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

Processor of the Year The North American cheese and dairy division of Kraft Foods took bold steps and placed big bets on new foods and manufacturing processes. It developed new products around popular brands like Philadelphia and Velveeta. Kraft is creating new foods, like dairy-based Milk and Granola bars. The company also is reducing the amount of energy and water used in processing and leading the dairy industry in research into sodium reduction. For these reasons and more, Dairy Foods names Kraft Foods North America the 2011 Processor of the Year. p. 34 On our cover: George Zoghbi is president of Kraft Foods’ North American cheese and dairy division, based in Glenview, Ill. The company is Dairy Foods’ Processor of the Year. Photo courtesy of Kraft Foods.

Features News & Trends 10 Newsline The German show Anuga is full of dairy ideas; Dannon forges relationship with a family farmer; MilkPEP names marketing winners.

62 64 69 70

Dairy Foods invited suppliers of blow-molding equipment to share their thoughts about how dairy processors can best use stretch, extrusion and injection blow-molding technologies. Vendors say processors must keep in mind that equipment makers provide more than machinery. There’s package design and prototyping, for example. p. 47

Products & Marketing 20 Dairy Market Trends

Ingredient Technology 26

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

New Product Review Juices, teas and waters

Frozen Desserts Time to finalize new flavors

The movers in the cheese category

Departments 8 16 18 56

Breaking the Mold

30

32

REPORTS 47

Blow-molding Equipment

Dairy is an ideal carrier for nutrients

52

Sayler on Safety

Culturally Speaking

54

Spotlight on Sustainability

Lab Talk

Controlling texture in cultured dairy

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.

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

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From the Editor’s Desk

Dairy Industry Rhyme Time s the days grow short and the nights get long, I’m about to launch into a rhyming song. We have come to December and the winter solstice, A time when Santa checks who was naughty and nicest. I won’t pass judgment on events of the past year. Rather, my aim is benign — to cheer, not jeer. Here are the people, products and brands we revere. Fluid milk, Greek yogurt and more. Am I clear? For instance, I sing of ice cream and sorbet. Even water ices and sherbets? Of course, let’s play. Unilever imported its premium Magnum bar. Ice cream from Europe. That’s pretty far. Baskin-Robbins’ Cake Bites are a tasty nibble. They melt in the heat, but let’s not quibble. Bang! made ice cream overloaded with caffeine. The company found new uses for the beloved coffee bean. Turning to milk, what’s new here you ask? Were processors at all up to the task? Milk sales were off. Boo hoo. Boo hoo. That didn’t stop Dean Foods from launching TruMoo. Chocolate milk proves to be a help in post-workout recovery. Stepping lively with that news is MilkPEP’s Vivien Godfrey. This year milk flowed to make more yogurt and cheese And farmers produced all they could please. A new chapter was written in Greek history with the No. 1 yogurt being sold by Chobani. Fage’s bold TV ads for a yogurt that’s Greek were lovely and eerie. They weren’t for the meek. From Washington came new Dietary Guidelines. They promote eating of dairy, within certain confines. The solons also wrote a food safety act. There will be more details; as yet it’s abstract. Congress is also preparing a new dairy bill, Let’s hope it’s not some poisonous pill. Producers wrote a draft to create a foundation. But processors were quick with their condemnation. Can Jerry Kozak and Connie Tipton weather the storm that’s swirling around this dairy reform? A trio of processors won Dairy Foods awards. We surprised a few. I know they were floored. These companies showed they have the goods: Congrats to Kraft, Graeter’s and Leprino Foods. Wisconsin Dairy Products made a champion of Gifford’s. Taste this ice cream from Maine and you’ll be in accord. The editors went on the road to see first hand how processors make dairy foods in this great land. We donned hair nets and booties to take the plant tour. In corporate boardrooms, owners shared company lore. In Indiana, Nestlé makes milk that’s shelf-stable, You can drink it on the go or at the kitchen table.

Jim Carper

A

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Dairy Foods | December 2011

Perry’s Ice Cream near Buffalo distributes other foods also, A bigger warehouse is helping them grow. We anointed DCI of Wisconsin the “ambassadors of cheese.” Saputo from Canada acquired the firm with ease. There is a Supercow atop Guida’s headquarters. The caped, masked bovine has its supporters. Dippin’ Dots in Arkansas fell into trouble of late. We’d like to see it recover and get back to the starting gate. Fage didn’t say much; claims its recipe is proprietary. But in its yogurt goes milk that is rBGH-free. In Cincinnati, we saw ice cream packaged by hand. With assistance from Kroger, did Graeter’s market expand. In Jersey, Marybeth Tomasino makes cheeses for Milano’s, like shredded Parmesans and Romanos. Long ago in Cleveland, “Pierre” churned ice cream. Today Shelley Roth has taken over his dream. Leprino Foods of Denver opened an office offshore. Go see the cheesemaker in far-flung Singapore. To tradeshows, fairs, forums and expos also we did go, To Miami, Las Vegas, Atlanta and Chicago. We saw the machines that form, fill and seal the dairy foods we consume at each meal. That’s the end of this column, my last for this year. In January I’ll start up again, I’ll begin in first gear.  Jim Carper is chief editor of Dairy Foods. Phone: 847-405-4009. Email: [email protected].

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News & Trends

NEWSLINE... Dairy Processors Set the Table with New Foods thnic dairy foods are emerging into the mainstream. Processors exhibiting at the German tradeshow Anuga Oct. 8-12 sampled their new products, including those with appeal to consumers from southwest Asia and central Europe. For example: • Canada’s Punjab Milk Foods Inc. presented its readyto-eat rasmalai (or ras malai), a traditional Indian and Pakistani dairy-based dessert consisting of individual balls of paneer, a soft, fresh cheese sitting in a flavored clotted cream. Punjab Milk Foods was a winner in Anuga’s taste11 awards program. Its refrigerated product comes in two traditional flavors — pistachio and saffron — with sugar-free options available. Each 1-kilogram package (2.2 pounds) contains a dozen balls. • Another taste11 award recipient was Lightfood OŰ from Estonia, which was recognized for its sour milk drink called Dietan. This slightly carbonated drink, also known as tan, is a less viscous version of kefir and is rich in probiotic bacteria. It is usually consumed plain, but if flavored, it will not contain added sugars. Tan has been consumed

E

 In October, 6,500 food and beverage exhibitors, representing 100 countries, set up shop at Anuga, the biennial trade show in Cologne, Germany. 10

Dairy Foods | December 2011

throughout the Caucasus mountain region since ancient times. Only in the past decade has it been commercially produced, with distribution primarily in Russia. A number of processors are now making it available for international markets. • Germany’s Probiotan GmbH sampled its line of tan beverages. The company produces the drinks in a variety of flavors, including banana, carrot, cherry, dill and strawberry. The fruit and vegetable varieties contain pureé or concentrate for natural sweetness. • Van der Poel Desserts Hengelo BV from the Netherlands was recognized by taste11 judges for its new dual pack of ice cream and cherry sauce sold under the Ambach brand. Consumers are instructed to warm the sauce in a microwave oven or on a stove top and pour it over the ice cream for a traditional Dutch dessert. U.S. processors among the exhibitors More than 155,000 buyers representing 180 countries attended Anuga, a five-day fair held in Cologne, Germany. About 150 U.S. exhibitors, showing in five product-specific USA Pavilions, were among the more than 6,500 food and beverage exhibitors who came from 100 countries. The dairy foods category was well represented, particularly in cheese, cultured dairy and frozen dairy, as these products offer the best opportunity for export. More than 500 companies entered more than 1,200 innovations in the taste11 competition. Judges selected 54 new products, representing all 10 of the fair’s specialized halls (bread and bakery, hot beverages, chilled and fresh foods, dairy, drinks, fine food, foodservice, frozen food, meat, organic and RetailTec). In addition to evaluating the quality and originality of the entries, the jury also considered packaging, userfriendliness, the recipe and visual appeal. Italy was designated a partner country and nearly 1,100 of that nation’s companies exhibited. Taste11 winner Pezzetta s.r.l. showed Formadi Frant, a mild, soft cheese with some of the savory and spicy nuances typical of an aged cheese. The contrast is made by mixing a variety of grated cheeses, all from Italy’s Friuli region, with salt, pepper and sour cream. The resulting soft cheese is aged until it becomes slightly firm. Luigi Guffanti 1876 s.r.l. received a taste11 award for its Formaggio 1/3 Birra, a whole cows milk cheese made with beer. The processor mixes beer made by Brewer Un Terzo directly into the whey during cooking, which lends the cheese its fine aroma and beer flavor. Continued on page 12

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News & Trends

German dairy makes a splash The dairy hall featured 365 exhibitors. One German company — DMK Deutsches Milchkontor — used the fair as a platform to demonstrate its new position as an international leader. The company was formed in May 2011 through the merging of Nordmilch with Humana Milchunion. With forecasted annual revenues of about 4 billion Euros (about $5.5 billion), DMK instantly became one of the Top 20 dairy companies in the world. “We are using Anuga to give the first ever overall view of our concentrated product, assortment and packaging competence. The development of new markets outside Germany, outside Europe, is one of the pillars of our corporate strategy and an important lever to increase sales volume and revenue,” says Rolf Janshen, DMK’s managing director of sales. The company recognizes growth opportunities for exporting select fresh dairy products and cheeses to retail and wholesale business and to work in collaboration with food manufacturing industries in other countries on future developments. A top priority for DMK is to educate and safeguard the “made in Germany” tagline. A number of other German dairies debuted an array of dairy innovations, also emphasizing their export capabilities. For example, family-owned Ehrmann AG generates almost half of its total turnover of 650 million Euros ($896 million) outside of Germany. Its Russian subsidiary has become Russia’s thirdlargest yogurt producer, and specifically from its Moscow

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Dairy Foods | December 2011

location, Ehrmann delivers long shelf-life yogurts to destinations as far away as China. (See New Product Review, page 23, for one of its new products.) J. Bauer GmbH & Co. KG used Anuga to emphasize its commitment to avoiding genetic engineering. Since April, J. Bauer has only been using milk from farms that do not use genetically modified animal feed. It developed its own “Without Gene Technology” quality seal. Emmi Group, Switzerland’s largest milk processing company, also emphasized that it is setting its sights on the international market. With annual revenues of about 2.7 billion Swiss francs ($3 billion), about one-fourth come from outside Switzerland. The company also has a strong presence in the United States, with a cheese processing facility in Monroe, Wis., and a fluid milk and yogurt plant in Penn Yan, N.Y. Products include Swiss-made foods, such as Kaltbach caveaged cheese, as well as domestically reproduced versions of Swiss innovations such as Swiss Premium yogurt and Caffe Latte. Emmi debuted a four-pack of this convenience coffee-milk beverage, which has the Rainforest Alliance seal of approval because Emmi committed to using only coffee beans from sustainable producers. Anuga is staged every two years. The next edition is Oct. 5-9, 2013. For more information, visit www.anuga.com. — By Product Development Editor Donna Berry, who attended Anuga.

News & Trends

Dannon, McCarty Family Farms Forge Relationship The Dannon Co. Inc., White Plains, N.Y., forged a new and unique relationship with McCarty Family Farms, Bakersfield, Calif., to supply the milk for Dannon’s Fort Worth, Texas, plant. Historically, Dannon has relied exclusively on a co-op for fresh milk. Dannon has been looking for alternative ways to source milk to reduce the impact of the volatility of the price of milk and continuously improve on environmental sustainability. “The volatile swings in the price of milk have on many occasions impacted our business planning process and other functions,” says Michael Neuwirth, senior director of public relations for Dannon. “Furthermore, seeking ways to continuously reduce Dannon’s environmental impact has been limited based on the indirect relationship between our company and dairy farmers through a co-op.” As part of the relationship, McCarty Family Farms’ fourth-generation dairy farmers in northwest Kansas will be providing milk exclusively and directly to Dannon. Both Dannon and McCarty Family Farms sought this relationship to overcome some of the pricing stability issues and lack of direct relationship between farmer and customer. This is a win-win situation for both companies, according to a Dannon press release. For starters, McCarty Family Farms and Dannon provide improved financial stability for one another during periods of volatility in milk pricing. Secondly, Dannon and McCarty Family Farms share ambitious goals for reduction of impact on the environment, which can now be implemented based

on the direct collaboration. The specifics of the relationship and agreements are confidential, however, this is a multi-year commitment that is expected to bring benefits to both parties. “We’re not in a position yet to talk about some of the environmental projects we’re going to be working on together at this point in time, but we’ll let you know as soon as possible once we’re ready to speak publicly about them,” says Neuwirth. “Needless to say, we’re very excited about them.” Continued on page 14

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News & Trends

IDFA Backs FDA Food Safety Priorities The International Dairy Foods Association, Washington, D.C., says it supports the Food and Drug Administration’s long-term strategic plan to improve effectiveness and efficiency under its Foods and Veterinary Medicine Program. Agreeing that the implementation of the Food Safety Modernization Act (FSMA) should be a top priority, IDFA urged FDA to help spur innovation by modernizing food standards and good manufacturing practices and completing rulemaking on yogurt and ultra-filtered (UF) milk. The plan outlines the agency’s priorities for 2012-16. “IDFA was a strong supporter of FSMA during the legislative process and continues to support FDA during implementation,” the report says. “Development and application of science-based preventive controls are vital to the new law’s success. Issuance of a proposed rule on preventive controls should be a very high priority for the agency.”

