cream (24%). One-quarter of Democrats,
Nostalgic flavors also continue to bring excitement to the frozen desserts category. Baskin-Robbins, a brand of Dunkin Brands Inc., Canton, Mass., offered scoop store patrons Picnic Punch as August’s feature flavor. This cool, refreshing watermelon- and green apple-flavored (red and green) sherbet swirl is reminiscent of classic hard candies that have always been a summer thirst quencher. Now they take the form of a classic
Photo courtesy of Salt & Straw Ice Cream
Using fresh and local ingredients, and touting their inclusion, is a growing trend among artisan ice cream makers. These efforts appeal to green consumers who are willing to dip a little deeper into their pockets in order to support the community. 42
Dairy Foods | September 2011
on the other hand, say vanilla is their favorite (26%) followed by chocolate (23%) and then butter pecan/Swiss almond (22%). For Independents, it is chocolate first (30%) followed by cookie dough/cookies and cream (24%) and then vanilla (22%).
Sea salt, chai tea, basil, white chocolate flakes and macadamia nuts are some notso-mainstream ingredients used by both artisan and large-scale ice cream processors. Nostalgic flavors also bring excitement to the frozen desserts category. sherbet dessert that is lower in calories than ice cream, but high in satisfaction and flavor, according to the company. “Sherbet is a classic ice cream alternative for those seeking a lower-calorie frozen dessert,” says Brian O’Mara, vice president of marketing. “Sherbets are wildly popular during the hottest months of the year, and we wanted to deliver a new fruity combination we know our flavor aficionados will enjoy. “Flavor enthusiasts are always seeking variety and originality in their ice cream and sherbet choices,” adds O’Mara. “The sweet, refreshing watermelon flavor combined with tart and tangy green apple flavor makes for a perfect summertime refresher that we think our guests will love.” With the summer of 2011 now behind us, frozen dessert formulators should be busy developing next summer’s big hits. And if what ingredient suppliers are saying is true, next summer will be even more dynamic than this year. Remember that better-for-you no longer translates to simply less fat or calories. It includes minimally processed ingredients and those considered green; indulgence and decadence reigns. The end result should be affordable luxuries that keep what is a relatively flat category alive and thriving.
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Ingredient Technology Photo courtesy of Dohler
Suppliers discuss natural and exempt colors, and how to match the color to the food. Donna Berry Product Development Editor
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olor plays an important role in food product development. In the dairy foods category, colorants are typically used to enhance or improve the color that consumers expect of their butter, ice cream or yogurt, rather than allure or shock, as in other categories such as beverage and confection. In the United States, synthetic food colors are classified by the Food and Drug Adminstration as color additives subject to certification (Title 21 Part 74 of the Code of Federal Regulations). They are certified with an FD&C number (indicating it has been tested for safety and is approved for use in foods, drugs and cosmetics, or FD&C), and further classified as standardized dyes or lakes. Dyes are a concentrated source of color and are water soluble and oil insoluble. Lakes, on the other hand, are made by combining dyes with salts to make them water-insoluble compounds. Thus, they are best described as providing color by dispersion. Lakes are considered to be more stable than dyes and are ideal for coloring products that either contain fat or lack sufficient moisture to dissolve dyes. Seven dyes were initially approved under the Pure Food and Drug Act of 1906. Over time, several have been delisted and replaced. Today there are still seven dyes, which can be combined into an infinite number of colors; hence, the seven are considered primary colors. FDA also provides a list of color additives that are exempt from certification (21 CFR 73). Some have synthetic origins or are processed in such a way that the perceived naturalness of the exempt color is questioned by natural foods authorities. Dairy Foods spoke with 11 suppliers of food colors to get their perspective of the industry. Here’s what they had to say.
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Dairy Foods | September 2011
Dairy Foods talked to: Rajesh Cherian, manager-application support-natural colors, Roha Food Colors Chad Ford, product manager-colors and specialty ingredients, Wild Flavors Inc. Emina Goodman, technical support manager-beverage and dairy group, Sensient Colors LLC Jim Hamernik, research and development director, Flavorchem Diane-Louise Hnat, senior technical marketing manager, DSM Nutritional Products Rodger Jonas, director-national sales, PL Thomas George Kean, director-colors R&D, Kalsec Inc. Stephen Lauro, technical services, colorMaker Inc. Byron Madkins, senior director-product development and applications-colors, Chr. Hansen Inc. Jody Renner-Nantz, application scientist, D.D. Williamson Kasi Sundaresan, manager-research, development and quality, iTi Tropicals Inc.
Dairy Foods: Are there any instances when it is impossible to avoid certified colors in dairy foods? Renner-Nantz: It’s almost never impossible to avoid certified colors in dairy foods; however matching the exact hue and stabilities of certified colors with exempt colors is where the challenge lies. It is easier in the hue ranges of yellow to orange and pink to red. Green and blue hues present a challenge over the
Ingredient Technology
wide pH range of dairy products. Blue hues are usually formulated with anthocyanins, which are blue at pH 7. Green is achieved through the mixing of blue and yellow, typically from turmeric. These blue and green hues have limited use since the blue hues degrade at neutral pH, typical of milk and some ice creams. Blue and green are also a challenge in low pH dairy products, such as yogurts and smoothies, since anthocyanins revert to a red hue in low pH foods. For the most part, dairy products are refrigerated or frozen and protected from light, so the light stability of pigments is not an issue. In terms of heat, exempt colors can withstand hightemperature short-time (HTST) pasteurization; however. most will not withstand ultra-high temperature (UHT) processing. Kean: One of the more difficult situations is using anthocyanins such as grape or black currant to color milk or ice cream pink. This is because the pH of milk and ice cream is typically greater than 5, and anthocyanin colors are not stable at this pH. The result is an unstable blue-gray color. There are other exempt colors such as beet and carmine that do produce stable pink hues under these conditions. Goodman: Natural color technology has advanced significantly during the past few years and we have been able to provide a wider variety of shades, allowing the dairy industry to have other options beyond certified colors. However, replicating the rich blue and green shades can still be a challenge. Cherian: Except when you need dark blues or bright greens, exempt colors are quite common in the dairy industry. For example, cheese has traditionally been colored with annatto, where protein interaction is an important factor in binding the pigment to milk protein. Butter has a standard of identity that allows for addition of beta-carotene, the naturally occurring colorant found in cows milk. Apo-carotenal, paprika oleoresin and turmeric are used in cheese spreads, dips, cheese powders and dairy-based dry blends. Yogurts and dairy beverages use watersoluble colors such as carmine, annatto, betacarotene, beet juice and turmeric concentrate to achieve specific shades of fruit. Certified colors are generally stronger, less expensive and provide the typical bright colors that consumers are used to. In order to achieve a similar color using exempt colors it is often necessary to use a more expensive color at a higher level, and even then, the resulting stability and color shade may not be as good. Photo courtesy of Flavorchem
Madkins: Exempt colors are the primary choice for the cheese and yogurt categories. Annatto is typically used to color cheese. It offers functionality not obtainable from any other color, as annatto specifically binds to the curd and does not wash away with the whey in the manufacturing process. Carmine is used frequently to obtain bright red and pink shades in yogurt that contains fruit preparations. Carmine is the only color that will bind to the fruit pieces in fruit preparations, providing a much more attractive final product by not allowing the fruit pieces to look washed out or gray/brown over time. Jonas: Botanical extracts can now bridge the gap for many of the color issues affecting a switch from lakes and dyes. What must be determined is how the manufacturing process, times and temperatures, pH and other factors impact the ingredient to be used. The other key parameter is storage conditions and expected shelf life. It is not enough to get the color right, you must meet the requirements for shelf life. Dairy Foods: Though exempt colors may be an option in certain dairy foods applications, when does it make sense for a manufacturer to stick with certified colors? Goodman: Companies who do not feel their consumers will see the value in changing to natural colors may choose to remain with certified colors. It really becomes a brand positioning decision by each company. Sundaresan: Exempt colors are often very expensive and usually require higher usage levels when compared to synthetic colors. Plus, many exempt colors are not very stable in different conditions, such as varying pH and temperature. Madkins: The use of exempt colors does typically involve a higher price than corresponding synthetic colors. However, as extraction methods and formulation concepts are becoming more optimized and improved, the cost differential between the use of natural and synthetic colors is not as notable as it was five or more years ago. The greatest color challenge with naturals is with blue and green shades. There are many options currently being evaluated for petitioning and FDA approval, including colors currently approved in other parts of the world. Ford: Exempt colors typically are more expensive than certified colors. The reasons for this are the cost of bringing the raw materials, such as fruits and vegetables, to market versus say, producContinued on page 46 www.dairyfoods.com
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Ingredient Technology
ing a chemical in a lab. Use rates are also typically higher with exempt colors, as there is more “stuff ” that comes along with them besides just pure pigment. Also, many manufacturers expect exact matches to their current products, but exempt colors may not always achieve the same vivid “artificial” look that comes with some certified colors, though they may be in the same ballpark. So, if manufacturers are unwilling to compromise on cost-in-use and potential shade differences, it may make more sense to stick with certified colors. Hamernik: Certified colors are generally stronger, less expensive and provide the typical bright colors that consumers are used to. In order to achieve a similar color using exempt colors it is often necessary to use a more expensive color at a higher level, and even then, the resulting stability and color shade are not as good. Exempt colors can additionally create off notes when used at higher levels. Lauro: One of the advantages of certified colors over those that are exempt is their extended shelf life, but this is seldom an issue with most dairy foods, which display a relatively short refrigerated shelf life. Another advantage enjoyed by certified colors is their significantly lower cost-of-use. While they may be priced similarly, pound-for-pound, certified colors are much stronger, whether in dye or lake form, and can therefore be used at levels as low as one one-hundreth of what you would need with an exempt color. Thus, the cost-of-use of the certified colors may become a factor in low-margin, high-volume dairy products. Another advantage of certified colors is their ease of
use. Minor color adjustments can often be made at the end of the process by personnel on the production line. This simply is not possible with exempt colors. The latter requires an in-depth understanding of both the color and the food system. An example is lemon-flavored ice cream. Sometimes the processor selects turmeric as a natural yellow color for this type of product, which is a good color choice. But the package may have a cellophane window, allowing the consumer to see the finished product. This is good for the consumer but bad for the turmeric, which is sensitive to light. The turmeric exposed to light in the package’s window fades and when the consumer opens the package, he or she may be greeted by a dull whitish circle on the surface of the ice cream surrounded by bright yellow lemon-flavored product. Dairy Foods: The term artificial colors is associated with certified lakes and dyes, and when certified colors are not used in a product formulation, marketers can use language such as “does not include any artificial colors.” Can you please comment on why most of the time they cannot say “naturally colored?” Kean: FDA only recognizes colors that are either exempt or nonexempt from certification. FDA does not recognize use of the term “natural color,” except in very rare instance when a manufacturer is using the same ingredient as the food to color it, for instance coloring cherry filling with cherry concentrate to enhance the red color. Renner-Nantz: Generally speaking, naturally derived colorings — those exempt from certification — are derived from natural Continued on page 48
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Dairy Foods | September 2011
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Ingredient Technology
sources, and synthetic/certified/FD&C color additives are manufactured from petroleum-based raw materials. The labeling of exempt colors continues to be a source of confusion. It seems intuitive that exempt colors should be labeled as natural since they are derived from nature; however, FDA has not defined the term natural as it relates to food colors and labeling exempt colors as natural is not permitted. However, exempt colors may be noted on the front principle display panel as “derived from natural sources.” If a food product is colored with an ingredient that is common to that food, for example, elderberry yogurt colored with elderberry color, then the product can be labeled as “naturally colored.” Photo courtesy of Comax
Lauro: Strawberry ice cream with added strawberry juice may be marketed as “all natural.” Unfortunately, it will not be very red because strawberry juice quickly turns brown even when frozen. On the other hand, strawberry ice cream colored with beet juice will be a vibrant red color, but because beet juice is not natural to strawberry ice cream, it is considered an artificial color in this application. Sundaresan: FDA clearly outlines the labeling requirements for colors. For example, spices such as paprika, turmeric, saffron and others that can be used as colorings, must be declared either by the terms “spice and coloring” or by the actual (common or usual) names, such as “paprika.” Exempt colors can be declared as “artificial color,” “artificial coloring” or by their specific common or usual names such as “caramel coloring” or “colored with beet juice.” Dairy Foods: Many food industry critics have issues with the perceived naturalness of exempt colors. What is the concern? Ford: Understanding color additives in the U.S. can be confusing due to the method FDA uses to classify colors. One reason many people become confused understanding color additives is because they look at color additives from the same perspective as flavors. Defining or classifying a flavor is quite different from defining a color additive.
A number of exempt colors are extracted from fruits and vegetables. Even though this seems “natural,” if it’s added to an unlike product, it is considered an artificial color.