One-third of standards cover dairy products Noting that more than a third of all FDA food standards cover dairy products, IDFA urged

the agency to modernize the food standards process and allow changes for non-characterizing ingredients without requiring new rulemaking. This change would enhance the industry’s ability to innovate quickly and save FDA considerable resources, without any negative impact on consumers. IDFA also called for FDA to finalize rulemaking that would allow UF milk to be used in standardized cheese products and update the standards of identity for yogurt. Waiting years for these rules to become final has hindered opportunities for greater dairy product innovation and growth, the comments stated. Timely testing and reporting of import and domestic samples are also important to the industry, especially for perishable products. As the agency increases its inspections of food facilities and begins to enforce the new preventive controls requirements, IDFA asked FDA to conduct sampling and report results in a timely and transparent manner. IDFA also offered suggestions for improving or clarifying several food safety provisions, such as modernizing the good manu-

facturing practices (GMPs), which were last modified 25 years ago. IDFA says increased regulatory attention to sanitation, employee training, and environmental and allergen controls would improve food safety, and asks the states to continue relying on inspections for Grade A milk facilities to ensure compliance with the Pasteurized Milk Ordinance.

Allow any safe and suitable sweetener In the area of nutrition, the comments urged FDA to grant IDFA’s petition, filed jointly in 2009 with the National Milk Producers Federation, Arlington, Va., to allow any safe and suitable sweetener to be used in sweetened milk products, including flavored milk. “This petition is especially timely, as the First Lady’s ‘Let’s Move’ initiative properly focuses attention on steps that can and should be taken to combat childhood obesity,” the comments said. “Because flavored milk is strongly preferred by many children, one way to reduce caloric intake is to allow alternative sweeteners that have zero or very few calories to be used in flavored milk.”

MilkPEP Names Winners of 2011 MilkPEP Awards The Milk Processor Education Program (MilkPEP), Washington, D.C., announced the winners of the 2011 MilkPEP awards. Six category winners and an overall grand prize winner were honored for their commitment to increasing fluid milk sales, promoting the benefits of drinking milk and their use of MilkPEP programs and resources to help increase awareness and sales of their dairies’ branded milk products. Grand prize winner Cindy Layne of Producers Dairy Foods Inc., Fresno, Calif., was selected for her cumulative efforts throughout the year to increase awareness and grow milk sales using MilkPEP programs and resources. Layne developed several successful programs in the Fresno Unified School District that encouraged students to drink more milk during breakfast. In addition, she organized several Refuel With Chocolate Milk sponsorship events, including the 100th annual “Bay to Breakers” race, which provided a venue for 24,000 participants and spectators to sample low-fat chocolate milk. Layne will be featured in an upcoming Milk Mustache “got milk?” trade advertisement. “MilkPEP is pleased to recognize this year’s MilkPEP Award winners. Each winner demonstrated creativity and a real commitment to success,” says Julie Buric, vice president of marketing for MilkPEP. “These sales and marketing professionals took advantage of the MilkPEP programs in their markets and maxi-

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Dairy Foods | December 2011

mized them in a variety of ways for their dairies. As a result, they helped to drive sales, build brands and educate consumers across the country.” Winners were named in six categories and received an iPad2 for their efforts. The following processors received categorylevel recognition: • Retail Promotions: Brian Rahill and Amy Forillo, Lehigh Valley Dairy, Lansdale, Pa. • School Milk: Cindy Layne, Producers Dairy Foods • Refuel With Chocolate Milk: Anthony Escobar, Super Store Industries, Lathrop, Calif. • Marketing & Product Innovation: Vince Front, The Kroger Co., Cincinnati • Local Processor Events: Carol Stewart, Prairie Farms Dairy, Hazelwood, Mo. • Social Media: Barry Wood, Goldenrod Dairy, Symsonsia, Ky. Sales and marketing professionals can enter the MilkPEP Awards any time throughout the year online at www. MilkPEP.org. Next year’s awards will include a new category, Breakfast at Home, which aligns with MilkPEP’s 2012 marketing plans. The 2012 annual awards will be announced in August 2012. For complete entry details and rules, go to www.MilkPEP.org.

News & Trends

Chobani to Open $100 Million Facility in Twin Falls, Idaho As part of the company’s continued strategic growth initiative, Chobani plans to open a second domestic manufacturing plant that will sit on 200 acres of agricultural and industrial land. “We visited numerous possible sites over the past several months, and met a lot of great people along the way,” says Hamdi Ulukaya, founder and CEO of Chobani, which is owned by Agro Farma Inc., Norwich, N.Y. “It was a hard decision to make, but in the end, we chose Twin Falls due to its abundant milk supply, skilled labor force and tight-knit local community. We’re looking forward to starting the next chapter of the Chobani story here in Idaho’s Magic Valley.” Chobani’s “Nothing but Good” philosophy, which includes supporting local farmers, job creation and community outreach, will be instrumental at their new site as the company begins to form roots in the Twin Falls community. Expected to be operational in 2012, the new plant is expected to create around 400 new jobs. “We anticipate Chobani’s planned investment to result in an additional $200 million in regional sales. Between construction activities, employment at the plant and the sourcing of local supplies like milk, there’s no question that the economic effect of Chobani’s new site will run deep throughout Southern Idaho, benefiting family farms as well as our dairy and construction industries,” says Idaho governor C.L. “Butch” Otter. “We’re thrilled Chobani chose Twin Falls as their second home.” Chobani’s new Twin Falls site will not impact plans to move forward with their announced expansion for the company’s landmark South Edmeston, N.Y., manufacturing plant. Continued on page 16

Leprino Foods Named Exporter of the Year

 Leprino Foods Co., Denver, was selected the Dairy Foods 2011 Exporter of the Year (see article in the November issue). At the annual meeting of the U.S. Dairy Export Council, Dairy Foods chief editor Jim Carper (second from left) presented the award to Leprino’s Paul Vraciu, Sue Taylor, Allison Specht and Derek Friedman. Photo by www.jeffellisphoto.com

www.dairyfoods.com

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News & Trends

PEOPLE The National Frozen & Refrigerated Foods Association (NFRA), Harrisburg, Pa. Officers and members of the board of directors for 2011-12 were sworn in at the association’s 67th annual meeting. Inductees include Bob Branham, General Mills, elected chairman-elect, and Scott Haws, Land O’Lakes, secretary. Newly elected to the board of directors are John Farmer, Global Dairy Products; and Steve Ostrander, Crystal Farms. Elected for a second term on the board of directors are John Arnold, Sargento Foods; David Davis, Welch’s Foods; David Epps, Sara Lee; Ken Gipple, Kraft Foods; John Mastropaolo, Dannon Co. Inc.; Joseph Mrozek, Pinnacle Food Group, LLC; and Louise Yerian, Nestlé USA. Sargento Foods, Inc., Plymouth, Wis. Ken Tobey was reassigned to customer research manager, responsible for all category management activities related to Kroger. Drew Carmichael was appointed core marketing manager and Keith Kronbeck as customer research manag-

16

Dairy Foods | December 2011

er for the Supervalu-Target team in Minneapolis. Meanwhile, Jana Johnson was named technology principal, responsible for leading R&D efforts related to natural cheese platforms and product launches. Charmaine Hilgert was appointed regional merchandising manager in the consumer products division, responsible for all retail operations and programs in the Southeast United States and overseeing key accounts. Sara Lee Corp., Downers Grove, Ill. Ingrid Baron was named chief marketing officer of Sara Lee’s international beverage business, CoffeeCo, once it spins off in the first half of 2012. Baron will be responsible for driving the innovation portfolio, brand strategy and marketing talent for the new business. Koch Membrane Systems Inc., Wilmington, Mass. Carlos Rodrigues was promoted to business development manager, industrial and life sciences for South America, responsible for all aspects of the contin-

ued development and expansion of KMS’ industrial and life sciences business. Deacom Inc., Wayne, Pa. Drew Schwoyer was named lead product consultant, bringing 10 years of manufacturing management experience and offering a unique perspective into Deacom software implementation. Matthew Keffer is the new senior sales executive, bringing more than 12 years of industry experience with engineer-to-order, make-to-order, make-tostock and mixed-mode manufacturing companies in the small- to mid-sized enterprise market. Plus, he specializes in working with ERP, SCM, CRM and BI software. Wixon Inc., St. Francis, Wis. Paul Whitaker was named consumer products divisional leader, responsible for growth of top-line revenue through direct sales and business development activities, divisional leadership of the consumer products cross-functional team, management of the day-to-day operations and organizing strategic and tactical planning.

News & Trends

B R I E F LY … Sargento, Tillamook Receive GFSI Certification Sargento Foods’ North Sioux City, S.D., plant became certified to the Global Food Safety Initiative (GFSI) with an “A” rating from the British Retail Consortium (BRC), demonstrating excellence in both food safety and quality operations. In addition to the North Sioux City plant, Sargento’s plants in Hilbert, Kiel and Plymouth, Wis., each received GFSI certification in 2009, and has maintained their “A” status during annual audits. Meanwhile, Tillamook County Creamery Association, Tillamook, Ore., received Level 2 certification under GFSI for its production facilities in Boardman and Tillamook, Ore., in August and October, respectively. Honest Tea Launches Consumer-interactive Tumblr Site Honest Tea released “Keeping it Honest,” the second edition of its annual Mission Report, available at www.honesttea.tumblr. com. This medium allows Honest Tea to maintain a regular dialogue with its readers through posts on individual topics of interest. The Tumblr page will be updated throughout the year, as the company works to advance its mission. For more information, check out the non-dairy beverage section of Dairy Foods magazine’s State of the Industry report, November 2011 issue. Nestlé’s Canadian Plant Receives Gold Medal IPM Partner Award Nestlé Ice Cream Factory Canada, a manufacturer of Nes-

cafe and Nesquik, to name a few, received the 2010-11 Gold Medal IPM Partner Award for its outstanding commitment to Integrated Pest Management (IPM) partnerships. The award was handed out by Orkin, LLC, Richmond, Va., the IPM Institute of North America, Madison, Wis., and NSF International, Ann Arbor, Mich. Nestlé’s Canadian plant utilizes Orkin’s Gold Medal Protection, a comprehensive IPM service that focuses on vigilant sanitation, prompt adherence to structural pest management recommendations, diligent record-keeping and staff participation in IPM training sessions. Hilmar Cheese Awarded 2011 Corporate Donor Honor Hilmar Cheese Co. Inc. received the 2011 Outstanding Corporate Donor in Philanthropy award by The Yosemite Chapter of the Association of Fundraising Professionals in cooperation with the Modesto Rotary Club, both in Modesto, Calif., for its generosity to Emanuel Medical Center, Turlock, Calif. Hilmar’s donations helped the center build, renovate, purchase equipment and provide hospice care. Bella Pak’s Plant Becomes USDA Organic Certified Bella Pak’s Appleton, Wis., plant is now USDA Organic certified by the Midwest Organic Services Association, Inc. (MOSA) to produce organic Parmesan and Romano cheeses under its Redwood Farms line. Bella Pak’s cheese comes from certifiedorganic farms and processing plants. Continued on page 18

www.dairyfoods.com

17

News & Trends

SUPPLIER NEWS Chr. Hansen cut the ribbon at its new Global Expertise Center in Milwaukee, Wis. Designed as the “go-to center” for natural color solutions to the international prepared foods industry, natural color specialists are on hand to help customers solve their technical issues

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Gold Coast Ingredients received certification for International Food Standard (IFS), Version 5, a standard that is benchmarked against the criteria of the Global Food Safety Initiative (G FS I). This certification provides evidence of the commitment of Gold Coast Ingredients to build and operate a management system capable of meeting these requirements.

G EA Process Engineering purchased an existing high-shear mixing technology that’s designed for the mixing of high-viscosity dairy and f o o d p ro d u c t s s u ch a s s w e e t e n e d condensed milk, ice cream mixes, processed cheese and spreads, ready-todrink iced coffees and chocolate and isotonic drinks. The new mixing business will be headquartered at G EA S k a n d e r b o rg i n D e n m a r k , a n d w i l l market products under the new Mixing Formula brand name. Autocrat LLC received an “Excellent” rating on its 2000 Level II certification by the Safe Quality Food (SQF) organization, enabling the company to meet product trace, regulatory, food safety and commercial quality criteria in a structured and cost-effective manner. Autocrat’s employees have been preparing for this certification for nearly two years under the guidance of certified SQF practitioner, Gina Brooks. International Paper (I P) announced its goals to increase energy efficiency and reduce greenhouse gas emissions by 20% by 2020. I P plans to achieve these reductions by increasing manufacturing efficiencies, exploring new technologies and engaging its employees to find innovative solutions throughout its operations.

Dairy Foods | December 2011

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News & Trends )ODYRU6\VWHPV

SUPPLIER NEWS Ecolab Inc. received the 2011 IDFA Innovation Sustainability Award for its Envirocid Plus clean-in-place cleaner that’s designed to help processing plants manage their effluent and operating costs while improving their sustainability profile. Envirocid Plus uses a patent-pending, blended acid formulation that helps reduce total phosphorus and nitrates in plant effluent. Spirax Sarco joined the U.S. Department of Energy’s Save Energy Now LEADER program, making a voluntary pledge to reduce its industrial energy intensity at its Blythewood, S.C., headquarters by 25% over the next 10 years. The LEADE R program is a new component of the existing Save Energy Now initiatives, which provide participating businesses with tools and training to help reduce energy and improve productivity, reliability, cost-

effectiveness and overall environmental performance. Solazyme Roquette Nutritionals is opening a Phase I I commercial production facility in Lestrem, France, to produce its lead microalgae-derived food ingredient — whole algalin flour. The 5,000-metric-ton facility is scheduled to be completed by end of 2012.

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New Products & Marketing

DAIRY MARKET TRENDS

String Cheese Makers Tie up Sales Increase  Marina Mayer Executive Editor

or a child in the 1980s, string cheese was the ultimate must-have lunch snack. The simple act of peeling strings away from a cylindrical-shaped “stick” was both exciting and innovative and transformed the way consumers eat cheese. Even today, cheese processors continue to revamp this $670 million category by introducing a slew of string cheese products that tout higher calcium content and less fat in a portable packaging concept. For starters, private label remains No. 1 with $227.9 million in sales, according to Chicago-based SymphonyIRI Group, for the 52 weeks ended Oct. 2. However, it was the Kraft Natural brand that experienced the most action with sales skyrocketing 364.3% and unit sales following suit with a 265.8% increase. That’s because the producer of Kraft Natural, Kraft Foods Inc., Northfield, Ill., launched a jalapeño flavor to its team of string cheese products, says Angela Wiggins, corporate affairs, cheese and foodservice. This natural low-moisture, part-skim mozzarella string cheese option offers 80 calories per serving and comes 12 snack sticks to a 12-ounce package. This new flavor, which has proven to be popular with adults, is sold under both the Kraft and Polly-O brands, with the latter slotting in at No. 9 with a 39% jump in sales and a 39.4% rise in unit sales. Sargento brand string cheese, produced by Sargento Foods Inc., Plymouth, Wis., garnered a 22.1% spike since last year, followed by a 14.7% increase in unit sales thanks to its Natural Light string cheese snacks, developed with 50% less fat. Last year, Schreiber Foods, Green Bay, Wis., partnered with Weight Watchers International Inc., New York, to create a line of reduced-fat cheeses, including Natural Light Smoked and Light mozzarella string cheese options, as well as Natural Reduced-fat Colby Jack and Cheddar cheese sticks. As a result, sales jumped 12.9% since last year and produced a 13.2% leap in unit sales. Meanwhile, Frigo Cheese Heads, owned by Saputo Foods Inc., Lincolnshire, Ill., placed third with a 4.9% rise in sales from last year, due in part to its lineup of light, low-moisture part-skim and whole milk string cheeses. However, it dipped 0.2% in unit sales.

Top 10 Brands of String Cheese

Some brands come untied While some string cheese items are riding the waves toward success, others are experiencing difficulty staying afloat.

Editor’s Note: For more about cheese, see Dairy Foods’ Annual Cheese Outlook (October 2011) and “Raw is the Draw” in Dairy Foods’ State of the Industry report (November 2011).

F

20

Dairy Foods | December 2011

Brands

Dollar Sales (millions)

% change vs. yago

Unit Sales (millions)

% change vs. yago

1

Private Label

$227.9

+9.3

102.7

-3.8

2

Sargento

$98.7

+22.1

21.8

+14.7

3

Frigo Cheese Heads

$78.2

+4.9

19.0

-0.2

4

Precious Stringsters

$35.3

-3.2

6.6

-7.9

5

Kraft Snackables

$25.4

-55.3

8.8

-44.0

6

Sorrento Stringsters

$22.6

-1.9

4.8

-7.8

7

Kraft Natural

$21.3

+364.3

4.5

+265.8

8

Schreiber Weight Watchers

$16.2

+12.9

3.9

+13.2

9

Kraft Polly-O

$14.3

+39.0

2.1

+39.4

10 Kraft Cracker Barrel

$11.6

-15.6

2.9

-20.8

52 weeks ended Oct. 2, 2011. Source: SymphonyIRI Group, a Chicago-based market research firm, www.symphonyiri.com

For instance, Kraft Snackables line of string cheese products underwent a 55.3% dip in sales, while Kraft Cracker Barrel brand string cheese items dropped 15.6%. Precious Stringsters and Sorrento Stringsters, both produced by Lactalis American Group Inc., Buffalo, N.Y., undertook a 3.2% and 1.9% drop in sales, followed by a 7.9% and 7.8% decrease in unit sales, respectively. Whichever way they are peeled, string cheese snacks are here to stay. 

From the breakfast line to the finish line, she made the most of MilkPEP. Cindy Layne Marketing Coordinator Producers Dairy Foods Inc., Fresno

How did Cindy Layne win our Grand Prize for 2011? She took her MilkPEP materials and ran with them. Cindy maximized the power of the “got milk?®” Breakfast Challenge to wake up Fresno students, increasing morning milk consumption in the winning school by 13%. And she hit the ground running with Refuel With Chocolate Milk, handing out 24,000 lowfat chocolate milk pouches at one race event alone. You could be next. Visit MilkPEP.org and tell us your story. You could win the Grand Prize, exciting monthly prizes or even an iPad 2!

2011 milkpep award grand prize winner

©2011 America’s Milk Processors got milk?® is a registered trademark of the California Milk Processor Board iPad 2 is a registered trademark of Apple Inc.

New Products & Marketing

NEW PRODUCT REVIEW Elk Grove Village, Ill..based Bel Brands USA, A, a subsidiary of Fro-mageries Bel, a family-owned cheesemaker headquartered in Paris, extends its worldrenowned Boursin Gournay cheese brand to flavored premium spreadable cheeses. Garlic & Herbs (the flavor lavor of the original Boursin cheese) was the first to debut about a year ago. Its success inspired the company to add Light Garlic & Herb, Spinach & Artichoke, Sundried Tomato & Basil and Vermont White Cheddar & Sage. Packaged in 6.5-ounce plastic tubs designed for serving, the new spreads are promoted with a tagline of “my mouth just went to heaven.” Alpina Foods LLC, Miami, is the recently established U.S. subsidiary of Alpina, a leading dairy-producing company in South America with global headquarters in Colombia. For almost a decade, the company has been importing an array of Hispanic-style dairy products into the United States. In 2012, Alpina will begin manufacturing yogurt from its newly built plant in Batavia, N.Y. This opens doors for innovations that will help grow its consumer base beyond the U.S. Hispanic population.

The most recent iinnovation is Revive, a line of authenticcally strained Greek yogurts that pack in yo protein (at least 15 pr grams per 6-ounce gr cup) and contain procup biotic cultures along bio with a number of functional ingredients. func The Revive line comes in four varieties, with each varietal’s name supported by the “extras” in the granola topping provided in an attached dome cup. They are: Aphrodite’s Youth, which supplies antioxidants to keep the mind and body youthful; Artemis’ Vitality, which helps sustain energy and vitality; Athena’s Focus, which is rich in omega-3 fatty acids to help the mind stay sharp and focused; and Hera’s Calm, which promotes calm and serenity.

A line of innovative fluid milk products branded Borden Life! debuted in Houston in four unique formulations: Calcium, Fiber, Multi-Vitamin and Protein. Developed by the Borden Dairy Co., Dallas, each formulation is supercharged with vitamins, minerals or select nutrients with well-recognized health and nutritional benefits. “Lots of people think all dairy is the same, but Borden Life! is different,” says Tim Hawk, general manager. “These four supernutritious new products stand out because they give people more choices to better fit their lifestyles and health goals while delivering an outstanding, creamy taste.” The four milks in the Borden Life! line were chosen based on extensive consumer research to understand the most important nutrients that families are concerned about getting in their current diet. A multi-vitamin and mineral milk, such as Borden Life! Multi-Vitamin Milk, is a product the whole family can enjoy. It contains 25% of the Daily

NOTEWORTHY I NTROD UCTION S W Watch out bars and shakes, there’s a new way to get concentrated whey proteins: cheese sauce. g Reston, Va.-based ProSynthesis Laboratories R IInc. introduces Unjury Protein’d Cheese Sauce powder. When one scoop (35 grams) is combined with water or milk, the result is a serving of cheese sauce with 21 grams of protein.

22

Dairy Foods | December 2011

Win Schuler Foods, Southfield, Mich., inntroduced Lia Marie’s Original Garlic Spread d and Five Cheese Garlic Spread. Both spreads, which are made with butter and cheese, among other ingredients, are avail-able in 12-ounce tubs and merchandised d near butter in the refrigerated dairy case.

New Products & Marketing

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

Value (DV) of eight vitamins (B2, B3, B5, B6, B7, B12, C and D) and two minerals (calcium and phosphorus) and 10% of the DV for vitamins A and E, magnesium and zinc. The other three formulations each focus on a single nutrient. Borden Life! Protein Milk has 12 grams of protein per serving while Borden Life! Calcium Milk contains 33% more calcium than its extra calcium regular milk and Borden Life! Fiber Milk is enhanced with 2.5 grams of fiber. All four products are packaged in light-blocking containers to preserve nutrition and extend shelf life.

Fit to Go is a new line of single-serve (5-ounce) cottage cheese cups from Friendship Dairies, Friendship, N.Y., a part of Dean Foods Co., Dallas. High in protein, cottage cheese is increasingly being recognized by health- and wellness-conscious consumers as a satiating snack. These portion-controlled cups make cottage cheese convenient and portable. Varieties are: 4% California Style, 1% Low Fat and 1% Low Fat with Pineapple. Ehrmann USA LLC, Mishawaka, Ind., a subsidiary of the family-owned German dairy Hermann AG, entered the U.S. dairy market with the rollout of All Nat-

ural Lowfat Bavarian Yogurt. Produced through a joint venture with Commonwealth Dairy LLC, Brattleboro, Vt., the full-bodied yogurt is a replicate of the company’s family recipe. It comes packaged in n 5.3-ounce dual-chamber cups to o allow for a custom m blend of yogurt and real fruit. Each variety contains 150 calories or less and packs 7 grams of protein rotein per serving with p h only 11.5 grams of total blackberryfat. Flavors are: bl kb pomegranate, blueberry, cherry, peach pom and strawberry. Initial distribution is throughout New England and upstate thr New York. The company reported in mid-October that retail distribution mid tripled within weeks of its introduction. trip ““We are very pleased to now produce delicious Ehrmann Yogurts fresh in del Vermont,” says Harald Bellm, president Ver and CEO of Ehrmann USA. “The positive responses we have received from America’s top retailers in the region are very encouraging. As we build upon our reputation and expand in this country, we’ll continue to look for new opportunities with retailers. We strongly believe that ‘Bavaria’s Finest Yogurt’ will attract new yogurt consumers and further expand the yogurt category in the United States.” Subscribe to Dairy Product Innovations (www.dairyfoods.com/enews), an e-newsletter focused on new dairy products and new products and services from dairy industry suppliers.

Manipulating texture is the latest rage when it comes to creating a point of differentiation in the crowded drinkable yogurt category. In Brazil, Coop, a global chain of supermarkets, introduces private label Whipped Part Skimmed Drinking Yogurt with Honey. The whipped texture adds a new dimension to the category. Innovative flavors are another way to stand out in the crowded drink able yogurt market. In Mexico, Groupe Danone adds a new functional ingredient — white tea — to ingredie Activia probiotic yogurt drinks. Though the combination of tea co and dairy is not neca essarily common, it e also not new; howis a e v e r, m o s t f l a v o re d milks and yogurts rely milk green tea for either on g flavor or function. White flavo tea is unique, as are the chamomile and apple vvariants. The new offerings springboard off the emerging trend of relaxation drinks, which are still m o s t l y a b s e n t f ro m the dairy category. Dessert trends come and go, and in recent years, macaroons have burst onto the global scene in a big way. This light, Frenchstyle cookie is generally made with egg whites and almond powder, giving it a delicate and crunchy appeal. In Finland, organic ice cream maker Peter Eis turned them into inclusions for ice cream with the rollout of Raspberry Ice Cream with Macaroons, which claims to contain 3% real macaroons.