Hnat: Artificial color, in the narrowest terms, refers to azo compounds, which are FD&C colors and must be cited on ingredient legends by the color and number. In the broadest sense, a color that is not inherent to a product, e.g., beet juice in strawberry ice cream, is also an artificial color. Even though beet juice is extracted from a natural source, it cannot be called a natural color. When it comes to beta-carotene, labeling options include: “color added (beta-carotene),” “beta-carotene as color” or simply, “artificial color.” In the case where beta-carotene is derived from a natural source, it can be labeled as “beta-carotene as color (from a natural source).” Ford: Color additives that are exempt from certification are generally termed “natural” within the industry, but are referred to as exempt colors in accordance with FDA regulations. According to FDA, an added color is natural only if it is inherently natural to the food holding the color. Still, the U.S. food industry commonly refers to exempt colors as natural colors. Hamernik: A color might be derived from natural sources, but is not considered natural when it’s used in a way not found in nature. For example, beet concentrate might be added to strawberry ice cream to obtain a pink-red color. Beet concentrate is natural but is not natural to strawberry ice cream. 48
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Cherian: Some take issue with the fact that beta-carotene can be extracted from a natural source or prepared synthetically, but either way, it is exempt from certification and the two forms are not differentiated on product labels. The food manufacturer should be responsible and choose a beta-carotene extracted from a natural source if they are marketing the product as one that does not contain artificial ingredients. Jonas: A purest believes that adding any ingredient for color is not natural. But because a food manufacturer is already mixing several ingredients to make a product, this is an area of much contention. Lauro: Most of the criticism surrounding natural colors has little to do with how they are extracted and more to do with how they look. The visual appearance of exempt colors is generally far lighter and more pastel than certified colors, which in comparison appear vibrant, strong, almost iridescent. When delving deeper into the methods of extraction, one will discover that oilsoluble colors such as paprika are often solvent extracted. Some question just how natural is an ingredient if it must be extracted by a solvent. But the majority agrees that when compared to the petroleum distillation processes by which all certified colors are created, exempt colors are pretty close to being natural. Madkins: Within the range of exempt colors, there are many sources and each is derived and extracted in different ways. For example, there are some colors, such as beet juice or purple carrot juice, where the color is simply expressed from the vegetable. In addition, there are colors such as turmeric, which are typically solvent-extracted in order to isolate and purify the color. And there are many different extraction and purification methods in between these two examples. A color like cochineal has an elaborate extraction process, from water extraction of the source to obtain cochineal extract, to the forma-
Ingredient Technology
tion of a calcium/aluminum lake, which is by definition, carmine, which is then alkali treated to obtain water-soluble carmine products. We recommend to our customers that they label color products by name. This falls well within and even exceeds FDA requirements. It is also the most informative for the end user. For example, if you are adding carmine and annatto to a yogurt, we recommend that you specifically state both on the label. With carmine, it is an FDA requirement. But they could simply state: carmine, color added. When using color products such as purple sweet potato or black carrot, we recommend that the customer use a statement such as “vegetable juice (for color).” If they want to specifically state the actual color sources, we will also provide that information.
ural sources. These colors can be achieved across the pH range of dairy environments. Black and brown hues can even be arrived at through combinations of blue with other natural colors. We also have an emulsion technology that allows for vibrant shades of orange, yellow and reddish-orange in water-soluble form. These emulsions are heat, light and pH stable, which make them well suited for dairy.
Hnat: Carotenoid blends can produce hues ranging from yellow to orange, and in dairy products, this provides a sense of richness, as the color is perceived as butterfat. It also suggests that the milk came from grass-fed cows, which typically have a beta-carotene-rich diet. Carotenoids are commonly used to color process cheese. The right carotenoid prevents pinking or fading of color, which can happen when Continued on page 50
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Dairy Foods: Most color suppliers have a few tricks up their sleeve. Can you share any? Madkins: Color stability in applications is our ultimate priority, and we have a range of microencapsulated natural colors that usually do the trick. We have taken the basic color pigment, such as bixin (annatto), carmine, paprika or turmeric, and have encapsulated it using food-grade ingredients to provide highly stable, waterdispersible pigments. As an example, a standard turmeric emulsion in a beverage usually fades when exposed to light, as turmeric is not very light stable. However, our encapsulated turmeric products will last for months with no loss of color. We also have a line of anthocyanin products (fruit and vegetable juices) where we take advantage of the inter- and intra-molecular interactions that occur between different sources, which in turn, provides increased stability in the finished applications, such as yogurt and dairy-based drinks. Goodman: We have made significant advancements in developing an acceptable blue shade. We previewed this exempt color at the 2011 IFT Annual Meeting + Food Expo in several applications, including dairy, and received an overwhelmingly positive response. As a result, we are testing it with interested customers under confidentiality agreements.
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Ford: We offer a natural acid-stable blue color derived from fruit juice, which allows for vibrant, even pastel-like colors in dairy that were previously unattainable with natwww.dairyfoods.com
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Ingredient Technology
the cheese is exposed to light. In addition, some carotenoids can be used to color ice creams and sherbets in the yellow to orange color range. Sundaresan: We supply fruit purée, which can be used to color various dairy foods. Each fruit is unique, having its own chemistry and stability, and thus usage is application specific. Fruits high in anthocyanins are most suitable in applications with a pH of less than 4. Beta-carotene is stabilized by the presence of ascorbic acid, while ascorbic acid will cause anthocyanins to degrade and fade. So the product developer has to consider different factors before usage of fruit ingredients. Lauro: It’s all about having an in-depth understanding of the color and the application. For example, a prepared food manufacturer may want to accent a product with blue cheese but cannot afford real Roquefort. A cheesemaker can select a color that delivers a shelf-stable blue-green color to produce a cheese sold as “blue cheese crumbles.” Cherian: Apart from offering total coloring solutions, we can customize hues and provide shade matching. We also offer caramel color substitutes that are from natural origin. Hamernik: We work with as many sources as possible to have access to the latest and best raw materials. We can use these items to mix and blend to achieve the desired color. Working closely with customers is key and allows us to thoroughly test the color to achieve the optimum result. Kean: If a manufacturer is looking for an all-natural paprika color for spray-dried cheese, we produce an oil-extracted paprika using only soybean or canola oil as the diluent. High-stability annatto and paprika pigments work well in spray-dried cheese, as they offer increased stability during the production of the powdered cheese as well as enhanced storage stability in snack seasonings. Renner-Nantz: Rather than simply offering a standard coloring, we work with dairy product developers and manufacturers to achieve exact hue wishes, which we validate in their specific product. For example, for an overseas cheese powder manufacturer, we recently converted an oil-soluble carotenoid coloring to a water soluble form of the same hue.
When formulating with any color, it is critical to meet FDA’s requirements for labeling. Dairy foods formulators should want to use exempt colors as a point of differentiation. They don’t want to attract unwanted scrutiny by using colors that are not permissible or labeled incorrectly. Photo courtesy of Sensient Colors LLC
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Jonas: Our tomato lycopene is unique in that it provides a stable red color in both acid and neutral environments and it survives HTST processing. We have refined it to include the option to add a blue hue and to not be sensitive to vitamin C. This exempt color can be declared in a number of ways on ingredient statements, including “color (lycopene)” or “tomato extract.” Dairy Foods: Looking inside your crystal ball, what’s next in the world of food colors? Kean: The outlook for food colors is exciting. There is widespread interest in cleaner labels both here and abroad and never before have natural colors been so popular in the U.S. Looking forward, there will be an increased need for low-cost production of raw materials in order to meet the increase in demand. Goodman: Aseptic packaging of colors will become increasingly more prevalent, as it allows for preservative-free exempt colors with enhanced shelf life. Renner-Nantz: Color manufacturers will continue to focus on improving emulsification techniques, which enhance the solubility of oil-soluble colors in water or water-soluble colors in oil. There will be more discussion and focus on nanotechnology from regulatory authorities as color product innovations develop. From a global perspective, color manufacturers will continue to evaluate new anthocyanin-containing fruits and vegetables, especially those with improved light stability that results from greater acylation of its chemical structure. Madkins: Consumers will continue to prefer foods that are label friendly and with ingredient legends reading “vegetable juice” or “annatto” instead of “FD&C Red No. 40.” Also, cleaner and greener methods for extraction and purification of exempt food colors will be a priority going forward. Hnat: There will be a continuation of the trend towards evaluation and use of colorants derived from natural sources, as well as the disclosure of the sources of color due to possible sensitivities. Jonas: Efforts will focus on improving color expression and stability, which should result in lower use levels to achieve the same color. The future is very straight forward, although simple-sounding, the work required is very involved and continuous in nature. Natural sources will eventually be the norm for all color applications. The issues with specific applications will get resolved as new sources and production techniques are developed.
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The Power of Packaging Dairy processors can pick the brains of packaging experts at the Las Vegas Convention Center in September.
T
he power of packaging is contagious. That’s why PMMI, the Reston, Va.-based organizers of Pack Expo 2011, is presenting one powerful show. Pack Expo 2011 is scheduled to take place Sept. 26-28 at the Las Vegas Convention Center in Las Vegas. Visitors will have the opportunity to connect with 1,600 world-class suppliers, check out total systems solutions and cutting-edge technologies and attend industry pavilions and an enhanced conference program led by industry leaders. The show will kick off with keynote speaker, General Colin Powell, former U.S. Secretary of State. In his address titled “Diplomacy: Persuasion, Trust & Values,” Powell will discuss how he defied racial barriers and how his leadership skills helped him found Chairman of America’s Promise Alliance, an organization that works with more than 400 partner organizations to provide resources that build better lives for America’s youth. Pack Expo remains home to the Processing Zone, where attendees can find innovative processing solutions for the food industry. The Reusable Packaging Pavilion, sponsored by the Reusable Packaging Association, Arlington, Va., showcases how choosing reusable pallets, hand-held containers, bulk containers, dunnage and other transport packaging solutions can raise productivity and profitability.
Attendees can swing by the Food Safety Summit Resource Center and learn from subject matter experts on the latest breakthroughs in food safety and receive insight into potential solutions. The Brand Zone—Containers & Materials that Shape Winning Brands, offers the latest advances in package design for glass, plastic, metal and paperboard packaging, decorating and labeling techniques. For example, the Showcase of Packaging Innovations features award-winning packaging from around the world. The 6th annual Pack Expo Selects awards recognize best-in-class consumer packaging by exhibitors. And, Project 2020: The Consumer Experience focuses on the future of packaging with a design competition that forecasts upcoming trends. Meanwhile, the Confectionery Pavilion, sponsored by the National Confectioners Association, Washington, D.C., will boast new innovations with candy confections and frozen dairy desserts. 䡲 For exhibitor and attendee information, travel arrangements, airfare discounts, registration links and more, go to www.packexpo.com. 52
Dairy Foods | September 2011
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Our cartons are recyclable for over 38 million households Our cartons are made with renewable materials – over 70% of the carton is made from paper using trees from responsibly managed forests Our cartons are made with renewable energy – over 50% of the energy used to make the paper in our cartons comes from biomass
Evergreen Packaging Cartons: The Smart Choice Consumers are demanding more from packaging than a cost-effective and convenient way to keep products fresh. Today a significant and growing number of consumers consider the environmental impact of the packaging in their product selection process. Over 70% of our carton is made from paper, derived from a renewable resource: trees. And for an ca increasing number of households, cartons are recyclable. in
So, consumers can enjoy milk kept fresh – and feel good about So their purchase decision. th www.evergreenpackaging.com w
Show Preview
Conference Sessions MONDAY, SEPT. 26 9-10 a.m. Considerations to Further Lean and Sustainability Initiatives in the Converting Environment Room N-259 Innovate for Positive Results on Costs and Profits Room N-255 Introduction to Beverage Packaging Room N-253 Real World of Project Management: A Cross-Industry Perspective on Best Practices in Managing Complex Projects — Part 1 Room N-257 10:15-11:15 a.m. Real World of Project Management: A Cross-Industry Perspective on Best Practices in Managing Complex Projects — Part 2 Room N-257
Reusables 102: Implementing a Sustainable Reusable Transport Packaging System — Part 1 Room N-259 Stress Crack Prevention Room N-253
12:45-1:45 p.m. Update on the Food Safety Modernization Act and What Some CPG Companies Are Doing to Comply Room N-255 The Cost of Sustainability Room N-259
Total Cost Ownership: A Brand Owner’s Keys for Managing Vendors Room N-255 11:30-12:30 p.m. Packaging Line Layout — Answering the Pertinent Questions Room N-255 Reusables 102: Implementing a Sustainable Reusable Transport Packaging System — Part 2 Room N-259
The Five Faces of Innovation: Integrating from Concept to Customer Room N-253 2-3 p.m. Food Safety Guidelines: Process Validation in Low Moisture Foods Room N-255
The Importance of Nondestructive Package Testing Room N-253
Sustainable Packaging: What’s Next Room N-259 The Perfect Ingredients for Packaging Innovation Room N-253 Continued on page 56
Metal Detectors & X-Ray Inspection
Eriez’ New Vibratory Inspection Conveyors
Our new Dual Inspection Vibratory Conveyors offer precise product control and uniform coverage giving hand inspectors easy visual recognition of imperfect product or foreign objects.
Features include:
• Vibratory action rotates and flips product • Easy visual inspection • Precise product control • Reduced noise • Safe operation with no rotating parts or lubrication • Sanitary wash down • “Green” low energy consumption
FREE!