Contributed by Krista Faron, former 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 24 www.dairyfoods.com

23

New Products & Marketing

NEW PRODUCT REVIEW: FOCUS ON NON-DAIRY BEVERAGES Dairy processors bottle so much more re than milk. For example, juice, tea and nd water are very common offerings. Milk lk movers can get some great ideas from m their non-dairy beverage competitors. For example, PepsiCo Inc., Purchase, N.Y., is exploring the addition of “tea” to its very popular lower-calorie Trop50 beverage line. The new product concepts in test market include Peach with White Tea, Pear Lychee with White Tea and Raspberry with Green Tea. All three new concepts claim to contain 50% less sugar and calories than juice blends. The beverages rely on a stevia-based sweetener, which allows for a “no artificial sweetener” claim. Honeydrop Beverages, New York, a producer of natural teas and juices made with a spoonful of honey, is growing its product range. “We are really excited to add three new, fresh brewed teas to the Honeydrop line,” says David Luks, CEO and founder. “We continue to work towards our goal of creating low-calorie beverages that taste great without using any refined sugars, artificial sweeteners or chemicals. Following the launch of our first three flavors, we listened closely to consumer feedback and developed a plan to introduce a series of simple, more traditional teas, which led to the introduction of our new Lemon, Lemon Ginger and Green Tea options.” Joining Honeydrop’s current line (Blood Orange, Blueberry and Chamomile Tea), each bottle is made with fresh brewed teas and all-natural juices and contains 90 calories or fewer. In addition to offering functional health benefits, which range from immune boosters and antioxidants to digestive aids, calming qualities and more, with each bottle purchased, new beehives are built in communities across the country

24

Dairy Foods | December 2011

through the company’s “Buy a Bottle — Save a Bee” thro campaign. Each 14-ounce glass bottle of Honeydrop cam contains one tablespoon of pure wildflower honey, con domestically sourced from regional beekeepers dom across the United States. ac SSince 1981, Ginseng Up has been on the lips of lloyal followers throughout the Caribbean eager to get their daily dose of ginseng. This botanical extract has been a nutritional supplement in Asian diets for more than 6,000 years and is believed to d boost energy, relieve stress and improve memory. b Now, after 30 years of popularity overseas, the N Rockleigh, N.J. -based namesake company is rollR ing out Ginseng Up throughout the United States. Ginseng Up is marking its debut with the addition of a crisp apple flavor. Unlike highly sweetened apple drinks that are diluted apple concentrate, Ginseng Up is 96% real apple juice blended with a touch of sparkling water. The company also designed new packaging for the U.S. market, which, while contemporary, graphically echoes ginseng’s Asian origins and expresses its benefits with a new tagline: The Root of All Power. NextFoods, Boulder, Colo., manufacturers of GoodBelly probiotic fruit drinks, adds GoodBelly Probiotic Coconut Water to its beverage lineup. All GoodBelly products promote digestive health thanks to the addition of the company’s patented probiotic strain, Lp299v. This replenishing coconut water is fortified with 20 billion live and active probiotic cultures per 8-ounce serving. Coconut water is highly regarded for its composition of natural electrolytes, including calcium, potassium, magnesium, phosphorus and sodium, which aid in effective hydration. The new drink has no added sugar and is 80 calories per serving. It comes packaged in a quart gable-top carton. 

Refreshing Teas for Dairy Processors Robertet Teas n

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

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

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

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With HACCP compliant facilities capable of producing

Unitized / Custom Packed

and handling a large volume of tea products, Robertet’s economies-of-scale translate into high quality, custom-blended, cost-effective tea products. n

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the best tea products available anywhere translates into your profits.

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Ingredient Technology Photo courtesy of Kerry Ingredients & Flavours

When the weather outside gets frightful, it’s a sign to finalize your new flavor innovations for the upcoming ice cream season.  Donna Berry Product Development Editor

emperatures and snow may have dropped a little earlier than many of us were ready for this autumn, but that winter chill served as a nice reminder to start planning for the upcoming ice cream season. And if innovations from this past year are any indicator of what’s to come, that winter chill will be quickly forgotten as processors get fired up for summer 2012.

T

Greece is the word Frozen yogurt has historically been considered a better-for-you frozen dairy dessert option by consumers. Thus, for an even greater health and wellness positioning in the freezer, Greece is the word. That’s right. The healthful halo surrounding refrigerated Greek yogurt makes the freezer a likely progression for this Mediterranean delight. This past year, a few entrepreneurs stepped out with frozen Greek yogurt concepts. For example, Apollo Food Group LLC, Boston, introduced Yazzo Frozen Greek Yogurt stick novelties in blueberry, raspberry and strawberry flavors. (See Dairy Foods, June 2011, page 24.) Based on a number of dairy ingredients, including Greek yogurt with live and active cultures, each 75-gram bar contains 70 calories, 6 grams of high-quality protein and no fat. It was only a matter of time before the national players jumped on the bandwagon. The first to do so was Stonyfield Farm, Londonderry, N.H., which now offers pints of Oikos Organic Nonfat Greek Frozen Yogurt in four flavors: blueberry, chocolate, honey and vanilla. Blueberry isn’t a traditional frozen dessert flavor, according to Gary Hirshberg, Stonyfield’s CEO. “And Greeks haven’t traditionally frozen

their yogurt. So, to make this indulgently rich and delicious frozen yogurt, we told tradition to step aside,” he says. A half-cup serving of the frozen Oikos product contains 6 grams of protein, which is 50% more than regular Stonyfield frozen yogurt. Some ingredient suppliers are offering solutions to produce frozen Greek yogurt with double the protein in order to more closely resemble claims made by their refrigerated counterparts. For example, one supplier has an ingredient system that not only doubles the protein, it removes 95% of the lactose, increasing the product’s appeal to consumers who must limit their lactose intake. At the International Dairy Show in September, this company sampled the concept with full Greek flair. The frozen yogurt had a rich baklava flavor and was swirled with caramel honey variegate, honey oat almonds and baklava pieces. Culinary creations Baklava is not the only dessert that showed up in ice cream at the dairy show. One supplier described how the company travels the Americas, and at times crosses oceans, in search of innovative bakery and confection concepts that can carry over into frozen desserts. Some recent frequent flyer miles have resulted in inspirations such as Blondie Brownie (caramel-flavored ice cream blended with Blondie brownie pieces and a peanut butter ribbon), Hot Chocolate Mint (hot chocolate-flavored ice cream swirled with a whipped cream ribbon and peppermint candy pieces), Sticky Bun Cheesecake (cheesecakeflavored ice cream blended with sticky bun dough pieces and a cinnamon streusel ribbon) and Whoopie Pie (chocolate ice cream blended Continued on page 28

26

Dairy Foods | December 2011

CUST M FORMULAT ONS Dairy product innovators have come to rely on ADM Cocoa for foor consistency c nsis co and quality. But what really sets us apart are the added extras you can’t get anywhere else. Like custom formulations. Our technical experts can help you create a one-of-a-kind, category-leading product your customers will crave. To find out more about how ADM’s technical expertise can give you an advantage, visit us at adm.com/ambrosia.

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For customers around the world, ADM draws on its resources—its people, products, and market perspective—to help them meet today’s consumer demands and envision tomorrow’s needs. © 2011 Archer Daniels Midland Company

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Ingredient Technology

Double Dessert Many believe that ala mode is the best way to serve cake or pie. So why not simply combine the two for a double dessert? That’s exactly what Wells Enterprises Inc., Le Mars, Iowa, did with its Blue Bunny Chef Duff Goldman ice cream creations. “For me cake and ice cream belong together like mashed potatoes and gravy,” says Duff, a celebrity cake baker on the Food Network and owner of Charm City Cakes, Baltimore. “We came up with these creations because they combine the best of both worlds and we are really excited to see the reaction of folks when they discover them in their freezer aisle.” Duff worked directly with Blue Bunny’s ice cream flavor experts in the development of the new line, which blends rich, creamy ice cream with actual pieces w of cake. Appealing to fans of Duff aand the increasing number of selfin proclaimed foodpr ies in America, the

with chocolate c cookies and a dual swirl of chocolate and whipped cream). Another processor showed how savory flavors complement the sweet, creamy profile of ice cream. For example, Bacon Me Crazy is brown sugar-flavored ice cream blended with maple bacon toffee pieces and brown sugar bacon pecans with swirls of caramel. Because this year’s dairy show was in Atlanta, this made Georgia’s state fruit — peach — the star of an ice cream with some southern kick. The concept was peach-flavored ice cream blended with chunks of peach, cinnamon sugar pie crust and swirls of barbecue-seasoned peach pureé. In addition to using supplier-developed culinary flavor combinations, another formulating trend is to tap into the creativity of celebrity chefs. For example, Wells Enterprises Inc., Le Mars, Iowa, teamed up with Food Network’s “The Ace of Cakes,” chef Duff Goldman. (See “Double Dessert,” above.) This trend is also catching on abroad. In Belgium, N.V. Belgian Icecream Group S.A. (BIG), has formed a partnership with Chef Roger van Damme, who is host of a cooking show on the European food channel “njam!” and is recognized throughout Europe as one of the most innovative Belgian patissiers. Marketed under BIG’s subbrand Arctic and carrying the njam! logo and Van Damme’s signature and photo, the four varieties of this premium ice cream are described as simple culinary pleasures. Café Glacé is said to taste like freshly brewed coffee and cream while Koekjes Biscuits resembles buttercream cake. Dame Blanche (white lady) swirls rich dark chocolate in pure vanilla ice cream. And, of course, there’s a plain vanilla, which the company says is anything but plain because it is made from the highest quality pure vanilla. Showcasing premium ingredients Working with a culinary professional is one way to provide validation to the premium nature of the product. Another is to really show it off. That’s a growing trend in Europe, where family-owned gelaterias and 28

Dairy Foods | December 2011

new culinary line brings an unprecedented dramatic c experience to the e category. Red Carpet Red Velvet Cake ke is red velvet cake-flavored ice cream swirled with cream cheese frosting-flavored ice cream and red velvet cake pieces. Chocolate Lovers Triple Chocolate Cake combines decadent chocolate ice cream with fudgy chocolate cake pieces and ribbons of thick, chocolate frosting. I Do! I Do! Wedding Cake celebrates the marriage of sweet buttercream frosting ice cream and white cake pieces wrapped in delicate ribbons of raspberry sauce. Strawberries are Forever Shortcake blends the sweet taste of strawberry ice cream with real strawberries, pound cake pieces and swirls of whipped cream frosting. With many more celebrity chefs ready and willing to license their name, we should expect to see more culinary ice cream creations in 2012, including gelato from chef Mario Batali. 

ice cream parlor owners are venturing into the packaged retail market in order to capture a greater share of the ice cream dollar. For example, Bruno Gelato GmbH, a family business headquartered in Germany and producing ice cream using its secret Italian family recipe, has been supplying foodservice venues throughout Europe since 1991. In 2010, the company started offering retailers the “My Ice Cream Parlor at Home” range. The key to the premium positioning of these products is the clear container that showcases the high-quality, identifiable pieces of fruit and other inclusions, along with the omission of anything artificial. “For banana ice cream, for example, we use a complex process to pureé the bananas ourselves, as the pureé required is only available containing preservatives,” says Stefano Lucchetta, production manager. “We use only ‘pure’ fruit pureés for all other varieties of fruity ice cream. Here, real fruits are processed that give our range of fruity ice creams their authentic taste and unique consistency.” A unique idea from Italy’s Pasticceria Quadrifoglio srl is drinkable ice cream. This refrigerated dessert is more than simply ice cream mix, as it is slightly aerated, yet pourable, and though not as cold as a product direct from the freezer, its texture and mouthfeel provides an illusion of being frozen ice cream. Called CremiXimo, this low-fat liquid dairy dessert comes in a recloseable bottle (200and 500-gram options with a suggested serving size being 100 grams) in six flavors: chocolate, coffee, mint, Sicilian lemon, strawberry and vanilla. Not only can it be consumed as is, it also can be used to garnish fresh fruits and cakes, as well as be a blender for cocktails. Ultra-high temperature processing provides a 50-day refrigerated shelf life. For many, the warm months can’t come soon enough. And they don’t even know about all the great frozen desserts being developed.  See page 67 for information about some of the ingredients referred to in this article.

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Ingredient Technology

LAB TALK

Needing Nutrients ver since I can remember I have been challenged with swallowing pills. When I was a little girl, my mom would dissolve the orange-flavored baby aspirin in a spoon of water for me to swallow. Thank goodness Flintstones vitamins were chewable. When I got older, my doctor encouraged me to take the same approach as one does with their pets, and that is to hide the tablet or capsule in a piece of cheese or some bread. Let’s just say it’s pretty challenging to trick oneself. I get frustrated because I want to enhance my diet with nutrients that I might be deficient in, but getting supplements down can be exhausting for me. And even once swallowed, I have a sensitive stomach, so I have to make sure I take them with enough food so they settle. There are others like me. Many of us have become fans of Vitamin Water Zero. It helps get the goods down without any calories, much like a pill. We also seek Photo courtesy of Cabot Creamery out nutrient-enhanced foods — products we consume on a regular basis, not additions to the diet, which is what many nutrition bars and shakes are. We don’t want additional calories, just additional nutrients. When studies such as “Dietary Supplements and Mortality Rate in Older Women: The Iowa Women’s Health Study” (Archives of Internal Medicine, October 2011) get picked up by mainstream media, consumers — OK, women of a certain age — get recommitted to supplementing their diets with key nutrients. And dairy foods, in particular milk, yogurt and cheese, are ideal carriers of these nutrients. At least they are for me, as these products are staples in my diet. The researchers in this study found that supplementation with vitamin B complex was associated with a 7% reduction in mortality, vitamin C was associated with a 4% reduction in mortality, vitamin D was associated with an 8% reduction, and the list goes on. “This study showed a benefit from taking B-complex, C, D and E vitamins, and calcium and magnesium,” according to Robert Smith, research associate professor, University of Pennsylvania, Department of Neuroscience, Philadelphia. “Therefore, if those wanting better health would take appropriate doses of supplements regularly, they would likely continue to achieve better health and longer life.” I want better health and a longer life. So, for me — and the many others like me — we rely on fortified foods. Some nutrients, such as calcium, are added to many common foods. But other nutrients vital for good health, such as vitamin D and magnesium, are not as easy to find.

E

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Dairy Foods | December 2011

Donna Berry

 My holiday wish is for more dairy processors to boost the nutrient profile of foods I consume on a regular basis, such as cheese, milk and yogurt.

Carolyn Dean, medical director of the nonprofit Nutritional Magnesium Association, Orange, Calif., says, “Most people can benefit from magnesium supplementation because this vital mineral is sorely lacking in our standard American diet. Over 75% of Americans don’t get their recommended daily allowance of this multi-tasking mineral. Additionally, many people may not be getting the full benefits from vitamin D without also supplementing their diets with magnesium, which is a vital nutrient that works synergistically with vitamin D. “Adequate levels of magnesium in the body are essential for the absorption and metabolism of calcium as well,” she says. “Magnesium converts vitamin D into its active form so that it can help calcium absorption. Magnesium stimulates a particular hormone, calcitonin, which helps to preserve bone structure and draws calcium out of the blood and soft tissues back into the bones, which can help prevent osteoporosis, some forms of arthritis and kidney stones.” And as we have learned in recent years, vitamin D, also known as the sunshine vitamin, does so much more than contribute to bone health. Vitamin D is involved with cell growth, neuromuscular and immune function, reduction of inflammation and even cancer prevention. Dairy foods formulators are uniquely positioned to add magnesium, vitamin D and other key nutrients to all types of dairy foods. Nutrient premixes, which are customized blends of vitamins, minerals and other nutrients, simplify the fortification process for manufacturers. The premix serves as a single addition to a batch process and reduces chances for error. Premixes maximize formulation and process efficiencies. Because many of today’s consumers prefer to get their daily dose of essential nutrients from foods and beverages rather than a tablet or capsule, it’s time to make fortification of common dairy foods a priority in 2012. Some dairies have started, such as the Borden Dairy Co., Dallas, which recently rolled out a line of milk products supercharged with vitamins, minerals and other select nutrients. (See page 23.) I hope others follow.  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

Techniques to Control Texture, Structure in Fermented Milk Products Phillip Tong

he consumer can find a wide range of textures in fermented milk products. From drinkable to spoonable to spreadable – these foods are expected to exhibit textures of semi-solid gels, viscous liquids or thin liquids, depending upon the specific product (for example, fermented milk beverage, stirred yogurt, quark, etc.) and consumer expectations. Additionally, many fermented milk products must withstand mechanical shear (pumping and/or stirring) without any liquid separation. The foods almost always must have a smooth, creamy mouthfeel with or without milkfat in the formulation. And, don’t forget this rule: Thou shalt not be grainy! Because consumers in part select such products based on textural attributes, they will not tolerate significant texture variation. Hence, gaining a more complete understanding of those factors that can influence fermented milk product texture is the first step to achieving consistent control and delivery of desired textural attributes. To manufacture these products, we take a relatively stable protein, casein, and usually subject it to thermal processing and acidification via lactic fermentation to modify its structure, promote interactions with other proteins and create casein instability, which leads to its aggregation to form the gel matrix of most fermented milk systems. Once we have created a relatively delicate, unstable system, we try to fix this structure (stabilize it) and/or improve upon it to make desirable and lasting food textures consistent with the fermented milk product. The first step is forming a gel at or near pH 4.6 by fermentation. In products that are not fermented in the finished package, we then gently agitate the sample, add other ingredients (some-

T

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Dairy Foods | December 2011

times) and then package. The firmness at initial gel formation (setting) becomes one of the key parameters to finished product texture for cup-set fermented milk products. However, stirred or vatset fermented milk products with higher firmness at set will also have higher viscosity after shear (stirring), which is often desired. Fortunately, there are several tools available to dairy processors to stabilize the range of textures we desire in the array of fermented milk products. Ingredient, culture and process strategies are all utilized to develop and control fermented milk textures. In fermented milk products, the array of dairy ingredients can complement the already functional components of the original milk to add structure, texture and stability. Supplementing milk with skim milk solids or milk protein concentrate adds casein, which after fermentation leads to a more dense casein gel network (firmer gels). Adding whey protein concentrates can improve water-holding capacity, which leads to more viscous fermented milk products. For example, many Greek-style yogurts commonly have twice the protein of traditional yogurts, and these yogurts tend to rarely have any whey separation, can have very smooth and viscous textures and have little to no other ingredients to provide structural or textural stability. On the other hand, yogurts formulated with lower dairy solids can achieve good textural stability and smooth textures through the addition of starches, gums, pectin or other functional ingredients. Processors also adjust the heat treatments given to the formulated milk base prior to fermentation to cause proteinprotein interactions that can lead to more product stability (no wheying off) and higher viscosity without the addition of added stabilizing ingredients. If excessive high shear occurs to the fer-

mented milk gel from pumping or stirring, this can result in very low-viscosity products. Additionally, for fat-containing milk blends, higher homogenization pressures lead to smaller fat globules and more casein at fat globule surfaces that can participate in the casein gel network formation. The result is firmer fermented milk textures/structures. Incubation times and temperatures impact structure formation and final pH, which affects texture. Finally, a thoughtful selection of the culture to use in the fermentation process can make big differences on texture. There is a wide range of cultures that produce exopolysaccharides that act as natural functional stabilizers by enhancing product viscosity, interacting with water and other constituents of the fermented milk product. If fermented milk product manufacturers remain cognizant of how ingredient, process and culture selection can impact product texture, they can effectively develop their manufacturing procedures to control texture and structure. Improved control of these factors will enhance product consistency to better meet consumer expectations.  Phillip S. Tong is professor of dairy science and director of the Dairy Products Technology Center at California Polytechnic State University. Read More About Yogurt Lee, W. J. and Lucey, J. 2010. “Formation and Physical Properties of Yogurt.” Asian Australian Journal of Animal Science, Vol. 23 (9):1127-1136. Sodini, I., and Tong, P.S. 2006. “Milk and Milk-based Dairy Ingredients.” Manufacturing Yogurt and Fermented Milks, R. Chandon,C. H. While, A. Kilara, and Y.H. Hui eds., Blackwell Publishing, Ames, Iowa, pp 167-178.

Processor of the Year

George Zoghbi, president of Kraft Foods’ North American cheese and dairy division, oversees the development of new products and R&D efforts for the Northfield, Ill.-based food and beverage processor.

Photo courtesy of Kraft Foods

Processor of the Year

The cheese processor is energizing old school brands like Philadelphia and Velveeta, developing new foods and formats, and adopting manufacturing practices that save natural resources.

Jim Carper Chief Editor

t’s difficult enough for any business to stay relevant, especially when it has brands established 100 or more years ago. Then throw in the challenge of adapting to ever-changing consumer tastes and habits, not to mention manufacturing in an era when a small carbon footprint is a measure of a corporation’s citizenship. That’s part of the landscape in the 21st century, and every business operates in it, some better than others. One of the better players is Kraft Foods Inc., the global food and beverage company based in Northfield, Ill. Of Kraft’s $49.2 billion in annual sales in 2010, net revenues from global cheese were $7 billion, or 14% of the total. Cheese ranks fourth, behind confectionery, biscuits and beverages and ahead of convenient meals and grocery. The North American division sold $3.5 billion of cheese in 2010 and had operating income from cheese of $598 million. Kraft places fourth on Dairy Foods’ 2011 Dairy 100, the list of the largest dairy processors in North America. It is the largest cheese processor based in the United States. The leadership in the cheese and dairy division has taken bold steps and placed big bets in recent years, including: • Developing new products around existing 100-year-old brands • Creating new dairy-based food od products • Adapting new packaging technolologies

I

• Reducing the amount of energy and water used in processing • Leading the dairy industry in research into sodium reduction • Reinvigorating marketing around its iconic brands For these reasons, Dairy Foods names Kraft Foods North America the 2011 Processor of the Year. George Zoghbi is president of the North American cheese and dairy division, based in Glenview, Ill., around the corner from corporate headquarters. He was named president in 2009, having joined Kraft Foods in 2007 as vice president and area director of Australia/New Zealand after a career with the global dairy giant Fonterra, where he had been global foodservices director. He expects those who work for him to be innovators, because, he says, Kraft recruits smart and entrepreneurial men and women. Zoghbi sayss it is

 Kraft Foods reformulated its cottage cheese to reduce sodium by 30%. It added a Greek yogurt under the Athenos brand. Continued on page 36 www.dairyfoods.com

35

Processor of the Year

 Philadelphia Cooking Creme has been a huge success. Over a threeyear period, Kraft Foods invested $100 million in the development and marketing of the food.

“a responsibility” and “a privilege” to lead Kraft Foods. His role as a leader is to take risks and encourage innovation, he says. His colleagues agree. Long-time Kraft employees remark that the corporate climate has changed in favor of smart risk taking. Philadelphia Cooking Creme is one such innovation that has paid off handsomely for Kraft Foods. Zoghbi recounts the risks: a three-year investment of $100 million in market research, product development and advertising. And to underscore the gamble, he notes, it was all done on spec. “There was no buyer who contracted for Cooking Creme,” Zoghbi says. Kraft believed in the product, but consumers would be the ultimate judge of its success or failure. Christopher Urban, brand manager for Philadelphia Cooking Creme, and his team asked: How can we grow usage occasions of cream cheese beyond a schmear on a bagel at breakfast or making a cheesecake? Their research found that 25% of Philadelphia Cream Cheese usage was in cooking applications. On their own, and not due to any marketing initiative on Kraft Food’s behalf, Philadelphia users were adding cream cheese to potato dishes and pasta sauce. The Philadelphia brand team had the idea to build a product that home cooks could use to create excitement in everyday dishes. “So, we gave it flavors and spices,” Urban says. They made it easy to use, too. The product is seasoned, so home cooks don’t have to buy spices, and it is spoonable from a 10-ounce plastic, foil-sealed cup. Cooking Creme melts easily and evenly. In all, Kraft Foods developed four so-called chef-inspired flavors for the 2011 launch. In 2012, there will be three new flavors, a 15-ounce size and two reduced-fat versions. With product development finished, the next task was to spread the word. Urban’s group partnered with the Los Angeles-based media company Eqal to tap into the Real Women of Philadelphia, 36

Dairy Foods | December 2011

an existing online community of loyal Philly users for the prelaunch. Participants in this social media network were sent the product and encouraged by celebrity chef Paula Deen to upload cooking videos to YouTube to win cash prizes totaling $25,000. In terms of consumer engagement, it took Kraft Kitchens a decade to get 500 “paper” recipes, and Real Women of Philadelphia three months to collect 5,000 in live-action, how-to video format. And they continue to pour in. There are now more than 45,000 registered users in the community. Eqal, Digitas and Kraft Foods received a 2011 Gold Effie award for the Real Women of Philadelphia campaign. Effie awards recognize effectiveness in the marketing communications industry. In addition to the competition, Kraft Foods backed the launch with free-standing inserts, coupons, in-store demos and sampling. Commuters even received samples to take home as they disembarked trains in the evening. Within eight weeks of launch, the product was in 76% of stores, and Cooking Creme has performed 15-20% better than expectations, Urban says. The product competes against condensed soups, sour cream and prepared pasta sauces. Sales were 80% incremental to the category and 88% incremental to the brand, which means that Philadelphia Cooking Creme was not siphoning sales away from other Kraft Foods products or brands. Velveeta moves beyond a chip dip Finding new reasons to eat Velveeta was on the mind of senior brand manager Katie Peterson. Food snobs love to hate the iconic yellow processed cheese, but it is the central ingredient in queso dip, a favorite in the South and Midwest. The recipe for microwavable queso dip (consumed at football tailgate or viewing parties) sprang up organically, Peterson says. To one pound of cheese, a cook adds a can of Ro-Tel diced tomatoes and green chiles and microwaves until creamy. Neither Kraft Foods nor ConAgra (RoTel’s owner) developed the recipe, but the two food companies have jointly promoted the recipe for seven years. Like her colleague Urban, Peterson was looking for new occasions to use Velveeta beyond dips, macaroni and cheese, and grilled cheese sandwiches. Kraft Foods is developing recipes that show off the brand’s characteristics of “creamy, melty, cheesy,” Peterson says. Chefs in the company’s test kitchen are developing meals, including enchiladas and chicken casseroles. Continued on page 38

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Processor of the Year

Peterson’s team has created brand extensions, including a white Velveeta (called Queso Blanco). Velveeta is appearing in new products, including a prepared dip that is “a quick way to enjoy our one-of- a-kind taste,” Peterson says. The shelf-stable jarred dip is typically sold in the Mexican aisle of supermarkets. The dips are easy to keep on hand for a quick weeknight snack or last minute get together, Peterson says. Preparing to launch Launching a new product at Kraft Foods requires the support of procurement, research and development, and the test kitchen. Mike McCully, director of dairy procurement, works with buyers for all the dairy raw materials, including cheese, milk, cream, milk powders and fats. “We work with the marketing teams to support their efforts,” he says. “We have to work cross-functionally with our plants, so they have (the ingredients) when they need (them).” For Cooking Creme, McCully had to line up sources for milk and cream and see that the ingredients were delivered on time. It turned out that Kraft Foods needed more cream and milk than forecast because of the popularity of Cooking Creme. “You can’t tell a customer: We don’t have enough product,” he says. Robin Ross, the associate director of culinary in the cheese and dairy division, was involved early on in the development of the product. Ross runs the test kitchens where she and her team evaluate the performance of Kraft’s foods and those of its competitors. Long before Ross created the first pasta recipe however, she was evaluating the aroma, taste and consistency of Cooking Creme. “The taste from a freshly opened container is different once it combines with food and is heated,” she says. She counseled the brand managers that the product had to be available in a sufficient quantity to cover meat, pasta and vegetables in at least a four-serving recipe. It is currently sold in 10-ounce and 15-ounce containers.