Vibratory Selection Guide & How-to-Use Brochures
Visit eriez.com Call 888-300-3743 54
Dairy Foods | September 2011
Vibratory Screeners
Magnetic Separators
Exopack packaging. The essential ingredient to success. For cheese that’s fresh and flavorful, for dried milk products that last, make sure your recipe for success starts with Exopack packaging. Our Halo™ films utilize a patented EVOH encapsulation technology for extended shelf life and are specifically engineered for sliced and chunk cheese products. Available in up to 10-color process print, they maximize shelf impact. Our shredded cheese flexible film with consumer-friendly laser scoring allows easy opening. Exopack Seal ‘n Vent® dairy bags have everything it takes to measure up, too: USDA approval, patented removable inner liner, and resistance to sifting and infestation. So before you package your dairy product, make sure you start with the most essential ingredient of all—Exopack. ®
,ET US TOUCH YOUR LIFE AT 0!#+ %80/ s "OOTH æ3OUTHPORTæ2OADæsæ3PARTANBURG æ3#ææsæWWWEXOPACKCOM 4OLLæFREEææsæ%MAILæmæEXPACK EXOPACKCOM
Touching Everyday Life
™
Show Preview 3:15-4:15 p.m. Going “Green:” From Should to Good Room N-259 TUESDAY, SEPT. 27 9-10 a.m. Managing and Protecting Your Reusable Packaging Assets — Part 1 Room N-259
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Packaging HACCP: What to Expect From a Supplier and How Suppliers Can Initiate a Sustaining Program Room N-257 10:15-11:15 a.m. Managing and Protecting Your Reusable Packaging Assets — Part 2 Room N-259
8
SCHNEIDER
PACKAGING
EQUIPMENT ONE IS NUMBER IN PACKAGING IN NORTH AMERICA FOR FANUC
ROBOTICS CARTONING CASE PACKING ROBOTIC PALLETIZING END OF LINE INTEGRATION Flexible, rapid ROI, and ready for the future.
R FO ER DE ID O E C HN PO R C X Q S E N N K A O AC SC FO T P IN A
P.O. Box 890 | 5370 Guy Young Road | Brewerton, NY 13029 315.676.3035 | fax 315.676.2875
[email protected] | www.schneiderequip.com
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Dairy Foods | September 2011
Product Security in Today’s Challenging Global Manufacturing Environment, Room N-257 11:30-12:30 p.m. Sustainability: Tracking Gateto-Gate from the Point of Manufacturing Upstream Room N-259 Understanding Third-Party Auditing Certification Room N-257 UV/EB for Food Packaging — Can/Should/Must We? Room N-253 12:45-1:45 p.m. Food Safety and Packaging: The Hazards, Recalls and New Strategies Room N-257 Introduction to Beverage Processing Room N-253 2-3 p.m. Required Packaging GMPs: One Voice from CPG Companies Room N-257 Responsible Packaging by Design Process Guide Room N-253 WEDNESDAY, SEPT. 28 10:15-11:15 a.m. What’s Coming Down the Packaging Pike? Room N-255 11:30-12:30 p.m. The Mobile Moment of Truth: Packaging, Retail and the Engaged Consumer Experience Room N-255 12:45-1:45 p.m. Trends in Contract Packaging and the Drivers Behind Them Room N-255
Exhibit Hours Monday, Sept. 26 Tuesday, Sept. 27 Wednesday, Sept. 28
9 a.m. – 4 p.m. 9 a.m. – 4 p.m. 9 a.m. – 4 p.m.
Exhibit show hours are subject to change.
Show Preview
BOOTHS Blueprint Automation
Brookfield Engineering
Join us in Booth C-2439 and check out our unscrambling “Rainbow” feeder, transferring product from bulk to a vision guided robotic cell for double pick tray loading of clear flexible packages at 150 PPM! The BPA Rainbow Feeder unscrambles and feeds rigid and flexible packages from bulk storage at 215+ PPM, while the packaging cell will include an “on the fly” vision robotic system utilizing new technology so even CLEAR packages are easily located by the robot! BluePrint Automation is a worldwide leader in packaging automation focused on three areas: • Vision-Guided Robotics • Case/Tray Packing • Complete Packaging Automation Systems
Brookfield Engineering the world leader in viscosity measurement and control for over 75 years! Also the largest manufacturers of viscometers and rheometers for laboratory and inline process applications. The AST100™ is a versatile instrument for viscosity control. The CT3™ Texture Analyzer (food industry) features the traditional Compression Mode and a new Tension Mode so manufacturers can test their products with packaging materials! This instrument offers six test modes (plus calibration check) and a wide choice of accessories. Brookfield’s DV-II+™ Pro Extra continuous sensing viscometer features Brookfield’s Ball Bearing Suspension System that delivers extended durability for instruments. The well-known trademarks of Brookfield products are reasonable pricing and high quality workmanship.
Blueprint Automation 16037 Innovation Drive Colonial Heights, VA 23834 www.bpa-flexolutions.com 804-520-5400 Booth: C-2439
Brookfield Engineering Laboratories, Inc. 11 Commerce Blvd., Middleboro, MA 02346 508-946-6200 or 800-628-8139
[email protected] www.belusa.com Booth: 6617
Delkor Systems
Eriez
With so many Retail Ready and Shelf Ready packaging concepts coming to market, Delkor has elected to dedicate its entire Pack Expo exhibit to this theme. In the past year Delkor has designed eight new machines for various applications of either Retail Ready or Shelf Ready packaging – and all will be high- Highly Versatile Trayfecta Servo Former lighted in the Delkor exhibit C-4045. Delkor is also introducing: • new Trayfecta ® Servo Former for cartons, cases, and trays with advanced precision change-over. Capable of forming either paperboard or corrugated cartons with precise tool-less changeover in 3 minutes; • new in-line Delkor Capstone Carton Closer. This compact carton closer offers innovation for producers that package with either paperboard cartons or corrugated cases. Dale Andersen, President and CEO 8700 Rendova Street, NE Minneapolis, MN 55014 800-328-5558
[email protected] Booth: C-4045
Metal Detector Conveyor Quick Ship Program Eriez’ stocks eight E-Z Tec® metal detector aperture heights and three stainless steel, wash down conveyor widths for quick assembly and delivery. The variable speed conveyors are available in 12, 18 and 24-inch widths with a food-grade polypropylene belt. E-Z Tec metal detectors offer the highest level of protection against metal contamination, are competitively priced and designed and manufactured in the United States. These systems are ideal for customers in the food, textile, pharmaceutical, plastics, rubber, chemical and many other industries.
®
www.Eriez.com 888-300-ERIEZ Booth: C-1208
www.dairyfoods.com
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Show Preview
Evergreen Packaging
Exopack, LLC
Evergreen Packaging introduces Fresh by Design™ packaging innovations Evergreen Packaging is introducing Twist-It™ spout carton. In tests, the improved drinking experience resulted in 15% more milk consumption, more nutrients received per child, fewer spills for cafeteria staff and less straw usage. In addition, our Evergreen carton with windows is the consumer preferred choice. In AcuPOLL® consumer testing, consumers indicated they find it superior to current packaging options at providing key benefits such as: • Making the product inside more appealing • Allowing them to easily see how much is left inside • Use of renewable resources Both of these innovative new products offer all the benefits of traditional cartons: eco-friendly features, maintenance of nutrients and fresh taste and great graphics to engage consumers of all ages.
Managing 18 production facilities strategically positioned across North America and the United Kingdom, as well as a global network of alliance partners, Exopack® is an established leader in the development, manufacture, and sourcing of plastic and paper flexible solutions for various consumer and industrial end-use markets. Exopack’s Menasha, WI facility manufactures the industry recognized film brand, Halo®, 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.
Evergreen Packaging
[email protected] www.evergreenpackaging.com Booth: C2818
Fortress Technology Inc. Introducing the
Metal Detector Fortress Technology Inc. is pleased to participate as an Exhibitor in the 2011 Pack Expo Trade Show. This year promises to be quite exciting as Fortress launches the newest addition to their PHANTOM series, the STEALTH Metal Detector. High-speed precision detection and ultra-sensitivity levels detect the smallest metal contaminants. Drop by to experience the STEALTH Metal Detector in person at Pack Expo Booth # S-5033. Fortress Technology Inc. 1-888-220-8737 or 416-754-2898
[email protected] www.fortresstechnology.com Booth: S-5033
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Dairy Foods | September 2011
Exopack, LLC
[email protected] 877-447-3539 www.exopack.com Booth: 5831
Fristam Fristam Pumps USA is a leading global manufacturer of sanitary pumps, blenders, and mixers known for their quality, reliable performance, and high lifetime value. Booth highlights will include the newly redesigned FKL Series positive displacement pump line and Fristam’s Powder Mixer. The redesigned FKL heavy-duty PD pump is built for all parts in “True CIP” and now has a cleaner exterior, split-style gear case for easy access to bearings/shafts, and customizable port-toport dimensions for easy drop-in replacement. Fristam’s Powder Mixer improves product texture, produces repeatable results, reduces processing time, are economical to operate and maintain, and feature low maintenance designs for continuous duty. All Fristam pumps and mixers are engineered for lasting performance. www.fristam.com/usa 800-841-5001 Booth: S-6402
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GEA Process Engineering Inc.
Krones Inc.
Learn about GEA Process Engineering’s innovative, reliable, and efficient processing and packaging solutions at the 2011 PackExpo show in Las Vegas, Nevada. We will exhibit on booth #4520. GEA Process Engineering is a leading supplier to the food and beverage industries. Whether you need service and spare parts, retrofits, new process units, or a complete new process line; we have the engineering solutions and the process integration know-how to exceed your expectations. • Heat treatment • Thermal concentration • Membrane filtration • Drying and particulate processing systems • Powder packaging and transport • Aseptic PET bottle filling lines • CIP systems and integration • Controls and automation Engineering Excellence. GEA Process Engineering Inc. 1600 O’Keefe Road, Hudson, WI 54016 USA Tel.: 715 386 9371, Fax: 715 386 9376 E-mail:
[email protected] Website: www.niroinc.com Booth: 4520
New: Krones ProShape for producing oval plastic containers A significantly optimised production process for oval or asymmetrical plastic containers: that’s the job description for the newly developed ProShape process from Krones. It functions by utilising the fieldproven heat-up and stretch blow-moulding technology of the current Contiform series, and combining it with a new module for orientation and selective temperature control of the preforms concerned. The ProShape module is integrated into the Contiform between a standard linear oven and a standard blowing wheel. The requisite temperature profile is applied to the preforms using temperature-controlled aluminium moulds specifically designed to meet the requirements of the subsequent bottle, thus achieving purposefully optimised material distribution for the downstream stretch blow-moulding process. ProShape thus offers optimum preconditions for producing extremely unusual designs and for lightweighting oval containers.
Martin Brothers, Inc
Mettler Toledo
Be sure to visit Martin Brothers, Inc at PACK EXPO 2011, Booth S-6410, at the Las Vegas Convention Center, September 26-28, where we will have our latest Ingredient Feeder, Scraped Surface Heat Exchanger, and Votator II to view. Martin Brothers rebuilds ingredient feeders with capacities up to 3000 gallons per hour. We have completely redesigned the famous Crepaco S4 series ingredient feeders, replacing the hydraulic system entirely with variable frequency controlled AC drives for quiet, cool, clean and super controllable operation. Martin Brothers also rebuilds SSHE’s used for continuous, closed processing such as; heating, cooling, freezing, mixing, cooking and gelling for dairy and food processing. We’ll be on hand to help you with your equipment and parts needs. Visit www.teammartinbrothers.com to see our current listing of equipment inventory.
METTLER TOLEDO invites you to a total 360° Product Inspection experience with a chance to see how our solutions can look at your inspection challenges from every angle. Take advantage of this opportunity to view our innovative, award winning in-line checkweighing, metal detection, X-ray and vision inspection solutions all in one place. Visit us in Booth C541 and learn how our solutions can increase efficiency, reduce manufacturing costs and improve the competitiveness of your business and you could win $1,000 gift certificate for Travelocity!
Krones Inc. 9600 South 58th Street Franklin, WI 53132-6241 United States
[email protected] Booth: #1800
METTLER TOLEDO 6005 Benjamin Road Tampa, FL 33634 www.mt.com/pi 800-221-2624 Booth: C541
www.teammartinbrothers.com Booth: S-6410
www.dairyfoods.com
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Show Preview
Reiser
Rieger GmbH & Co.
Reiser will feature live demonstrations of their complete line of processing and packaging equipment. Of special interest to food processors will be Reiser’s range of packaging solutions, including Repak horizontal form/fill/ seal packaging machines, Ross tray sealers, and Supervac vacuum chamber packaging machines. Reiser will demonstrate its Ross S-Series Tray Sealer, which produces modified atmosphere packages (MAP) from preformed trays. It packages fresh, refrigerated, retort or frozen food products at a full range of output rates. Reiser will also demonstrate its Repak horizontal form/fill/seal packaging machine in combination with their Vemag hamburger patty forming system, showcasing a complete processing-topackaging solution.
PARTNERING FOR THE PERFECT FIT Any valve manufacturer can insist you modify your equipment to work with theirs. In fact, many of them do. But not us. Rieger, a world-class manufacturer of hygienic and aseptic valves, has partnered with Flow Products, a proven provider of individualized liquid process solutions. We believe it’s our responsibility to customize our products to suit your needs, not the other way around.
Reiser
[email protected] 781-821-1290 www.reiser.com/cheese/cheese.php Booth: 5335
Gebr. Rieger GmbH & Co. KG Postfach 1640, 73406 Aalen, Germany Phone: +49 (0) 7361 57 02-0
[email protected] www.rr-rieger.de Booth: S-7239
Schneider Packaging Equipment Co., Inc.
T.D. Sawvel Co. Inc.
Designed to handle multiple products and packing combinations, the RCCL/Spider uses two multi-axis spider robots to locate, inspect, and orient product for high speed nesting into a carton. Equipped with advanced vision guided robotics, even products with a complex shape can be tightly packed, minimizing packaging materials and maximizing sustainability. A modular design increases throughput and can be configured to top load cartons, cases or trays, in combination or separately, on the same line. Schneider Packaging Equipment Co., Inc. 5370 Guy Young Road Brewerton, NY 13029 www.schneiderequip.com 315-676-3035 Booth: 2018
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Dairy Foods | September 2011
Flow Products, LLC 5732 95th Ave, Suite 800, Kenosha, WI 53144 3144 Phone: 262-657-5566 Fax: 262-657-5058
[email protected] www.flowproducts.us
T.D. Sawvel offers a range of liquid scale filling machines for products that seek their own level. Our most popular scale-filling package is the Model 113, perfect for liquid foods or products like donut icing, edible oils, fruit flavorings, mayonnaise and sauces. The standard Model 113 is a semiautomatic dual station scale filler featuring stainless steel construction and the latest digitally controlled scale for an extremely accurate fill. It offers continuous product flow, dual electronic weighing system, and throttled-down final fill. The Model 113 can fill sizes from 1-6 gallons, with tooling available for pails, bag in box, jugs, and jugs in box. For customers filling large plastic pails, the 113 with the Model 119 pneumatic lid press has been especially popular. T.D. Sawvel designs and manufactures high quality stainless steel equipment and tooling to fill, lid, denest, or seal a wide variety of product demands and packaging shapes, from one ounce to six gallons. Since 1976, T.D. Sawvel has worked in partnership with its customers to identify the best-case automated packaging solutions to help customers achieve their business objectives. T.D. Sawvel Co. Inc. Troy Sawvel, President 5775 Hwy. 12 West, Maple Plain, MN 55359 toll free: 877-488-1816; local: 763-479-4322; fax: 763-479-3517 www.tdsawvel.com Booth: 3938
Our Huntley, Illinois plant is focused on providing printed packaging solutions that exceed our customers’ requirements. Our concentrated focus ensures that we remain on the leading edge of technology (materials, adhesives, SQF Level 2 coatings, and printing Certified processes). As a result... • Foil and Non Foil Lidding • • • • • • • •
(roll and die cut). Single Serve Portion-pack Lidding Pressure Sensitive Labels (paper and films). 2 Part Laser Lids Die Cut Printed Lids in Register Top & Bottom Roll Film Top & Bottom Printing Multi-laminate Pouch Printing Seeding Coupon & Sweepstake Promotions Cups Also Available
Leah resides at the Brookfield Zoo, Brookfield, IL
847-669-3600 847-669-1170 FAX WWW.HSCROCKER.COM 12100 SMITH DRIVE HUNTLEY, IL 60142
Food, Dairy, and Specialty Printing Lid Solutions Since 1856
S U C C E S S
S T O R I E S
HOW A VEMAG CHEESE FORMER
E LI M I NATE D WASTE and increased YI E LD S A T RU E S T O RY: A few years ago, we met a cheese maker who lamented how much waste he had from the off-cuts of his cheese block slicing and cutting processes. Some of this cheese could be shredded, but that solution did not work for all of his varieties. He came to Reiser with the request to reform the cheese scrap so that he could eliminate waste and increase yields. Reiser put its engineers to work and after extensive testing they developed the Vemag Cheese Block Former. The Vemag was able to take the cheese pieces and reform them into usable cheese blocks. The USDA Dairy Accepted Vemag features a powerful double-screw pump which compacts and transports the cheese extremely gently and without smearing. An Extruder attachment gives the reformed block its shape, and a cut-off device controls the length of the block while ensuring exact-weight portions and clean, even edges. Our solution helped the cheese maker repurpose his cheese scrap, eliminate his waste, and increase his profitability.
THE VEMAG PRODUCES PERFECTLY FORMED CHEESE BLOCKS Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com
Leading the food industry in processing and packaging solutions.
sneak peek a look inside…
Training is Milano’s Middle Name
REPORTS
B
etween new product development and maintaining food safety, the folks at Milano’s Cheese Co. pride themselves on training, training and more training. Page 68.
Dairy Processors Learn To Move It C
ase studies of how some dairy processors are using automation in their facilities, plus a look at new equipment. Page 76.
Store Brands Are a Healthy Opportunity for Packaging W
hether you call them own brands, store brands, control brands, private label or private brand, there has been tremendous growth in this sector both globally and nationally for the last decade, writes Mike Richmond. Page 82.
Pumps and Valves Showcase M
any of today’s pumps and valves are designed with ease in mind. Find out what’s in store for dairy processors. Page 86.
Anthony Caliendo, vice president of sales and marketing, and Marybeth Tomasino, CEO and treasurer, help direct Milano’s Cheese Co. into becoming an up-and-coming competitor in the cheese industry. Photos by Vito Palmisano
Diamond in the Rough Milano’s Cheese may not be the largest producer, but its tenacity for food safety, innovation and growth make it an up-and-coming competitor in the cheese industry. Marina Mayer Executive Editor
fast forward what’s coming in October… Pierre’s Ice Cream Co. Rigid Packaging Warehouse Automation
New Product Showcase
F
ive years ago, consumers wouldn’t be caught red-handed buying private label products or clipping and saving coupons. Over time though, the rollercoaster economy has forced even the wealthiest of shoppers to compare prices and opt for the cheaper brand. Now, “consumers want to be challenged, they want something unique and exciting, something that no one else has,” says Anthony Caliendo, vice president of sales and marketing for Milano’s Cheese Co. “I think that’s one of the advantages we’re going to have as a company, is to be innovative with new ideas that propel us ahead of our competition.” Continued on page 64 www.dairyfoods.com
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Corporate Profile Milano’s has been able to stack up an impressive list of credentials, but couldn’t have achieved any of its certifications without the passion and persistence from the quality control, logistics and sales teams as well as those in the business office and executive management.
It’s that tenacity for innovation and growth that make Milano’s an up-and-coming competitor in the cheese industry, despite how consumers save and spend. That’s why the 250-employee, $40 million producer of Italian hard cheese is considered a diamond in the rough, “that company that not everybody knows about but everybody wants to find,” Caliendo says. Milano’s team of products includes 10 SKUs, ranging from 8-ounce to 5-pound containers of grated, shredded and shaved Parmesan, Romano and Asiago cheeses, which are produced out of its 75,000-square-foot headquarters facility in Linden, N.J., and distributed to foodservice accounts (75%), ingredient users (24%) and retail outlets (1%). Despite the emphasis on institutional customers though, Milano’s is making a push into retail in a big way. For starters, it became a member of various food trade organizations, such as International Food Technologist, International Dairy-Deli-Bakery Association, Private Label Manufacturers’ Association, American Dairy Products Institute and the National Association of Pizza Operators. Additionally, it started hosting tabletops at these organizations’ tradeshows, including the International Pizza Expo, Mar. 1-3 in Las Vegas; the NRA Show, May 21-24 in Chicago; IDDBA’s DairyDeli-Bake Seminar & Expo, June 5-7 in Anaheim, Calif; IFT Food Expo, June 11-15 in New Orleans; and the ADPI International Whey Conference, Sept. 18-21 in Chicago. Coming up, Milano’s will make a tabletop presence at PLMA’s Private Label Tradeshow, Nov. 13-15 in Chicago. 64
Dairy Foods | September 2011
To better target its retail customers, Milano’s created a 64-bag shipper, which substitutes the run-of-the-mill cardboard with a metal frame that holds four black wicker baskets and is adorned with Italian-style colors and artwork.
Corporate Profile Aside from making a name for itself and exposing its brand through various media, it helps that Milano’s target audience is, “anyone who eats cheese,” Caliendo says. “It doesn’t really matter what their nationality is. In general, when it comes to Italian food, there’s not really many people who don’t like it. When it comes to cheese, specifically Italian cheese, it really has the flavor. It gives it that kick that tastes better. It’s a product that every consumer knows and every consumer wants. I’d say that the percentage of consumers who have Italian cheese in their house is really, really high, probably in the 80-90% range. It’s like not having ketchup in the house.” In fact, from 1999 to 2009, per capita sales and consumption of Parmesan cheese doubled from 0.41 to 0.80 pounds, according to the International Dairy Facts 2010 Edition, produced by the International Dairy Foods Association, whereas Romano rose from 0.17 to 0.25 pounds per captia over the 10-year timeframe. The data are in the company’s favor. Milano’s is on the fast track to success just by being able to bring the consumers what they want.
Operating cut and dry While the Milano’s name has been around for some time, it was just recently certified as the doing business as name of JVM Sales Corp., its parent company. “No one knew what JVM Sales was and that it had to do with Milano’s cheese,” Caliendo says. However, JVM Sales has been a family-owned and operated business for nearly two decades. In 1983, Joseph Falcone purchased JMV and ran it as chief executive officer until 2000, when he became blind and his daughter, Marybeth Tomasino, took over. Tomasino, currently the chief executive officer and treasurer, acquired JVM in September 2010. JVM was built on the strong principles of hard work, dedication, integrity and family values of the Old Country, and has evolved throughout the years thanks to the family’s combined 60 years experience as gifted cheesemakers. Continued on page 66
Automated Milk Component and Somatic Cell Testing Engineered for dairy laboratories and dairy processing facilities that require highly reliable and accurate instrumentation.
If you’ve been looking for a company that offers a full line of aseptic valves, you can stop looking now.
• Fat, protein, lactose and solid analysis by FTIR spectroscopy • Up to 500 samples per hour
We’re Rieger, a world-class manufacturer of hygienic and aseptic valves. For over 100 years, we’ve been delivering bestin-class valve solutions for food, chemical and pharmaceutical companies around the world. And now, we’re happy to announce we’re making our innovative products available here in North America. This includes our industry-leading line of aseptic valves, customizable to work with your existing equipment. Ready to learn more? Contact Flow Products of Kenosha, Wisconsin at (262) 657-5566 today.
• Somatic cell count by flow cytometry • Extensive remote diagnostic capabilities
CALL: 952.448.7600 (USA) EMAIL:
[email protected] VISIT: www.bentleyinstruments.com
Also available: IBC-M: Rapid enumeration of individual bacteria and somatic cells BactoCount Series: Real-time analysis of total Flora
Flow Products, Inc.
262-657-5566 • 5732 95th Ave., Ste. 800 • Kenosha, WI 53144 www.flowproducts.us • info@flowproducts.us
www.dairyfoods.com df09114flow.indd 1
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Corporate Profile In addition to leading the company, Tomasino holds 10 certifications, ranging from food safety to product development to employee training, and she trains each individual employee herself. “We’ve always been proactive in the food safety department,” she adds. “[And], the regulations that just changed in the [Food Safety] Modernization Act have only helped this company because we used to chase our customers on information for our third-party orders and any kind of regulatory documents, and now they have to give it to us much quicker.” To comply with the revised Dietary Guidelines for Americans, for instance, Milano’s is working to create low-sodium items, “however, there is a standard for Parmesan and Romano,” says Tomasino, who maintains a degree and certification in ingredient development and works with suppliers and local pizza joints to test certain concoctions. “When there is a range of three to five [for sodium content], we try to get a little above three for salt.”
Polishing up its portfolio While the folks at Milano’s are busy pumping out nearly 400,000 pounds of product a week (see related article, beginning on page 68), they’re also redeveloping their product line and packaging materials to better segue into the retail market. For starters, Milano’s is in the process of launching a spiced Parmesan and spiced Parm-Romano line, which blends red peppers, jalapeños and other spices to provide a Latin/Italian-type flare. “There’s so many things you can do with spiced items like this,” Caliendo says. “If you go to any major company, like Subway, you’ll see that they have Parmesan, then they have a red pepper, a basil or oregano and then you’ll watch them shake it on there. So, why have all three when you can have one? We want to try to consolidate it for our clients and make it easier for them, and do the same thing for the retail shelves.” Milano’s also introduced a sabori seasoning, which boasts red peppers and Italian vegetables to provide an Italian flair with a little kick.
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Dairy Foods | September 2011
Corporate Profile
Marybeth Tomasino (bottom right) is CEO and treasurer. She prides herself on operating as a family-run business, which is why her children (clockwise, from bottom left), Justin, assistant manager of production, and Mary Jean, assistant manager of quality assurance, spend their summers working in the plant. Kimberly, business development manager, works full time.
“There always has to be some kind of niche that separates you from the rest, and that’s what we’re really going to focus on as a company — how do we create the marketing, the taste of the product, the ideas that open the door for people to want to try our product,” adds Caliendo. Meanwhile, Milano’s developed a 1-pound economy-size pillowpack bag featuring a zipper seal that was designed to give consumers more product for less money. “As the economy went backwards over the last three years, we’ve seen changes in packaging, changes in major companies that have changed their sizes,” says Caliendo. “They maybe went from 8 ounces to 6 ounces. They tried to cut down some of the product to really lower the price for the economy. What we did is come up with a 1-pound bag that really gave the consumer more product, not less product, for a very, very good price.” To accompany the 1-pound bag, Milano’s created a 64-bag Italian cheese supermarket shipper, which substitutes the runof-the-mill cardboard rack with a metal frame that holds four black wicker baskets and is adorned with Italian-style colors and artwork. On the sides of the shippers, consumers can find brochures, directing them to the company’s website, which is in the process of being updated to include a more in-depth arena for consumer interaction and recipe sharing. “After talking to many dairy buyers, one of the biggest problems I’m hearing is, how do we display cheese? That’s why we designed the new shipper,” Caliendo says.