 Kraft Foods is in on the trend toward adding flavor to cheeses. The company added herbs and black pepper to its Cracker Barrel Cheddar cheese.

Ross says she has a two-fold responsibility: Help the home cook deal with “dinner anxiety” and acknowledge that food budgets are tight. That means simple-to-prepare and affordable meals. The pantry in the test kitchen mimics that of the average consumer. 38

Dairy Foods | December 2011

Based on surveys, Ross knows what ingredients a home pantry has on hand (there is probably chili powder, not turmeric in the spice cabinet, for example). Drawing on the contents of the pantry, Ross and her team create recipes. Her goal is to help create a meal that can be made in 30 minutes or less with minimal ingredients – five or fewer. The eight kitchens are outfitted with all the major appliance brands and fuels (gas, electric and microwaves) and recipes are tested accordingly. Vice president of research and development Nigel Kirtley says his role as a manager is to “put the right people and resources in place, then to just get out of the way.” He tells his staff that R&D’s

 Velveeta has been a Kraft Foods brand since 1928. Recent new products include a white version (queso blanco) of the iconic yellow cheese.

role is “to do stuff that has never been done before. Re-invent the game and the rules.” Innovation alone is not a guarantee for a successful product. The timing must be right, too, Kirtley says. Some innovation is also market positioning or re-positioning. String cheese has been traditionally a snack for children, but Kraft Foods made the product appealing to adult palates by adding a jalapeño flavor. The R&D headquarters has a pilot plant where foods are developed. But innovation does not happen solely in the lab. He d credits colleague Gary Smith for the development of Milk and Granola bars. Smith and his daughter conceived the product one day at home in their kitchen. Milk and Granola bars are made with fresh dairy and calcium to deliver the calcium content equivalent to 8 ounces of milk. Milk helps to bind the cereals and makes the bars soft and chewy. The flavors are oatmeal raisin, strawberry, peanut butter and mixed berry. Walmart was the first retailer to carry the refrigerated bars. In 2012, Kraft will sell the product, renamed MilkBite, to other retailers. The revised Dietary Guidelines for Americans released in January call for less consumption of sodium. That is a priority in Kirtley’s R&D lab. “You can’t make it go away completely,” he says, because milk itself contains sodium. But “we are going to lead” in reduction efforts, Kirtley vows. He serves on a committee at the Innovation Center for U.S. Dairy, Rosemont, Ill. Already, Kraft has reduced sodium by 30% in its Breakstone’s cottage cheese. Yet reducing sodium is only one challenge researchers are solving. Another is developing new foods that naturally don’t require added sodium, Kirtley says. Continued on page 40

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Processor of the Year

 Kraft Foods launched a cheeky ad campaign starring a Greek grandmother (yiayia) for its Athenos Greek yogurt.

Food safety initiatives The revised dietary guidelines were not the only fedderal government initiative sending ripples throughout hout the food processing industry. Another was the Food Safety Modernization Act, signed into law in January.. “The law will have a significant impact on the food ood industry,” says Carol Kellar, senior director, North America quality, scientific and regulatory affairs. “While Kraft Foods already has robust food safety programs in place, we welcome the opportunity to make them stronger. Some changes that the industry should expect include new FDA regulations requiring all food companies to have a Food Safety Plan and a Food Defense Program and more frequent visits to manufacturing plants.” Kellar says Kraft Foods looks at the lessons learned from its own food safety experiences and from others in the industry. “We share our learnings when we have the opportunity. After all, food safety should never be a competitive advantage.” Safety begins with each recipe, Kellar says. “We start with the highest-quality ingredients,” which are approved through a comprehensive supplier program. “Then we bring the ingredients together in a clean environment where our employees, who are trained in food safety, take great care to make sure that they make the best possible product.”

AT A GLANCE Kraft Foods Inc. Headquarters: Northfield, Ill. 2010 net revenues: $49.2 billion 2010 net earnings: $4.1 billion Revenues from cheese: $7 billion Revenues of North American cheese and dairy division: $3.5 billion President of the division: George Zoghbi Dairy Foods’ Dairy 100 rank: Fourth Brands: Kraft Singles, Kraft Natural Cheese, Philadelphia, Velveeta, Breakstone’s, Athenos, Knudsen, Cracker Barrel, Polly-o Products: Natural cheese, processed cheese, Greek yogurt, cream cheese, sour cream, cottage cheese, cheese blends

40

Dairy Foods | December 2011

Kellar says Kraft Foods is investing in additional resources, such as education, training and hiring new employees to manage the new Food and Drug Administration requirements. “Our employees must understand the new requirements and what we have to do to meet them, as well as ensuring we maintain appropriate records,” she says. Kraft Foods hired about 20 people in its manufacturing facilities to act as compliance managers. Packaging that catches the eye Of course, food has to taste good and perform well in recipes. But food marketers need to catch the eye of shoppers as they scan the dairy case. Kraft Foods switched to an in-mold labeling printing process for its tubs of Philadelphia cream cheese. This process is more expensive than the dry offset printing method it had been using, but the new process allows for better rendition of images and colors. Photos of strawberries and chives on the packages appear more realistic, and Philadelphia’s signature silver color appears more refined. (See “Show and Sell” in the June Dairy Foods for additional details.) Best practices in waste reduction Kraft Foods has 11 plants in Arkansas, California, Illinois, Minnesota, Missouri, New York, Pennsylvania and Wisconsin that process cheese, yogurt and other cultured dairy products. Milk is sourced from within a 100-mile radius. The plants are ISO 14001 certified. Plant employees go through environmental awareness training where they are asked: What can you do in your job to reduce waste? Tom Anders, the associate director for safety and environment, says he relies on green teams (whose members are hourly employees) to hunt for savings. “These employees are on the floor every day. They know how equipment works and where to save,” Anders says. For instance, they can reduce water use by fixing leaks and optimizing sanitation routines. Kraft Foods changed to a loop clean-in-place regiContinued on page 42

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Processor of the Year

 Kraft Foods has 12 plants in the United States, including this one in Campbell, N.Y.

men instead of a single-pass CIP procedure. Doing so has proven to reduce energy and water use. Over five years, the manufacturing facilities collectively reduced energy use by 10%, carbon (heat recovery, lighting) by 12%, water by 20% and landfill by 45%. Two plants (in New Ulm, Minn., and Lehigh, Pa.) are 0% landfill. These locations have an agreement with Sunoco to acquire waste (plastic trimmings and corrugate) going into and out of the plant. In Beaver Dam, Wis., Kraft Foods sends its waste whey to an anaerobic digester that creates methane gas. (Previously, the waste was hauled away and spread on fields.) With stimulus funding from the federal government, the city built a wastewaster pre-treatment system and a digester. Methane generates enough electricity to power 800 homes, and waste heat from the generators is captured and used in the pre-treatment anaerobic process. The system went online in the spring. The U.S. Environmental Protection Agency gave its prestigious Pisces award to the new wastewater treatment facility.  An example of Kraft Foods brand managers working together are the Kraft shredded cheeses made with Philadelphia cream cheese. The cream cheese and the longer shreds cause the cheese to melt better, the company states.

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What next? In August, Kraft Foods’ board of directors announced plans to split Kraft Foods into two independent public companies: one a global snacks business and the other a North American grocery business, which would include Zoghbi’s cheese and dairy division. Through the first nine months of 2011, cheese sales in North America were $2.6 billion, compared to $2.5 billion in the previous period. Zoghbi says his focus is to grow consumption and bring new cheese products to the world. He points out the factors in his favor. “World consumption of dairy is increasing,” he says, and farmers are more efficient. “Retailers are devoting more shelf space to cheese. Consumers see it as a positive food,” Zoghbi says. He’s tying that momentum to teams of motivated market researchers, brand managers and food scientists. They have already demonstrated their talents for developing new products, extending brands into new SKUs and making foods safely in an environmentally friendly manner. With bets like Philadelphia Cooking Creme paying off, expect more innovative products to come to market. 

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DAIRY FORUM 2012 January 15-18, 2012 La Quinta Resort & Club La Quinta, California

IWC 2011

No Way! Yes, Whey Whey components can do all this: promote infant gut health, improve body composition, create novel foods and affect brain function. Scientists at the 6th International Whey Conference shared their research.  Sharon Gerdes Contributing Writer

ilk is a complex biological food, which yields unique bioactive fractions that can be harvested via the whey stream. At the 6th International Whey Conference, Sept. 18-22 in Chicago, more than 425 attendees from 25 countries learned more about “The Power of Whey.” IWC 2011 was co-hosted by the American Dairy Products Institute, Elmhurst, Ill., and the European Whey Products Association, Belgium. Highlights of the conference included new information about how whey components can promote infant gut health, improve body composition, create novel foods and beverages and impact brain and cognitive functions.

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BMO extraction Human milk oligosaccharides are complex sugars present in breast milk that serve as prebiotics, or substrates for specific beneficial bacteria in the gastrointestinal system. Cow’s milk has a dif-

 At the International Whey Conference, attendees sampled a reduced-sodium butternut squash soup made with whey permeate. Also served was “whey-vos rancheros,” a wheybased breakfast item. Photo courtesy of U.S. Dairy Export Council

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ferent concentration of these unique oligosaccharides than human milk. Identifying and extracting these bovine milk oligosaccharides (BMOs) from the whey stream has been the focus of several researchers, such as Daniela Barile and David Mills from the University of California Davis, Davis, Calif. Mills is exploring the synbiotic relationship between prebiotic BMOs and probiotic bacteria to improve intestinal tract health. The presence of these beneficial bacteria can have longterm consequences for reducing intestinal pathogens, promoting neural development and decreasing the risk of developing allergies, asthma, eczema and autoimmune diseases. Dairy foods, such as yogurt, are traditional delivery vehicles for probiotics, but face strong competition from dietary supplements. To compete against the supplement industry, the dairy industry needs to focus on milk’s distinctive healthy halo, as well as the unique structures and functions of BMOs and their synbiotic relationship to probiotics. Given the challenging regulatory environment for probiotics, speakers suggested that next generation efforts should concentrate on specific gut health targets and specific market segments, such as infants at high risk for allergenic diseases and individuals with irritable bowel syndrome. Metabolic implications Metabolic syndrome is a complex disorder that includes multiple markers such as insulin resistance, abdominal obesity, diabetes, dyslipidemia and hypertension. It affects one-third to one-half of the U.S. adult population, and is increasing globally. Several studies presented demonstrated the benefit of whey protein on metabolic health. G. Harvey Anderson of University of Toronto noted that short-term studies with milk protein indicate an inverse association between dairy consumption and metabolic syndrome. His work showed that consumption of whey protein (55 grams) before a carbohydrate meal (30 grams) stimulated insulin secretion, slowed gastric emptying and reduced post-prandial glycemia in patients with type 2 diabetes. Further research by Margriet Westerterp-Plantenga of Maastricht University in the Netherlands found that at 10% of energy, whey decreased hunger more than casein or soy.