Milano’s is also tapping in to one of the hottest trends in the food business — going green — by initiating discussions on creating a biodegradable bag. “We want to become the first cheese company to actually come out to market with these biodegradable go green-type of cheese products,” Caliendo says.” In addition to its nationwide customers, Milano’s is expanding into the international world of cheese. In doing so, it hired an in-house counsel who has helped the company acquire EEU certification, as well as other export qualifications. Plus, the Milano’s plant is just 10 minutes from the port, providing an attractive means of exporting overseas. “The way we look at is, we can’t control the government, but we can control our destiny,” Caliendo says. “We have to go out there and work on international markets, focus on the world, not only the United States. Doing so, I think within the next three years, we can probably increase our business by 20-30%, just in international business.” “We have a very unique position here,” Caliendo adds, “being able to not only build a brand name, but to be able to build a retail product at a great price and then be able to work on the private label side.” Before long, Milano’s will be more than just a diamond in the rough — it’ll be a gem in the cheese industry where everyone knows their name. www.dairyfoods.com
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Plant P lant C Close-up lose-up
Shredded Romano cheese travels through a tumbler into the packaging area to be placed in the company’s newly redesigned 16-ounce bags.
Photos by Vito Palmisano
Training is Milano’s Middle Name Between new product development and maintaining food safety, Milano’s Cheese Co. prides itself on training, training and more training. Marina Mayer Executive Editor
I
n 1983, when Joseph Falcone purchased JVM Sales Corp., it was nothing more than a mom-and-pop cheesemaker that produced Italian hard cheeses for foodservice accounts. “One of the biggest challenges on the sales and marketing side is really letting people know that we’re here, that we’re a company who’s been around for a long time but [no one] doesn’t really know about,” says Anthony Caliendo, vice president of sales and marketing for Milano’s Cheese Co., the doing-business-as name for JVM Sales. Today, the $40 million family-owned and operated company employs approximately 250 people and pumps out close to 400,000 pounds of grated, shredded and shaved Parmesan, 68
Dairy Foods | September 2011
Romano and Asiago cheeses from its 75,000-square-foot facility in Linden, N.J. But, the secret behind Milano’s success isn’t its story, its quality products or its redesigned packaging concepts (see “Diamond in the Rough” on page 63). Milano’s hires quality people who bring passion and loyalty to each and every order. “We’ve always been proactive in the food safety department. I have a fantastic staff under me that follows through on everything,” says Marybeth Tomasino, Falcone’s daughter and the chief executive officer and treasurer. “JVM’s middle name is training.” Through continuous training, Milano’s has been able to stack up an impressive list of credentials. For example, in May 2010,
Plant Close-up
䡲 Left: Milano’s pumps out close to 400,000 pounds of grated, shredded and shaved Parmesan, Romano and Asiago cheeses from its 75,000-square-foot facility in Linden, N.J. Above: A sheeter pushes the cheese up to a bucket elevator and into the 50-foot zigzagged vibratory conveyor that aligns the ceiling.
it passed the Silliker Good Manufacturing Practices audit, and just one month later, received approval for food establishment for the U.S. Military Armed Forces Procurement. Then, in October 2010, Milano’s received SQF 2000, Level 2 certification and is vying to obtain Level 3 in the fall. The plant also underwent HACCP certification. It also trains on an assortment of other programs, including but not limited to, lock-out/tag-out, metal detection, warehouse, forklift, food security, pest control, pallets and more. The Milano’s facility undergoes a makeover about every six months, whether it’s adding a new line or enhancing a piece of machinery. Today, the Milano’s production site is fully automated, cutting production down from three shifts, six days a week to two shifts, five days a week, with the second shift being a skeleton crew. Cleaning and sanitation are carried out after both shifts are shut down for the week. It also conducts two mock recalls a year, once during business hours and once after.
“What we’ve been focusing on for the past three years was automating, so we have fewer hands in the product,” Tomasino says. “So, we generated a new line that would go across the room along the ceiling in vibratory conveyors to add room to our new packaging line and a new sheeter line with 12 scales. Then we invested in a new line that would take it directly from the packaging area through an X-ray machine that we just purchased a year ago. I’m also putting up a wall right now to enclose the new packaging line to insert a new refrigerated cooler and a new finished product cooler extension.” Operating autonomously At the time of Dairy Foods visit, Milano’s was churning out Romano cheese for its retail customers. Cheese comes in from various domestic and imported suppliers in wheel forms (in a multitude of sizes), which are sliced in halves and then sent through a bowl chopper, which is actually a buffalo chopper used to chop up buffalo. While in the Continued on page 70 www.dairyfoods.com
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Plant Close-up
䡲 Top left: After being chopped, a conveyor lift moves product into the vibratory conveyor, which travels into the packaging area. Left: Cheese comes in from various domestic and imported suppliers in wheel forms (in a multitude of sizes), which are sliced in halves and then sent through a bowl chopper. Above: While in the chopper, which holds 500 pounds of mix, operators add an anticaking blend to protect the product.
chopper, which holds 500 pounds of mix, operators add an anti-caking blend to protect the product. The chopped-up cheese then exits through a screw conveyor into a sheeter, which pushes product up the bucket elevator and into the 50-foot zig-zagged vibratory conveyor that aligns the ceiling. The conveyors travel through the wall and feed into a scaler, then a hopper and then down into pre-set bags in the packaging area. (The actual processing of the cheese is a proprietary
process; therefore Milano’s didn’t comment further). All product goes through the newly installed X-ray machine. Operators calibrate the machine four times a day alongside a metal detection check, also four times a day. If product doesn’t pass the test, Tomasino says, the belt drops down into a bucket and empties the remainder of that line’s product. Then, the product runs through the line again. Should the product still not pass, the entire line’s
product is dumped and analyzed by a metal agent to determine what foreign objects entered the line and at what phase. Once the product passes through the X-ray system, it travels into a 100-foot swivel conveyor that zig zags through the packaging room. Product enters the filling line where it dumps into jars, bags or containers, then travels through a second metal detection unit and around into the capper station. Once the container is capped, it enters the labeler and into the Continued on page 72
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Dairy Foods | September 2011
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Plant Close-up
䡲 Left: Milano’s developed a 1-pound economysize pillowpack bag featuring a zipper seal that was designed to give consumers more product for less money. Above: Milano’s conducts monthly environmental swabs and a weekly aerobic plate count to test for micro-organisms and spoilage.
casepacker before being manually palletized and shipped out through one of the company’s four docking stations. There are three batch dryers (a continuous dryer is in the installation phase) that are equipped with a vacuum that sucks out the cheese from the dehydraters and sends it through the piping system. Each batch dryer hold 1,000 pounds of product and is turned over every 20 minutes. Aside from its credentials and automated facility, Milano’s also prides itself in continuous testing through its in-house laboratory, which scans for salmonella, listeria, yeast, mold, moisture and more. All incoming raw materials and outgoing orders are tested every day, all day. Milano’s also conducts monthly environmental swabs and a weekly aerobic plate count to test for micro-organisms and spoilage. Additionally, Milano’s invested in an accupoint machine to ensure that cleaning and sanitation are being carried out correctly. “One of our big niches is the ability to custom blend by taking an existing product, formulate it, match it and then try to give them a better price on the foodservice end,” Caliendo says. Good thing Milano’s has the credentials and the diligence to maintain its training streak. 䡲 72
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AT A GLANCE JVM Sales Corp., dba Milano’s Cheese Co. Location: Linden, N.Y. Year Opened: 1975 Sales: $40 million Size: 75,000 square feet Employees: 250 Brands: Milano’s Products: Italian hard cheese, such as Parmesan, Romano and Asiago Total processing capacity: Two shifts, five days a week, not even at full capacity. Pasteurization type: None. Everything comes in pasteurized. No. of filling lines: Five No. of packaging lines: Five No. of SKUs: 10 Storage capacity: Three coolers, with a new continuous cooler to be installed. Distribution range: Foodservice accounts (75%), ingredient users (24%) and retail outlets (1%).
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Plant Close-up
Behind the Scenes A photo gallery of Milano's Cheese Co., doing business as JVM Sales Corp., Linden, N.J. Photos by Vito Palmisano
䡲 Top: Cheese comes in wheel form, sliced in halves and then sent through a bowl chopper, which is actually a buffalo chopper used to chop up buffalo. Left: Operators manually load pallets, which are shipped out of one of the company's four docking stations.
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Dairy Foods | September 2011
Plant Close-up
BEHIND SCENES the
For more photos, visit www.dairyfoods.com/behindthescenes. Or, take a picture of the mobile tag with your smart phone to go online now. Get the free mobile app at http://gettag.mobi.
䡲 Cheese heads to the bowl chopper, where an operator adds an anti-caking blend to protect the product.
䡲 Above: All product goes through the newly installed X-ray machine. Operators calibrate the machine four times a day alongside a metal detection check, also four times a day. Left: Once the product passes through the X-ray system, it travels into a 100-foot swivel conveyor that zig zags through the packaging room. Product enters the filling line where it dumps into jars, bags or containers, then travels through a second metal detection unit and around into the capper station. www.dairyfoods.com
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Packaging Technology
Dairy Processors Learn To Move It Plant managers use conveyors and robotic palletizers to reduce handling costs.
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t is not enough for dairy processors to make a great product. They need to get it off the line, on a pallet and out the door. That’s what conveyors and palletizers do. This equipment minimizes the bending and lifting that plant employees must do in moving crates and cases around. Conveyors and palletizers can save on labor costs, as employees are re-assigned to more high-value tasks. Or, the positions are eliminated. Dairy processors running at or near capacity might find that they can increase output by re-arranging lines instead of building an addition or new facility. “Both production volumes and the number of SKUs are increasing, requiring current floor space to be utilized to the fullest,” says Terry Zarnowski, director of sales and marketing for Schneider Packaging Equipment, Brewerton, N.Y. “The flexibility of robotic palletizing systems accommodates these increases without adding additional lines. An automated palletizing system can be laid out to be compatible with almost any current plant layout to minimize the distance to transport consumable materials.” He adds that this kind of “spatial economy” can significantly reduce handling costs and work in process by eliminating double handling, buffering and inventory. Following are case studies of how some dairy processors are using automation in their facilities, plus a look at new equipment. Case Study: Processor Installs ARB Switch To Feed Two Milk Lines Canélia, a milk producer based in Petit-Fayt, France, is part of Lactalis Group, the world’s second largest dairy company. At the Canélia bottling site, 1-liter polyethylene bottles of milk are shrink-wrapped in groups of six, eight or 10 at a throughput rate of 15,000 bottles per hour. The 8-liter and 10-liter packs are fed to the palletizer at the line’s maximum throughput rate. To meet new demands, the dairy needed to create a new pallet format as well as revise the arrangement of the bottles on each pallet layer, all the while maintaining throughput. The dairy was using lateral side rail conveyance technology to feed the palletizer via one line. To achieve the new pallet format, 76
Dairy Foods | September 2011
however, two lines were required. As side rail technology required timeconsuming adjustments to accommodate the different pack sizes, it was no longer a viable conveyance solution. Additionally, it was to blame for frequent jams and damage to the package shrink-wrap. So, Canélia consulted with the OEM integrator and 䡲 An Intralox switch optimized Intralox for a better con- production throughput and enabled a dairy processor in France to meet veyance solution. In a simulation, Intralox, market demand for various pallet sizes Harahan, La., presented the and arrangements. activated roller belt (ARB) switch, an automated conveyance solution to feed the palletizer via two lines, requiring no adjustments for varying package types. The result is the elimination of the side rails (and the associated headaches). The Intralox switch optimized production throughput and enabled Canélia to meet market demand for various pallet sizes and arrangements. “What’s remarkable about the ARB switch is its simplicity, as it continually, smoothly moves the products. This solution responded perfectly to our needs,” says Mathieu Agranier, head of production at the Canélia dairy. Contributed by Intralox, a subsidiary of Laitram L.L.C. www.intralox.com
Case Study: Dean Foods, Kroger Find Label Verification System Results in Long-term Cost Savings With the growing awareness of food allergies in both children and adults alike, and the increasing importance of correct nutritional information for those with special dietary needs, proper labeling has become one of the most important facets of food production and distribution.
Packaging Technology When a retail grocer receives a two-truck shipment of milk from a dairy processing facility, every pallet is checked for the correct product labels. If even one pallet is labeled incorrectly, the entire shipment is returned to the distribution center and the product is deemed unsellable, resulting in a loss of tens of thousands of dollars for the processor. Grocery stores are not alone in their policy, as other major and minor retailers have begun to adapt this no-tolerance approach. Local and state governments also entered the discussion and begun passing new legislation to protect the consumers. Conveyor manufacturer Integrated Packaging Machinery, Comstock Park, Mich., developed a vision inspection system that is cost-effective for the dairy processing facility and userfriendly for their workers, with virtually no human interaction during use. The system identifies even the smallest inaccuracies and quickly segregates the suspect product from the finished goods. If five consecutive defects are flagged, the entire line can be stopped to limit costly waste and rework. Whether a label is missing, jammed, crooked or simply inaccurate for the product being run, the label verification system catches it. The worry of sending even one pallet (let alone a truckload) of incorrectly labeled milk is completely negated.
Continued on page 78
The small footprint of the IPM label verification system means it can be adapted to any manufacturing line. The company makes conveyors and integrates its label verification system into a client’s operation.
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Packaging Technology The IPM label verification systems have a small footprint, can be adapted to any manufacturing line and are used for a wide range of applications, including labeling, cap detection, date code verification and more. IPM’s systems were adapted by Dean Foods and Kroger for their dairy lines in 2010, resulting in long-term cost savings and enhanced relationships with their retail partners. Product that is incorrectly labeled in any way never makes it off the line. Contributed by Integrated Packaging Machinery, www.callipm.com
Westfalia’s Deam Systems division installed an automated emptycase handling system at a Canadian dairy processing plant.