IWC 2011

While obesity is a concern for many in the United States and other countries, under-nutrition affects 830 million people in the developing world, whereas severe acute malnutrition affects 195 million children. The incremental use of dairy ingredients, such as 3% of whey protein concentrate 80 in ready-to-use nutritional foods like Plumpy’nut, shows promise to combat malnutrition in vulnerable populations. Consumption of whey protein can also have a positive effect on muscle synthesis, but there are distinct differences in protein utilization by younger active adults and the elderly. “Carbohydrate and protein supplementation post exercise can enhance the rate of recovery and improve subsequent exercise performance by increasing rehydration, glycogen storage and reducing muscle damage,” says John Ivy of the University of Texas, Austin, Texas. In a 9-month study with active adults, Brian Kupchak of the University of Connecticut, Storrs, Conn., found that resistance training with whey protein supplementation was superior to soy protein for elevation of fat-free mass. Sarcopenia, which literally means “poverty of flesh,” is an age-associated decline in skeletal muscle mass. Stuart Phillips of McMaster University, Hamilton, Ontario, explained that 20 grams of whey protein optimally stimulated muscle protein synthesis in young men, while up to 40 grams was required for optimal stimulation of MPS in older men. Improving whey flavor and functionality The dairy industry continues to develop new process and novel ingredients from whey. New technologies presented included a biofraction isolation plant, which would produce unique ingredients enriched in lactoferrin, lactoperoxidase, immunoglobulins and/or whey growth factor extract. On the horizon are various non-thermal technologies, including high-pressure processing, high-power ultrasound, pulsed electric field and microfluidization, which can preserve bioactive fractions of whey. Ongoing work is exploring whether complexing dextran with protein will enhance functionality, and at the same time mask the IgE binding sites of the protein, potentially decreasing food protein allergenicity. A variety of whey protein aggregates with various structures and physicochemical properties can be produced by controlling pH and adding salts. This technology could produce whey protein with optimal foam stabilization in dairy beverages. Various methods to restrict protein denaturation by providing steric hindrance and manipulating protein charge were presented. These offer promise to improve heat stability of whey proteins. The impact of various whey processing steps on the

Allowable Protein Claims in Europe The European Food Safety Authority approves theses protein claims for growth and maintenance of muscle mass: • Muscle maintenance and recovery • Maintenance of muscle mass of elderly people • Development of muscle mass of strength athletes • Reconstruction and repair of muscle proteins after exercise in endurance athletes • Supports skeletal muscle protein accretion

“An Optimal Strategy” to Offset Age-Related Sarcopenia • Daily intakes higher than the RDA (1.2-1.6 grams per kilogram per day) • Emphasis on whey proteins, which are high in leucine • Consuming doses of 20-25grams per serving to maximize responses • Equally spaced protein meals throughout the day • Consumption of whey protein immediately after exercise. Recommendations by Stuart Phillips, McMasters University.

flavor and aroma of whey proteins and various strategies to further enhance the quality of whey ingredients was also explored. Methods for fractioning whey into specific bioactive proteins using a cascade of anion and cation exchanger membranes have been performed at lab scale and are ready for scale up at the pilot plant scale. Microparticulation of fractions of α-lactalbumin and β-lactoglobulin shows unique functional properties that could improve texture in yogurt and reduce meltdown in ice cream. Special non-gelling whey proteins show potential to improve texture and shelf life in bars and to improve texture and flavor in yogurt. Regulatory updates Conference presenters explored the regulatory climate from both European and U.S. perspectives. In Europe, the European Food Safety Authority (EFSA) has broad powers to control nutrition claims, not only on food labels, but also at pointof-sale materials, in brand names and on websites. Recently, EFSA approved a number of protein claims, but these claims are allowed for all protein ingredients, regardless of protein quality. In the United States, there is greater room for structure-function claims, as long as the food manufacturer has adequate substantiation for the science behind the claim. The Dairy Research Institute, Rosemont, Ill., developed a number of resources to help food companies navigate the regulatory environment. Future needs and opportunities Conference attendees also learned of the potential of whey to move into new arenas as functional and nutritional ingredients. One area that is being explored is the formation of whey fibrils, which are unique filamentous structures with potential to enhance viscosity at low concentrations. Their unique amyloid-like structure warrants exploration in biomedical applications, including the study of Alzheimers and Parkinson’s disease. The next International Whey Conference will be held in Europe in 2014.  Sharon Gerdes writes Dairy Foods’ Dairy Detective column. She is a food industry consultant who works with the U.S. Manufacturing & Ingredient Marketing program at the U.S. Dairy Export Council. www.dairyfoods.com

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Thank Th Tha han You

Dairy Foods says “Thank You” to the companies that have welcomed us into their boardrooms and plants in 2011. Thanks to their corporate and plant management teams, our feature articles delivered in-depth, behind-thescenes coverage not available anywhere else.

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February Perry’s Ice Cream March DCI Cheese Leading Perry’s Ice Cream Co. are (from left) Brian Perry, executive vp and vice chairman; Robert Denning, president and CEO; and Gayle Perry Denning, director of sustainability.

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

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Curt Jones, founder of Dippin’ Dots, added beverages, frozen yogurt and ice cream cakes to his company’s menu.

SUPERCOW joins Guida’s executive team (from left): Alexander Guida, chairman of the board; Wesley Sliwinski, director of plant operations; James Guida, vp sales; David Drezek, director of distribution and customer service; Michael Young, executive vp; and Michael Guida, president and ceo.

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August Graeter’s Manufacturing, 2011 Plant of the Year

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October Pierre’s ice Cream Brothers Robert and Chip Graeter flank their cousin Rich Graeter. The three assumed ownership of the company in 2007.

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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.

By developing new products, CEO Shelley Roth is leading Pierre’s Ice Cream Co. to markets far from its Cleveland headquarters.

Is your company also leading the way in dairy innovation and helping drive the industry? You could be here in 2012. We are looking for processors of Áuid milk, ice cream, cheese, cultured products, novelties, and juices/teas to proÀle in future issues. Contact Dairy Foods editor Jim Carper at [email protected] or 847-405-4009. DFR-Cover.indd 63

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sneak peek a look inside…

Blow Molding

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ompanies that build machinery to produce, trim and handle packages are a valuable resource to the package designer. Their experience with a broad array of packages can benefit a dairy processor. Page 47.

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Sayler on Safety hat key factors does the U.S. dairy industry depend on to deliver safe dairy products? Allen Sayler writes that there could be many answers, but the predominant factor is an educated, motivated and welltrained workforce. This factor can overcome aging equipment and facilities. Page 52.

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Spotlight on Sustainability he U.S. dairy industry has been diligently gathering data, crunching numbers and double-checking methodologies to ensure that the carbon footprint and life-cycle assessments for fluid milk and cheese are consistent with internationally accepted schemes and protocols. Now it’s time to create value by reducing your carbon footprint, writes Clay Detlefsen. Page 54.

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Packaging Showcase T

hree pages of equipment to solve a dairy processor’s packaging problems. Page 56.

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quipment and ingredients for dairy processors. Page 62.

fast forward what’s coming in January…  Emmi Roth USA’s Aseptic Plant  X-ray Detection & Checkweighing  Secondary Packaging Systems  Cheesemaking Equipment  Antimicrobial Products

Wilmington Machinery designs and builds specialty and standardized rotary blow-molding and structural-foam machines.

Breaking the Mold Vendors of blow-molding equipment offer more than machinery. Dairy processors can turn to them for advice about package design and manufacturing efficiencies. ompanies that build machinery to produce, trim and handle packages are a valuable resource to the package designer, says Brian Dowler of Graham Engineering, York, Pa. Their experience with a broad array of packages can benefit a dairy processor. Lessons that equipment vendors learned in one application, such as the production of bottles for non-food applications, often can be applied to produce innovative options for food packages as well, he says. Container light weighting is one example.

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“The best possible package emerges when the package designer is closely in touch with the people who best understand how the package is produced – the machinery suppliers and processors,” says Dowler. Dairy Foods invited suppliers of blow-molding equipment to share their thoughts about how dairy processors can best use this machinery. Blow-molding technologies include stretch, extrusion and injection. Vendors contacted by Dairy Foods say it is important to keep in mind that equipment makers provide more than machinery. Continued on page 48 www.dairyfoods.com

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Packaging Technology “At Graham Engineering, our R&D staff cooperates closely with package producers and brand companies, offering everything from complete package design to design reviews and prototype sampling,” Dowler says. “Design engineers and experienced processors work together to help optimize package designs before the first test mold is cut, leading the way to a smooth product launch.” Turnkey system services from Tecumseh, Mich.-based Uniloy include container design, mold development and manufacturing, prototyping and preproduction runs and system commissioning. It has an extensive parts and service network. “Creating tailored packaging solutions that meet multiple needs such as reliability, flexibility, cost and sustainability — all at the same time — is not easy,” according to the communications department of the Sidel Group, an international firm based in Switzerland. “These are

perhaps four of the most important issues for leading bottlers today, but there are others too. Each company is different, and each has its own demands,” according to Sidel, whose U.S. office is in Norcross, Ga. Jeff Newman of Wilmington Machinery, Wilmington, N.C., says his company offers economical blow-molding options. “Processors looking for light-weight HDPE bottles for milk and yogurt drink products, or multilayer containers for barrier or hot-fill applications, will find some blow-molding systems extremely suited for their needs.” He adds that many processors “have found rotary blow-molding systems best for these applications compared to shuttles or reciprocating screw machines. The reason: rotary systems are now the simplest to use and provide processors with the means to produce the absolute lowest-cost bottle at the highest quality level.”  A Uniloy N2N (neck-to-neck) reciprocating blowmolding machine was used by Russian dairy processor Wimm Bill Dann.

 Dairy processors can achieve twice the output from a single machine with neck-to-neck bottles.

Russian Dairy Is Made More Productive n 2009, when Wimm Bill Dann (a major Russian dairy processor acquired by PepsiCo in 2011), was looking to add capacity, it turned to Uniloy, an equipment maker based in Tecumseh, Mich. At the time, Uniloy just introduced the Neck-to-Neck (N2N) UR Series reciprocating blow-molding machines. This machine produces two containers oriented neck-to-neck per cavity in a single cycle. The result is high output with reduced energy usage and cycle times, compared to other blow-molding machine technologies. The first two N2N machine systems were delivered to Wimm Bill Dann to produce 100-milliliter HDPE liquid yogurt containers. Each machine could produce more than 20,000 of the 6.5-gram containers per hour. Uniloy spearheaded the container and mold design to help optimize the container, which had weighed 9 grams. This 30% weight reduction yielded three key benefits: • The overall cost per container was reduced significantly. • The cycle time to produce the container was reduced dramatically. • There was a 30% reduction in the raw material reducing environmental impact to help the company meet sustainability goals.

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“This turnkey, consultative approach is typical of Uniloy’s total systems thinking,” says Rich Smith, Uniloy commercial director. “As North America’s only single-source solution provider, we’re able to use technology to optimize the clients’ container design and provide customized machine systems that help them with their business needs.” “We are extremely happy with the machines, which our staff find easy to operate and maintain,” says L. Danilushkin, chief engineer at Wimm Bill Dann. “We average over 98% efficiency on these machines and find weight variations are less than 5%. In fact, we’re so satisfied, we’ve just agreed to purchase another two lines.” Uniloy originated the lightweight, handled, plastic milk jug in 1963, and its reciprocating blow molding machine has since become the “industry standard,” with more than 3,800 in use worldwide. The information in this article was written by Uniloy and edited by Dairy Foods. Continued on page 50

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

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

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

Packaging Technology

Sidel’s Stretch Blow-molder is Energy-Efficient idel uses stretch blow-molding technology for plastic containers. Its blow-molding machines are called SBO machines (biorientation technology). Sidel’s portfolio includes linear machines (up to 7,200 bottles an hour) and rotative machines (from 12,000-64,600 bph). Container sizes range from 0.2-10 liters (about 6.8 ounces to 2.6 gallons). In addition to using the material polyethylene terephtalate, the machinery can also produce RPET, BioPET, Polypropylene – PP, Polylactic Acid – PLA and stretch-blow

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molded HDPE (high-density polyethylene) bottles. The SBO machine has been designed to reheat PET preforms and then blowmold bottles at high pressure. Bottles are produced with injected preforms (preforms are manufactured in an earlier stage through an injection press), according to features of the end product. The SBO can be integrated into a complete bottling line or sold as a standalone equipment. Shown is a new oven design on the SBO Unversal2 Eco blow molder that requires less energy.

Krones Revamps its Stretch Blow-molding Machines he Contiform 3 is the latest generation of stretch blowmolding machines from Krones. The blow-molding module has been entirely revamped. The field-proven linear oven of the Contiform S/H series has been design-enhanced and optimized in regard to its energy consumption. In developing the new machine, Krones had the following objectives: • Increase production output per blow-molding station • Reduce total air consumption

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• Reduce total energy consumption • Improve hygienic design • Shorten product changeover times, increasing flexibility • Further enhance user-friendliness The machine has been developed in sizes ranging from 8-36 blowmolding stations, thus enabling record outputs to be achieved of up to 81,000 containers an hour. The machine can be directly monoblocsynchronized with a filler, or in the ErgoBloc L with both a labeller and a filler.

5 Ways One Blow-molding Technology Save Money Jeff Newman of Wilmington Machinery says single parison rotary technology saves money by giving companies the lowest cost per bottle because: • Material cost. This is the largest area for savings. Some customers have been able to reduce the target weight by as much as 10-15%. • Energy savings. The second largest factor is the energy savings, which could be as much as $100,000 per year. • Real estate. Processors save floor space. A single rotary system can replace 3-4 older molders and requires less floor space. • Labor savings. Wilmington’s system requires a single operator. This can save a processor 60-70% in labor costs. • Operating and maintenance costs. Plant operating efficiency can improve 3-5% and a processor can save hundreds of hours annually in downtime from preventive maintenance. Newman says a rotary machine’s simplicity “comes from the fact they are now all mechanical and uses no complex expensive hydraulics. Not only are the machines simple, they are extremely energy efficient and can save you as much as $100,000 per year in electric.”

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Graham Engineering...........................www.grahamengineering.com Krones .............................................................................www.krones.com Sidel.....................................................................................www.sidel.com Uniloy............................................................................ www.uniloyna.com Wilmington Machinery.....................www.wilmingtonmachinery.com

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The 24th annual Practical Membrane Technology Short Course will mark the 7th consecutive year that Dairy Foods Magazine and Filtration & Membrane World LLC have partnered to produce this one of a kind event. This 2 ½ day Short Course will focus on the basics of membrane technology and process design as well as new membrane technologies, materials and applications. Registe Guided facility tours will be held on the 3rd day of the Super Earlr short course allowing participants to get up close and and SAVE y personal with new and existing membrane products Expires 2/ BIG ! 29/12 and processes.