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Case Study: Empty-Case Handling System Improves Efficiency for Milk Processor in Canada At Northumberland Dairy in New Brunswick, Canada, difficulties arose from the manual de-palletizing operation. The top-out de-stacking system was too slow to accommodate rising demand, and the case-washing system was old and inefficient. So, the dairy processor installed an automated empty-case handling system that includes a case stack de-palletizer, stack conveyors with 3-to-1 merging, a bottom-out de-stacker and wheel drives transferring cases overhead to a new case washer. Clean cases are then color sorted with a case-reject system, and accepted cases are transported to production on new cable conveyor system. Constructed of stainless steel, the entire system is suitable for washdown. Northumberland operates with 16-quart plastic dairy cases on 40-inch by 40-inch pallets. The dairy chose equipment from Westfalia’s Deam Systems division, York, Pa. From the point of entry where a forklift driver places a full pallet of seven-high case stacks onto the de-palletizer, the system is fully automated. Using clamp-and-lift technology and at a rate of two to three pallets per minute, the de-palletizer removes stacks from the pallet onto three stack conveyors, which merge into one conveyor leading into the de-stacking machine. The bottom-out de-stacker operates at rates of up to 90 cases per minute and discharges cases onto a wheel drive that transfers them via a vertical up-chute to the new case washer on an overhead mezzanine. After running through the new steam-cleaning washer, cases are conveyed on a cable conveyor through a color-sensing case-
Packaging Technology sorting unit. It pushes off rejected cases and releases to production accepted cases. The fully automated empty-case handling system enabled Northumberland to reduce labor costs associated with receiving and handling empty cases, achieve higher operating speeds and improve washing efficiency. The de-palletizer features a full-color HMI with touchscreen and 330-degree swivel mount, providing operators easy access to the system controls. Safety of the staff is paramount, and the new de-palletizing system has full safety guarding with light curtain protection. Contributed by Westfalia Deam System, www.WestfaliaUSA.com.
A Combination Casepacker/Palletizer Fits Into Compact Environments Schneider Packaging Equipment Co.’s new case packer/palletizer cell is said to offer flexibility, compactness and production efficiency in dairy processing facilities with minimal floor space or low ceilings. An integrated pallet-side drive system from Schneider minimizes floor space requirements while building full height pallets, even in plants with low ceilings.
RMT Robotics’ gantry-based solution offers limitless layout options and can operate in sub-zero warehouses. products. The robotic gantry-based solutions offer limitless layout options and operate in warehouses as cold as – 4°F. The RMT picking systems can handle milk, cream, yogurts, cheese and other dairy products. Regardless of case or crate packaging, the systems are said to be designed to pick individual or multiple cases out of active storage. As soon as the system receives orders and products, it begins the pre-picking process. When the required products for a certain order are ready, the system can quickly complete it. Using automated controls, cases or crates are delivered in exactly the desired pallet-build sequence for automated mixed palletizing at the dock. The system provides precise information on the location of all products as well as the ability to isolate SKUs in the event of a problem or recall, the company states. RMT Robotics, www.rmtrobotics.com
Equipped with a FANUC long-arm robot, the integrated case packer/palletizer automatically transfers pallets using a side-drive system that moves pallets into position at floor level, eliminating pallet conveying. The loaded pallets are then moved out of the system at floor level where they can be removed by a standard pallet jack or fork truck while the system continues to operate. The design is based on Schneider’s award-winning Pack/Pal combination robotic cell in which cases are automatically erected, loaded, sealed, labeled and palletized in a single integrated unit occupying roughly a 240-square-foot footprint. The integrated pallet-side drive system minimizes floor space requirements while building full height pallets, even in low-ceiling environments. Other pallet handling options are available, including manual exchange, semi-automatic exchange with an over/under conveyor and standard pallet conveyor. Pallet and slip sheet dispensing are also available options. Schneider Packaging, www.schneiderequip.com
Case-and-Crate Picking Solutions Streamline Operations, Lower Costs for Dairy Processors A case-and-crate picking solution from RMT Robotics, Canada, is said to reduce the footprint of standard pick modules, pick in exact customer sequences and provide complete traceability of
How A Cheese-Avicel Blending Conveyor Increases A Processor’s Productivity Measure, mix and convey with one versatile system. Hayward, Calif.-based Heat and Control’s FastBack cheese blending system (photo, right) is said to accurately meter Avicel powder and shredded cheese, mixes them and then conveys without shaking off the coating. Dairy processors can meter and blend many types of cheese and coatings. Load cells precisely measure the delivery of each ingredient to maintain blend accuracy within 4% of the target, according to the company. The gentle horizontal motion prevents separation of blended ingredients. The slow-forward/fast-back conveying motion prevents Avicel from falling off and building up in the conveyor pan, the manufacturer states. This prevents unscheduled line shutdowns for conveyor cleaning. The sanitary, easy-to-clean onepiece conveyor pans and menu-driven recipe selection facilitates fast changeovers. Modular design permits easy expansion and flexibility to blend multiple products. Heat and Control, www.heatandcontrol.com www.dairyfoods.com
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Sayler on Safety
Dairy’s Future Depends on Product, Processing Innovations
“I
nnovation” means different things to different people. Some believe it is a synonym of “continuous improvement.” I believe these two terms are very different. Continuous improvement provides incremental, positive benefits in an organization using existing tools and approaches. Innovation utilizes new ideas, technology and scientific concepts or the combination of existing ideas, technology and scientific concepts in novel ways to create unique products and processes. Apple Computer Inc.’s iTunes, iPod and iPad certainly are innovations in the electronic gadgets market, which have resulted in Apple being the world’s highest-valued company. Dairy industry innovation will not occur without a culture of innovation that drives new solutions to existing challenges. Such a culture will also recognize new product solutions that consumers and customers are not even aware they need. Think about 3M’s Post-it notes or intelligent cell phones (and 3G and 4G networks). Do we in the dairy industry have a Steve Jobs, Apple’s leader, who can not only create a culture of innovation, but demand it? Everyone has the ability to be an innovator; we just need to be willing to have a vision of the future, then use innovation to take us there. Past examples of U.S. dairy industry innovations include the chugstyle, grab-and-go milk bottle. It changed the entire pattern and image of milk consumption. Other examples include string cheese and reduced-temperature churning of ice cream. Membrane technology is a processing innovation that allows fracturing of whole milk into components, which create new innovative products. In the near future, dairy product innovations are likely to fall in the following categories: • Cross-over foods, associated with a single culture but are gaining popularity because of health benefits, flavor and visual appeal. Example: Greek yogurt • New food, “invented” and popularized locally, then spreading regionally, nationally and finally internationally. Example: Artisanal cheeses • Hybrid food, consisting of unique combination of foods from two or more existing “mainstream” foods, but with new and unique health benefits, flavor or visual appeal. Example: Macaroni and cheese • Modified preparation food, which changes the traditional preparation by a consumer to render it ready-to-eat. Example: Microwave popcorn • Existing foods in novel packaging. Examples: square-gallon plastic milk containers and plastic film-wrapped single slices of cheese Some dairy processing innovations on the horizon that will also improve product safety include: • The “living” processing plant. Managers will install advanced and integrated wireless sensor systems throughout the processing plant to provide real-time information, allowing rapid processing adjustments, reducing ingredient and product loss and production downtime, driving finished product consistency and improv-
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Allen Sayler
ing product safety. Wireless sensor and control systems allow for a rapid reorganization of equipment on the plant floor without the time delay associated with running new hard-wired electrical cabling. An additional benefit is to reduce the time plant supervisors and workers spend entering production data, freeing them up to do their “real” jobs. • Artificial intelligence for data management. This entails dedicated software to upload, organize and analyze plant operational information. Today’s dairy plant managers are overwhelmed with data so the plant is managed by exception. Only when a parameter is exceeded or an alarm is triggered are processes checked and adjusted. Using data management software with artificial intelligence capabilities can provide an early warning of developing problems. Dairy companies need to be installing and using dedicated LIMS (laboratory information management systems) software, PIMS (plant information management systems) software and ERM (enterprise report management) software together, producing meaningful reports for senior management. • Alternative pasteurization technology. To improve the taste appeal of drinking milk, reduce energy consumption, retain protein characteristics and reduce “cooked” flavor defects, alternatives to heat pasteurization of milk are badly needed. Actually, they already exist. Such alternatives include UV light treatment, membrane filtration and electric pulse treatment. The primary blocks to using this technology in the United States are large capital investment in HTST pasteurization units and regulatory requirements at the state and FDA level. The dairy industry as a group needs to drive alternative pasteurization technology by piloting it, working with regulators to modify regulations restricting its use and installing the innovative technology in dairy plants. Success will result in new product and ingredient opportunities, which will drive additional growth in the industry. A serious impediment to dairy industry innovation is the outdated dairy standards of identity enforced by the U.S. Food and Drug Administration. The U.S. dairy industry needs to work together to convince FDA that these 30- to 40-year-old regulations need to be updated. Such updating will allow dairy industry innovators to develop new product, contributing to the growth of the industry. Innovation is one of those rare concepts that almost everyone supports, but only a few do anything about. To become the world leader, the U.S. dairy industry needs to adopt a culture of innovation, develop a clear vision of the future and use innovation to get there. 䡲 Allen R. Sayler is vice president, food safety, technology and regulatory solutions of Randolph Associates Inc.
[email protected]. H. Randolph Inc.’s QA Studio is a LIMS software system that fully integrates into plant and dairy company PIMS and ERM software systems. To learn more, contact Andrena Schermerhorn, 775- 232-4856 or andrena.
[email protected].
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Packaging Technology Packaging Points
Store Brands Are a Healthy Opportunity for Packaging
W
hether you call them own brands, store brands, control brands, private label or private brand, we have been seeing tremendous growth globally and nationally for the last decade. These brands are no longer generics in whiteand-black packaging with lower-quality ingredients. They now range from low cost/good quality to national brand comparability to premium private brand. There are so many articles on private brands (PB) that it is nearly impossible to keep up with what is changing. New York-based Forbes identified generics as one of the fastest-growing and most-popular items for sale at stores today. More and more product testing services are identifying PB as equivalent as and sometimes better than national brands. According to Chicago-based Nielsen, households with incomes greater than $100,000 are the fastest-growing segment for PB. Just about every channel has a PB offering these days, including 7-11 and brand owners like Procter & Gamble (Bounty Basic). Typically, store brands are about one-third less expensive than national brands, so the retailers make considerably more money selling their own brands. Online retailer Amazon is now in the space with AmazonBasics, a line
of consumer electronics. So if you are somewhere in the value chain, you need to think about how you can participate in this important area. Private brands are growing at nearly double the pace of national brands (1.7% versus 1%, according to Nielsen) and they represented $88.5 billion in sales in 2010. And guess what? Packaging is a big part of their success and will play an even more important role in the future. I believe the old black-and-white generic packaging was a key part of the failure of generics many years ago. After all, the entire package represents the product from a quality, brand and image perspective. Looking at PB now, you see new package formats, including standup pouches with zippers, shrink labels on bottles and high-end canisters for dry products. Now that packaging is adding to the overall product value equation through enhanced graphics and improved
Private Brand Packaging Checklist • Graphics should support brand image and essence. • The packaging’s features/benefits are equal to or better than the national brand. • Packaging is on-trend for consumers and customers, as evidenced by convenience, freshness, portability and retail readiness. • The packaging meets universal design considerations for ease of opening, usage, readability and other points. • The cost-to-value parameters have been developed and are understood internally. • The environment/sustainable packaging story and end-of-life scenarios have been developed in terms of recyclable materials, design for disassembly, use of renewable materials and adherence to FTC Green Guides.
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Mike Richmond
Chokablok is a new dairy brand from Tesco, a UK retailer.
features and benefits (for example, enhanced freshness, convenience or microwaveability), there will be additional growth opportunities across product categories and retail channels. While there are spots where dairy packaging has made some advances like Chokablok (the new brand from UK retailer Tesco), dairy packaging has been playing in the low-to-middle PB tier. But, there is real opportunity for brand owners and suppliers to step up their game. We have heard from credible sources that PB growth in the United States could double in the next 10 years. The good news for dairy is that dairy foods represent high-quality ingredients, safety, quality, health and better-for-you. There is a real opportunity to let the packaging help you communicate this to your customers and consumers. Packaging is a key enabler for brand growth. There are significant opportunities out there to enhance graphics, improve freshness, portability, convenience, usage, closability and more. This is a good time for dairy to step up to the challenge and really look at what packaging can do to help grow the top and bottom line. See the checklist to help you get started. Mike Richmond is the president and CEO of Packaging & Technology Integrated Solutions, Shelbyville, Mich. Reach him at
[email protected].
Innovative cheese packaging solutions in every shape and size. At Reiser, we offer a variety of packaging solutions designed for all types of cheese products and applications. From Repak form/fill/seal machines to to Supervac vacuum chamber equipment to Ross modified atmosphere tray sealers, Reiser is the one source for all your packaging needs. Join other satisfied customers that trust Reiser to deliver the perfect solution. For more information, call Reiser at (781) 821-1290.
Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com Leading the food industry in processing and packaging solutions.
Global Insights
Can China Slack Dairy Exporters Thirst?
I
n the last three years, China has become the world’s largest single dairy importer by far. The nation purchases more than twice as much as runner-up Russia. As such, it is almost impossible to understate the impact of the melamine crisis on the global dairy situation since the fall of 2008. From 2002-07, China increased milk production by 4-5 million tons (9-11 billion pounds) per year. We forget sometimes, but China was a relatively minor importer (other than whey) up until 2008. In fact, in 2007 and 2008, China was a net exporter of whole milk powder. In other words, domestic production was pretty much keeping up with consumption growth. All that changed with the melamine crisis. China dairy consumption declined immediately following the crisis, then it came back fairly quickly. But with the restructuring of the domestic milk sector, production declined and imports exploded. Try to imagine what the world dairy situation would look like without China’s buying over the last three years. From 2007-10, global trade of milk powder, cheese and butterfat increased by 822,000 tons, according to the Food and Agricultural Policy Research Institute (FAPRI). During that same time, China’s net imports increased by 405,000 tons. So, one country accounted for nearly half of all the increase in global dairy trade since 2007. Of course, you could make the case that China’s domestic production growth rates were illusory, that the same cornercutting that got the sector in trouble in 2008 was what enabled China to grow so quickly in the first place. Maybe it would be importing huge quantities now anyway if the nation had done things differently from the start because local production would have grown more slowly. China’s thirst for milk Either way, the structural tightness of the world dairy industry today is due, more than any other factor, to China’s unquenchable thirst for milk. Short-term, lack of consumer confidence in domestically produced infant formula, milk and other dairy products should keep imports high. It is the highest-impact example of the larger global trend of the increasing dairy consumption by the rising middle class in emerging economies. But what about later? As China restructures and reinvests in its domestic dairy industry, will it eventually be able to serve its population and cut back on imports? This is a critical question. As the U.S. dairy industry gears up to rely more heavily on overseas growth, we need to know if China will remain a disproportionately huge draw on world milk supplies or if its buying is a temporary, melamine-driven phenomenon. The Innovation Center for U.S. Dairy’s “Globalization Refresh: 2011 Update”, a strategic analysis of the world dairy landscape funded by dairy check-off promotion funds through 84
Dairy Foods | September 2011
Tom Suber
USDEC released this summer, concluded that despite foreign investments, commercial dairy farms in China will be unable to keep up with ongoing demand growth. The report cites China’s economic development, which will add 200 million more people to its middle class by the end of the decade. Meanwhile, an influx of investment over the next few years will continue to stimulate demand in foodservice and retail channels and improve a still vastly underdeveloped cold chain. Yes, China’s milk production will grow. The nation’s latest five-year plan aims to modernize the dairy sector with measures that will boost productivity and efficiency. Investors are trying to set up Western-style, large-scale dairies. But the cost of quality milk production in China is turning out to be very high, estimated at more than $20/cwt. Resources (water and feed) are scarce. And even New Zealand’s investments in local farms will add just a fraction of total production. Whereas production growth rates averaged more than 20% per year from 2000-07, FAPRI forecasts expansion of just 5% per year from now to 2025. Cheaper to import than produce The economics are such that the Chinese can’t produce milk as cheaply as they can import it. The situation is facilitated by relatively low import tariffs, plus a free-trade agreement with New Zealand and a pending deal with Australia. In addition, other regions are expected to ramp up import needs as well. Consumption growth in India, Southeast Asia, the Middle East and North Africa will account forr more than half the global increase in non-fluid dairy airy use over the next four years, the Globalization Refresh report says. Structurally higher prices rices will encourage dairy supply growth throughout out the world in the years ahead. Still, the United States can increase supply as cheaply as just ust about anyone, putting the U.S. industry in a good position ion to capitalize on its stilllimproving ability to meet diverse product needs — from China and elsewhere. 䡲 Tom Suber is president of the U.S. Dairy Export Council, Arlington, Va. He can be reached at
[email protected].
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.
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New Product Showcase
Pumps & Valves For more than half a century, Waukesha Cherry-Burrell has been involved in the design, manufacturing and application of external circumferential piston (ECP)-style, rotary positive displacement (PD) pumps. Users are said to benefit from decades of continuing product improvement and the availability of a stainless steel gear cases. The PD pumps are in service around the world in food, dairy, canning, bakery, beverage and pharmaceutical processing. SPX Flow Technology 262-728-4912 SPX Flow www.spx.com Unload and transfer highly viscous materials like caramel, chocolate and fruit purees into dairy products with Graco’s SaniForce pump line. SaniForce air-operated double diaphragm pumps, which are available with 3-A certifications, are ideal for low- to medium-viscosity applications. And, the piston pumps and drum unloaders can effortlessly move highly viscous materials with up to 99% evacuation rates. Graco Inc. 877-244-7226 www.graco.com/sanitary Aseptomag has more than 30 years experience providing products and expertise to its international client base. Its valves are designed to be used where the most stringent sanitary conditions are required. And, its AV aseptic shut-off valve is the foundation of the product line. The line is said to be reliable, adaptable and ease to maintain with a low total cost of ownership. Aseptomag North America LLC 815-633-8411 www.aseptomag.us
Graco Inc.
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Dairy Foods | September 2011
The 365it Complete is the first PMO mix-proof valve that does not require a full port leakage chamber and meets 3-A Sanitary Standard 85-02, which includes cleaning via valve seat lifting for use in dairy plants. Compared to traditional mix proof valves, the 365it Complete weighs less, loses less CIP during seat lifting and uses less air. By combining the 365it Complete PMO with the IntelliTop 2.0, processors receive maximum efficiency and safety in a smaller footprint. Südmo North America Inc. 815-639-0322 www.sudmona.com
View videos demonstrating the newest dairy equipment by visiting www.dairyfoods.com/tv
New Product Showcase GEA Tuchenhagen Martin Brothers provides new, used and rebuilt product pumps, including those by Crepaco, Cherry Burrell and Waukesha. All items are in stock and ready to ship. Martin Brothers 800-652-2532 www.teammartinbrothers.com
under Memorandum M-b-353 and M-b-359, respectively). Additional services include concept design engineering, manifold prefabrication, preventive maintenance and customer training. GEA Tuchenhagen 207-797-9500 www.tuchenhagen.us
Fristam’s new FKL A positive displacement pump series 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.” Plus, its balanced rotors, largediameter shafts and heavy-duty gearbox make it durable and reliable. Fristam Pumps USA 800-841-5001 www.fristam.com/fkl
Ampco’s new ZP line of positive displacement pumps are said to be gaining acceptance with end users. ZP pumps are 100% interchangeable with other leading brands, and include valuable upgrades such as a standard 304 SS gear case, 316L wetted parts, 17-4 SS shafts, helical gears and stainless bearing retainers. Ampco Pumps Co. 800-737-8671 www.ampcopumps.com
GEA Tuchenhagen offers a wide range of sanitary flow components for the dairy, food and beverage industries. Products include mix-proof, single-seat, divert, modulating, butterfly, pressure relief and sample valves, valve control technology, inline instrumentation, cleaning devices, vessel protection and cleaning systems and the mixproof 24/7 PMO Valve and the 24/7 PMO Tank Valve (said to be the first to be authorized by the FDA
Ampco Pumps
Cipriani Harrison Valves manufactures a broad range of sanitary stainless steel processing valves. The latest addition to the Cipriani line is the new 40-Series weir-type diaphragm valve, which is designed for throttling, sampling or shutting off the flow of Continued on page 88
www.dairyfoods.com
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New Product Showcase liquid in ultra hygienic and aseptic applications. This new valve is 3-A authorized and utilizes a patented new seal design called hygieniseal. Cipriani Harrison Valves Corp. 949-589-3978 Cipriani www.ciprianicorp.com Spirax Sarco unveiled a new range of lift check valves — LCV3 (cast iron), LCV4 (carbon steel), LCV6 (stainless steel) and LCV7 (SG iron). Designed for EN and ASME standards, these check valves feature a “clamp-in-place seat,” which offers quick and easy in-line maintenance, thus reducing downtime. The check valves also prevent reverse flow in pipelines carrying most types of liquids, steam and gas, protect any item of equipment and avert pressure surges associated with hydraulic forces, such as water hammer. Spirax Sarco Inc. 800-883-4411 www.spiraxsarco.com/us Spirax Sarco
The LKH 75 centrifugal pump from Alfa Laval is designed for high-volume milk receiving required by most dairies. Similar to the entire LKH series, it features enlarged inlets combined with an advanced impeller design, resulting in unobstructed product flow and very low NPSH requirements. The pump has a capacity of up to 1,000 gpm and pressures up to 200 feet of water, and features low power consumption and noise emission levels. Alfa Laval Inc. 801-222-5300 www.alfalaval.com Alfa Laval’s Unique PMO Plus family of continuous process valves offer a host of continuous processing features. For example, the CP is a PMO-compliant mix-proof valve specifically designed for continuous dairy processing. The CP Cheese Curd valve offers gentle yet efficient continuous handling of the largest curd particulates. And the CP tank valves are completely drainable in vertical or horizontal positions for continuous processing right up to the tank port. Alfa Laval Inc. Alfa Laval 801-222-5300 www.alfalaval.com
Sine pumps - gentle and reliable for dairy • Low shear pumping protects product integrity • No pulsation or meshing rotors • Fewer parts - lower maintenance and is fully CIPable • Improve cheese curd yield by lowering fines • Perfect for curds and whey, yogurt, cream and cottage cheese
Food and Beverage Division MasoSine
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Bredel Watson-Marlow
Dairy Foods | September 2011
masosine.com 800-282-8823
New Product Showcase Tetra Pak offers a complete range of flow equipment, including pumps, valves and fittings for all sanitary processing needs. Its premium flow equipment is said to outperform customers’ expectations for installations, performance and sanitary production. Tetra Pak flow equipment includes LKH centrifugal and SRU rotary lobe pumps and Unique SSV (7000) single-seat and Unique PMO mix-proof valves. Tetra Pak Inc. 847-955-6000 www.tetrapak.com
flow through the valve, providing maximum reliability and failure-free performance under the most extreme conditions. Standard sizes range from 1 ½ to 4 inches. Lee Industries, Inc. 814-342-0461 www.leeind.com
MasoSine now offers a 20-year warranty on Sine pump housing. Unlike lobe pumps, MasoSine food and beverage pumps are engineered for a long service life without the high cost or inconvenience of off-site factory remanufacturing or reconditioning. Customers can eliminate inventory of Continued on page 90
piCLASSIC is Piab’s upgraded vacuum pump series based on COAX technology. Suitable for a wide range of handling applications in the dairy field with large capacities despite its small size and low weight, the piCLASSIC is designed with greater efficiencies than previous pumps in this size class. With an initial high amount of flow, there is no need for expensive vacuum tanks and vacuum valves that are usually needed on machines performing at high rates of speed using rotary vane pumps. With its compressed air source for energy, the piCLASSIC is easy to turn on/off, thus making it ideal for operations that only need vacuum intermittently — a great energy saver. Piab 800-321-7422 www.piab.com
011 X PO 2 8 Sep. PACK E , 26 Sep. – 2 s a g 1800 Las Ve , Booth ll a H l Centra
Lee Industries Lee Industries’ fluid transfer in-line and flush-bottom jacketed, 3-A sanitary-certified ball valves are designed for unobstructed flow while discharging or in-line piping of liquid, semi-liquid or solid-inliquid batches. The unique design of these valves makes them an ideal solution for the dairy foods industry. Precision made of Type 316-L/316 stainless steel, they are designed for corrosion-resistant, sanitary applications where product solidification is a concern. The solid construction assures hot or cold
Just as fresh as your product: fillling technology from krones. www.krones.com
New Product Showcase custom parts for reconditioned lobe pumps because Sine pump parts are always the same size. Plus, with a single shaft and rotor, there is no need for the complex timing gears and multiple seals associated with conventional rotary lobe pumps. MasoSine 800-282-8823 www.masosine.com The Gamajet-88 is a rotary impingement system designed specifically for tanker cleaning. The Gamajet-88 creates high-impact jets, which scour the tank interior, blasting residue from the surface. What makes the Gamajet-88 different from traditional Gamajet machines is the utilization of two machines to specifically focus the impact at the bulkheads. These dual machines work in unison to offer a concise global indexing pattern that covers the entire tanker with twice as many passes at the bulkheads, resulting in the most efficient and effective cleaning in under 20 minutes with 75% less water and chemicals than any other process. Gamajet Cleaning Systems, Inc. 877-426-2538 www.gamajet.com MasoSine
Rieger partnered with Flow Products to bring a full line of aseptic and hygienic valves to North America. Meeting the highest industry standards, Rieger and Flow Products are committed to innovation, customer care and product reliability. Flow Products, LLC 262-657-5566 Rieger www.rr-rieger.de The MD Series of rotary feeder valves from ACS Valves consists of a material metering valve that immediately contributes tangible operating efficiency advantages and long-term production and maintenance savings. Constructed with an 8-vane rotary valve that ensures proper pressure sealing at the inlet and outlet flange, these are equipped with an outboard bearing design that removes the bearings from the path of damaging and contaminating materials and protects the bearings in applications up to 750ºF, while easily managing application pressure differentials up to 15 PSIG. ACS Valves 800-655-3447 www.acsvalves.com
FREE Mobile App New for 2011, PROCESS EXPO attendees have access to a FREE show directory mobile app. Exhibitors, conference schedules, show Áoor maps and local area resources at attendees’ Àngertips! Take a picture of the mobile tag to the right with your smartphone or go to www.myprocessexpo.com/ mobileapp and download the PROCESS EXPO show directory mobile app today! NOTE: First time mobile tag users will need to download the free mobile tag app. at http://gettag.mobi.
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Dairy Foods | September 2011
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PLANT EQUIPMENT Omega Engineering’s IR-USB series of infrared temperature sensors provide a reliable and economical method for most PC-based, non-contact temperature monitoring. The unit features an IR sensor/ signal conditioner installation with a direct USB connection and free user software that converts PCs into a temperature meter, chart recorder or data logger. Omega Engineering Inc. 203-359-1660 www.omega.com Bete Fog Nozzle introduced the HydroWhirl Poseidon, a versatile, high-impact, clean-in-place, rotating tankwashing nozzle that combines slow moving rotation and high-impact spray pattern for more efficient cleaning. It is ideal for tanks up to 22 feet in diameter. Bete Fog Nozzle, Inc. 413-772-0846 www.bete.com Fowler Products introduced a compact waterfall-style cap sorter for production lines running between 100-300 bottles per minute. The WSI 300 waterfall sorter has an 8-cubic-foot cap bin, which sits flush to the capping machine for minimum footprint, and a minimum height for lowceiling environments. Fowler Products, a division of Pro Mach 877-549-3301 www.fowlerproducts.com OCS Checkweighers debuts its full range of industrial PC-controlled checkweighers, ranging from basic ECEssential (up to 150 pieces per minute) to high-end HC-Avantgarde (up to 640 pieces per minute). It is operated by an industrial PC and characterized by its 10.4inch mobile touch display. OCS Checkweighers Inc. 678-344-8300 www.ocs-cw.com The ergonomically designed C150 onsite multifunction calibrator from Palmer Wahl features unique built-in “easy connect” terminals, portable and bench top flexibility and easy-to-use intuitive embedded software. Fully protected with an external anti-shock rubber boot with IP 54 rating, it features five user-selectable languages, 0.005% accuracy, NIST trace92
Dairy Foods | September 2011
ability and HART transmitter compatibility. It also comes equipped with an elastomer keypad to protect from dirt and grease. Palmer Wahl Instrumentation Group 800-421-2853 www.palmerwahl.com Easy-Lock by Aplix is a reclosable system for flexible packaging applications pertaining to cheese, sliced meat and more. Made of food-grade polyethylene, Easy-Lock is comprised of self-mating micro-hooks that provide ease of use and a more resistant closure track. Aplix 704-588-1920 www.aplix.com AlumiSeal from Impco is a high-performance, brush-on methacrylate compound specifically formulated for sealing porosity in aluminum parts and welds containing liquids or gases under pressure. Once AlumiSeal has cured, any excess material on the surface is easily rinsed away with water, leaving the surface clean and ready for painting or other finishing. Impco Inc. 800-779-2491 www.impco-inc.com
R & D INGREDIENTS IOI-Loders Croklaan introduced Freedom IC500 dairy fat replacer, a dropin solution that provides frozen dessert manufacturers with the ability to reduce and control costs while maintaining the desired quality of the end-product. Freedom IC500 is based on palm oil, which provides a less volatile raw material base relative to dairy fat. Loders Croklaan North America 800-621-4710 www.croklaan.com Chr. Hansen introduces Mild O, a cheese culture range that provides flavor and texture in various cheese types. The new culture blends slow down the acidification process, which removes the risk of a brittle or hard cheese texture. The main applications for Mild O cultures include soft cheese, white brined cheese, quark and specific gourmet-style continental cheeses with blends of goat, sheep and cow milk. Chr. Hansen Inc. 800-558-0802 www.chr-hansen.com
FOX IV Technologies released the 5410 mini label printer applicator, integrating Zebra Technology’s RFID-ready 110 Xi4 printer into a rugged, industrial frame. It features a 10-inch OD label roll, can print on either thermal transfer or direct thermal label stock at 203 or 300 dpi, has a maximum print width of 4 inches and is capable of high-quality printing at speeds up to 10 ips. FOX IV Technologies Inc. 877-436-2434 www.foxiv.com
Symrise offers a new line of tropical fruit flavors, featuring mango, guava, papaya, pineapple, lychee, passionfruit, pomegranate, coconut water and prickly pear. This line was created for confections, desserts, toppings, still drinks, tea and other fortified food and beverage applications. Symrise Inc. 201-288-3200 www.symrise.com
Terlet/OMVE released the HT121 bench-top pasteurization and sterilization system, specially designed for compact-size flexibility. These systems allow operators to conduct trials with less than one liter of material, thus reducing the required amount of ingredients and preparation, start-up and processing time and increasing the amount of trials conducted in a single day. Terlet/OMVE USA 856-241-9970 www.terlet.com
Mettler-Toledo introduces ProdX, an advanced connectivity software program that allows centralized monitoring, control and data documentation for checkweighers, metal detectors and X-ray systems. Multiple product inspection devices are integrated into a central monitoring system that can be monitored from multiple locations. Mettler-Toledo Product Inspection Group 813-889-9500 www.mt.com/productinspection
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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EQUIPMENT FOR SALE
EMPLOYMENT
Tetra Pak Product Manager – Flow Equipment Position Responsibilities: The Product Manager’s main responsibility is to drive the flow equipment business to meet sales targets. Responsible for creating a strategy and marketing plan to drive sales and market share through direct and distribution channels for the US/CAD Processing organization. Provide technical expertise internally and externally through technical support in the form of: product selection, specifications, pricing, regulatory issues and troubleshooting.
S er v ing Wit h
Great Lakes Separators
9 46 Pride Since 1
SQUEEZE YOUR WASTE INTO PROFITS!
Now Available: Reconditioned ALFA-LAVAL and WESTFALIA Separators Consultants: Dick Lambert, Rick Veneer and Bill Gooderham
THE PYTHON SEPARATOR It opens, empties, and compacts containers of dairy products and juices.
www.pythonseparator.com CALL today for a competitive quote!
McClaren Machine and Tool, LLC 202-17th St., Brodhead, WI 53520 P: 608.897.4017 • F: 608.897.2958
Call Dave Lambert (920)863-3306
Other Position Responsibilities also include: Customer visits and proposal presentations; Proposal preparation, specifying, engineering solutions; Strategic plan formulation and execution; Supervise and coordinate delivery of sold equipment. Education: Bachelor’s Degree Required - Food Science, Mechanical, or Chemical Engineering Professional Skills and Experience Required: 5 - 7 years direct related experience with strong technical, communication and organization skills Food industry experience preferred Experience with fluid dynamics and sizing of pumps and valves preferred Ability to maintain positive customer relationships Other Skills Required: MS Office (Outlook, Word, Excel, PowerPoint) AutoCad Light or similar software SAP Please send a copy of your resume to the attention of
[email protected]
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Judge INC is an industry-leading recruiting ¿rm specializing in food and beverage manufacturing for over 40 years. Contingency or Retained Search: Mfg./Operations/Plant Mgmt. Engineering & Maintenance Production/Maint. Supervision/Mgmt. Quality and R&D (plant and HQ) To submit your résumé or engage searches, please contact: Tina Gannon ƒ Vice President, Judge INC Ft. Myers Of¿ce ƒ (239) 332-0931
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www.JudgeINC.com 96
Dairy Foods | September 2011
Ad Index
Company Name
Page No.
Company Name
Page No.
Company Name
Page No.
ADM Cocoa......................................................... 39
Fortress Technology .......................................78
Mettler-Toledo ................................................... 49
Ajinomoto Food Ingredients LLC. .......... 29
FPSA................................................................22, 23
MilkPEP .................................................................47
BASF ...................................................................... 21
Fristam Pumps, Inc. .......................................... 4
Mintel International .........................................97
Beneo........................................................................ 7
Fruitcrown Products Corp............................. 9
Neogen.................................................................. 81
Bentley Instruments...................................... 65
GEA Process Engineering, Inc. ............. IFC
Relco....................................................................... 14
Blue Print Automation.................................. 40
GEA Tuchenhagen North America .......71
Brookfield Engineering ............................... 66
Gelita ...................................................................... 16
Cargill Salt .............................................................. 3
Gertrude Hawk Ingredients ...................... 41
DD Williamson................................................... 46
Gram Equipment ............................................. 15
Dairy Conveyor ..................................................77
Gum Technology ............................................. 38
Danisco USA Inc.............................................. 31
H.S. Crocker Company, Inc........................ 61
David Michael & Co. ....................................... 25
International Dairy
Richmond Baking ........................................... 35 Robert Reiser & Co. ................................62, 83 Schneider Packaging Equipment Co., Inc...................................... 56 Sensient Food Colors................................... 51 SensoryEffects ................................................. 14 SPX Flow Technology Segment...........IBC Sudmo North America, Inc. ........................17
Delkor Systems, Inc. .................................... BC
Foods Association ......................................73
T.D. Sawvel Co. Inc. ........................................... 6
DSM Nutritional Products, Inc. ................ 43
iTi Tropicals ..................................................18, 87
Tate & Lyle............................................................ 33
Eriez Magnetics................................................ 54
KRONES .............................................................. 89
*Tetra Pak Hoyer ......................................18 a-b
Evergreen Packaging ................................... 53
Martin Brothers, Inc. ...................................... 66
Tindall Packaging, Inc................................... 85
Exopack ............................................................... 55
MasoSine ............................................................ 88
Weber Scientific ................................................11
Flow Products, LLC......................................... 65
Matsutani ADM ..........................................12, 13
*Indicates Regional Advertising
ACCELERATE YOUR
INNOVATION Mintel provides the most relevant, reliable & current market intelligence available. Flavor, ingredient & preparation trends Nationwide restaurant menu tracking Global new product monitoring & analysis
www.dairyfoods.com
97
Inside Perspective
Taking an Intuitive Approach to Sustainability
A
urora Organic Dairy is a leading organic dairy company that serves the private-label market. With headquarters in Boulder, Colo., the company began marketing organic milk in 2004 and has been on a growth track ever since, as the demand for high-quality organic milk continues to grow. As a vertically integrated organic dairy company, Aurora Organic Dairy (AOD) learned early in its development that sustainability initiatives are not only good for the planet, they can also contribute to improved operating efficiencies. With organic dairy farms in Colorado and Texas, and a fluid milk plant in Colorado, AOD built many of its facilities from the ground up and incorporated sustainability initiatives along the way. AOD completed a three-year product life-cycle analysis with the University of Michigan in 2011, which provides a benchmark for the company’s carbon footprint, energy use, water footprint, solid waste and nutrient densities. Information about the products’ environmental impact — from seed to shelf — has allowed us to identify opportunities and reduce the carbon footprint of a gallon of organic milk by 13% and energy use by 7% since 2008. Armed with this valuable data, we can better determine our sustainability priorities and report the progress in our first corporate sustainability report. This report will reflect AOD’s holistic approach to sustainable business by considering its impact on key stakeholders as well as the environment. In this process, management found that establishing its product life-cycle data and knowing where AOD stands with environmental performance is actionable and can be an important stand-alone sustainability initiative. Tracking this information allows companies like AOD to better make common sense and capital investment decisions where they will have the most impact. From energy-efficient systems in our processing plant to emission-reducing ini-
98
Dairy Foods | September 2011
tiatives at our dairy farms, we have focused on enhancing operations to reduce our impact on the environment. One practical example at AOD’s farms is mitigation of methane gas emissions from animal waste. AOD composts or ages its manure at all dairy farms, cutting down on these emissions and providing the dairies with organically approved fertilizer for its pastures. Additionally, some of its facilities use a dry vacuum system to collect manure, which uses less water in the barns than other systems.
Sonja Tuitele
variable speed motors, advanced refrigeration systems, low-wattage lighting and construction materials to prevent energy loss. Continued demand for organic dairy products prompted a major plant expansion in 2011, allowing the processing facility to reduce its carbon footprint per gallon of organic milk as the facility leverages its energy efficient systems. Furthermore, in 2011, AOD’s processing plant became one of the first to participate in an off-site solar panel leasing program
Our processing plant became one of the first companies to participate in an off-site solar panel leasing program with its electricity provider. Another result of AOD’s research was a shift from the disposable udder wipes used in milking parlors to washable microfiber towels. AOD learned it could save thousands of pounds of solid waste this way with a modest capital investment. After careful testing, the reusable wipes showed no loss in milk quality while potentially eliminating more than 9,000 pounds of paper towel waste per year once implemented at all farms. The project can also reduce CO2 emissions by more than 300 metric tons and cuts down on water use by the equivalent of 10 Olympic-sized swimming pools each year. With ample sunshine at all its locations, AOD also identified creative ways to use renewable solar energy. A solar thermal hot water heating system is being used at one facility to heat 900 gallons of water used for its dairy parlor wash-ups every day. This installation can reduce the propane and natural gas used in other water-heating systems. At AOD’s fluid milk plant, energy savings were built into the state-of-the-art facility when it was constructed in 2004. An energy-efficient design included
with its electricity provider. This allows the processing plant to source renewable solar energy while saving the significant capital investment of installing its own solar panels. Other operational initiatives, such as increasing feed and product transportation efficiencies and recycling processing plant materials, have helped reduce our company’s impact on landfills and the environment. Aurora Organic Dairy’s position as an integrated dairy business provides its people with a unique perspective on the role both producers and processors play in environmental stewardship. Being a sustainable business is a long-term commitment requiring operational creativity and ownership of results across the entire organization. This intuitive approach can result in a more efficient supply chain and lower environmental impact, from cow to carton. 䡲 Sonja Tuitele is the director of communications and sustainability for Aurora Organic Dairy, Boulder, Colo. Dairy Foods seeks essay from dairy processors. Contact
[email protected].
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packaging innovation at work.
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