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Sayler on Safety

Product Safety Begins With the Workforce hat key factors does the U.S. dairy industry depend on to deliver safe dairy products? There could be many answers, but the predominant factor is an educated, motivated and well-trained workforce. This factor can overcome aging equipment and facilities. Yet, do we really know the work force in our dairy plants well enough to provide them with the resources and motivation to consistently deliver safe milk, cheese, ice cream, cultured and powdered dairy products? Who works in dairy plants today? If you ask a dairy plant manager, production or quality assurance supervisor, human resource director or their corporate counterparts, the answer is usually Maria, Tom, Jose or Diane. Many supervisory staff do not understand the broader group dynamics that can drive product safety and quality as well as increase production. Four main groups make up our workforce. An analysis of these groups can allow plant management to focus the resources and tools needed to improve product safety. 1. Builders, also called the Greatest Generation, are retiring and when they leave, their technical on-the-job skills will retire with them. 2. Baby Boomers (born between 1945-1962) are present in reduced numbers in the dairy industry, partly because of the consolidations that occurred during the late 1990s-2001. This is the first “Me” generation. Boomers will not admit to growing old, they expect work to be an adventure and they tend to be optimistic and loyal in personal relationships and with their employers. Challenges working with this group include conflict avoidance (“I’m okay, you’re okay”), a tendency to be more driven by peer pressure and a focus on process over results. Boomers can be judgmental and sensitive to feedback. Their favorite saying is “no problem.” 3. Generation X (1963-1980) are the first children of the Boomers and were the original latch-key kids. They are less optimistic than the Boomers, but are more accepting of diversity in gender, economic class, religion and race. They are often children of divorced parents. Their lives are characterized by change, which may explain their need for instant gratification. Unlike their parents, who challenged leaders with an intent to replace them, Generation Xers tend to ignore leaders. Yet a 2011 publication, “The Generation X Report,” finds that the generation is educated, active, balanced, happy and family-oriented. The study dispels the slacker, disenfranchised stereotype often associated with Gen X. This generation is skeptical of authority and tends to not respect hierarchy, status or title. Generation Xers seek worklife balance and prefer an informal, fun workplace. Characteristics of the Gen X workplace would include emphasis on self-reliance, projects assigned to individuals or small teams, minimal supervision and measurable goals or benchmarks. This generation is not interested in spending hours in meetings; instead the Xer demands

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Allen Sayler

an informal work atmosphere, self-reliance and high productivity. He or she prefers to complete tasks as quickly as possible to free up more personal time. Their favorite saying is “no fear.” 4. Generation Y (1981-2001) was the first generation where the number of single-parent families and two-parent families were almost equal. They are also the first generation where the price of a college education has become a significant problem and where their career-earning potential may be less than prior generations. While this group may be present in lower numbers in the dairy plant workforce, it is important to understand they tend to be cynical and distrustful of leaders/supervisors who do not respect them. They are more likely to switch jobs, and tend to be team players (“No Child Left Behind” educational philosophy). They do demonstrate some individualistic tendencies that result in less uniformity in group characteristics because of geography, ethnicity, social and economic conditions. They clearly are more tech-savvy than prior generations and more comfortable with advanced processing technology, such as programmable PLCs and computers. Generation Y has a strong desire to be viewed as individuals; 40% have tattoos. Supervisors are most effective if they use the “coaching” approach. Their favorite sayings are “whatever” and “I want it right now.” Communicating with a multigenerational workforce At work, generational differences can affect everything, including recruiting, building teams, dealing with change, motivating, supervising and increasing productivity. Research indicates that people communicate based on their generational backgrounds. Each generation has distinct attitudes, behaviors, expectations, habits and motivational buttons. Learning how to communicate with the different generations can eliminate many major workplace disruptions that cause food safety and quality problems as well as decreases in production. In summary, a key to training and managing these four groups to attain consistent product safety, quality and production targets is to involve them in the plant information flow and provide feedback and opportunities for their input into operational decisions, particularly if it affects their job responsibility. Avoid training boredom (meaning, you tend to use the same materials and trainers year after year). A positive work environment with managers and supervisors who coach and provide overall direction will motive all four generations to perform at a higher level.  Allen R. Sayler is vice president, food safety, technology and regulatory solutions at Randolph Associates Inc. Learn more about Randolph’s QA Studio, a LIMS software system that fully integrates into plant and dairy company’s PIMS and EMR software systems. Phone Andrena Schermerhorn, 775-232-4856, or send email to [email protected].

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Spotlight on Sustainability

Create Value by Reducing Your Carbon Footprint he U.S. dairy industry has been diligently gathering data, crunching numbers and double-checking methodologies to ensure that the carbon footprint and life-cycle assessments for fluid milk and cheese are consistent with internationally accepted schemes and protocols. Since we are pretty much done with those, now what? It is time to cash in — or should I say “create value” — by reducing your carbon footprint. Many folks in the dairy industry have been doing that for longer than the word “sustainability” has been around. But the buzz around sustainability has energized efforts to increase efficiency, reduce waste, reduce greenhouse gases and add to the bottom line like never before. Check out the Innovation Center for U.S. Dairy’s website (www.usdairy.com) and you will see how busy the industry has been and what we are achieving. The case studies on the impact of switching from incandescent lamps to LED lighting show doing so reduces electrical energy consumed substantially. It also shows LEDs save time and money by reducing maintenance time and costs because they last up to 20 times longer than incandescent lights — LEDs can last up to 40,000 hours. There is a case study about one of my favorite technologies — thermal solar heat — at Oakhurst Dairy, Portland, Maine. I mentioned this case briefly in my first column (Dairy Foods, January 2011, page 124), but it’s worth a little more ink here. That facility in Maine — yes, Maine — has been saving more than 7,500 gallons of No. 2 fuel oil per year with the potential for improvement. Currently, that represents annual savings of about 224,000 pounds of CO2. What I like about this project is that it went forward despite having an unusually long payback period. Payback in this case will be eight years versus the indus-

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try standard of one to two years that most projects need to get capital funds. After the first eight years, the system will be paid for and should last another 22 years, which will save the company an estimated $350,000 at today’s oil prices. If fuel prices increase, which you and I know they will, the savings grow. So solar can pay out, even in Maine. Energy audit finds savings Sometimes value comes not from adding something new, but rather making better use of what you have now. That was the case for an Ohio novelty plant that had multiple air compressors running off local controls. After my friends at Solution Dynamics Inc., Brookfield, Wis., performed an energy audit of the facility, they discovered that adding another air compressor at a cost of $50,000 was not the solution. Instead, they focused on getting the most out of what was already there. They did this by integrating the multiple units, adding larger controlled storage capacity, installing high-efficiency nozzles and other equipment and, of course, fixing leaks. In the end, the company invested a little more than $76,000 with a life expectancy of 10-15 years and an annual cost savings of nearly 850,000 kWh or $38,250. The payback came in at 1.4 years — right in the sweet spot needed to get capital funds. Value to processors can also be delivered by new refrigeration systems, refrigeration system upgrades or by replacing outdated milk evaporators with reverseosmosis systems, as was done at the Maryland & Virginia Milk Producers Cooperative’s balancing plant in Laurel, Md., in 2009. Here too, the payback period was unusual for the dairy industry: 4.4 years. But, the company clearly saw the value when it benefited from reduced electrical demand and natural gas usage savings of nearly $500,000 per year. Reduced maintenance on this low-

Clay Detlefsen

temperature technology was a bonus and it eliminated nearly 2,700 metric tons of CO2. It really drives home the opportunities offered by the dairy industry’s voluntary commitment to reduce greenhouse gas emissions for fluid milk by 25% by the year 2020. Dive into the motor pool Delivering value can also come from the transportation side of the dairy industry. Transportation, processing and distribution comprise about 17% of the greenhouse gas emissions associated with a gallon of consumed fluid milk. Raw transportation to processing locations amounts to nearly one-half the amount of greenhouse gas emissions associated with processing. So, there are lots of opportunities to be had. For example, Dairy Farmers of America, Kansas City, Mo., installed a GPS-based electronic fleet management system, which delivered an incredible value. The system delivered data on fuel consumption, route information, inspection data and driver speed, which is wirelessly routed to fleet managers. With a relatively small investment of $138,000 plus $50,000 per year in maintenance for 150 trucks, the payback period was six months. That’s excellent. Annual fuel savings came in at $377,000 — or 94,250 gallons of diesel at an estimated cost of $4 per gallon. This represents an approximate 950 metric tons of greenhouse gas emissions avoided. While the title and the premise of this column is about capitalizing on value associated with reducing greenhouse gas emissions, readers should not be complacent about water. We will deal with that issue, too, but suffice to say for now: Water saved is greenhouse gas emissions reduced.  Clay Detlefsen is vice president for regulatory affairs for the International Dairy Foods Association, Washington, D.C.

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New Product Showcase

Packaging Materials and Equipment Overnight Labels is a manufacturer of custom printed products, including shrink sleeves, labels and flexible packaging. Shrink sleeves are printed and seamed in-house. All presses run laser-engraved digital plates and are equipped with real-time monitoring systems for print/color precision. Overnight Labels Inc. 631-242-4240 www.overnightlabels.com

Sealed Air’s Cryovac food packaging brings an optimized level of efficiency to automated bag loading with the BLX-F2 taped bag loader. Ideal for loading cheddar and Italian cheeses, the high-speed system offers processors configurable options using roll or boxed taped bags for a variety of sizes ranging from 8 ounces to 12 pounds. Sealed Air Corp., Cryovac Food Packaging Systems 800-845-3456 www.cryovac.com

Overnight Labels Inc.

A-B-C Packaging Machine’s palletizer is designed for stacking cases filled with cheese for warehouse and grocery distribution. The palletizer features a counterweighted, stainless-steel transfer table for smooth transfer of bulky cases, heavy gauge steel frame for maximum durability, plus low level construction that gives dairy processors the convenience and economy of floor level operation. A novel automatic grouping module allows layer transfer during product accumulation, effectively staging and stacking up to four layers per minute. The servo-operated overhead orienter provides panel orientation during high-speed operation. A-B-C Packaging Machine Corp. 800-237-5975 www.abcpackaging.com

SIG Combibloc Inc.

SIG Combibloc’s combiblocMini now comes in a 180-milliliter option volume. The new volume gives beverage producers the opportunity to offer a 6-ounce aseptic carton package to the market. There is no need to re-sterilize or change machine parts, and output delivery remains consistent (12,000 or 24,000 finished products per hour). SIG Combibloc Inc. 610-546-4200 www.siggroup.com

Sealed Air Corp.

EPI Labeler’s B-Series wrap labeler features a self-calibrating bottle labeler, ideal for contract packaging, private label, personal care, nutraceutical and spice and condiment applications. With more than 30 years of experience in the industry, EPI knows durability and simplicity are top priorities. All functions on the bottle labeler are controlled by a color touchscreen HMI. Simple adjustments allow for ease of set-up and fast changeovers, most within a few minutes. EPI Labelers 877-316-3768 www.epilabelers.com From yogurt to pallet, Markem-Imaje offers a full product line of coding equipment. The small character 9000 Series inkjet coders, for example, facilitate operator activities by offering intuitive and improved ergonomic utilization. Also, the printhead requires little intervention and guarantees high qual-

Markem-Imaje

Continued on page 58

dftv 56

Dairy Foods | December 2011

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

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

Le leader de l’industrie en termes de transformation et de conditionnment.

New Product Showcase ity print, thus increasing customers’ overall productivity. The 9040 IP65 small character inkjet printer is protected against water during production line cleaning, features a 5- or 8-meter umbilical for easy placement, contains up to two printheads to print simultaneously on several products and comes with a standard wheeled base for easy movement from one production line to another. Characterized by their Touch Dry hot melt inks, the 5000 Series high-resolution, large character inkjet printers are said to offer excellent adhesion and print quality onto carton cases, trays and shrink wrap. Lastly, the CimPak Pallet print-and-apply systems allow for precise marking with perfect GS1-compliant barcodes. Markem-Imaje, subsidiary of Dover Group 770-421-7700 www.markem-imaje.com OK International Corp. OK International introduced its redesigned stainless-steel case liner, the Superliner SL220. This machine comes equipped with enhanced controls and an improved sequence, making it capable of running up to 18 cycles per minute. It also makes bags with an adjustable length from rolls of continuous gusseted tubing. The bag is then opened and placed into a case, crate, drum or tray with the neck cuffed over the edges, providing a hygienic container ready for filling. Other standard features include a dual roll holder for easy loading and changing of the rolls of film, a stainless-steel conveyor and Allen Bradley controls with self diagnostics. OK International Corp. 800-521-2908 www.okcorp.com Delkor Systems Inc.

Printpack Inc. Printpack provides heat shrinkable film products for a wide variety of applications. Offerings include Affinia shrink film family and the Colorpack proprietary prepress separation method that delivers enhanced graphic details and creates the “pop” that makes products stand out on the shelf. Printpack Inc. 404-460-7000 www.printpack.com North America IML Containers specializes in manufacturing plastic cups with in-mold labels. These labels are tamper-evident, leak proof and freezer-grade resin. North America IML Containers Inc. 450-258-3130 www.iml.ca IML Containers Inc.

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Dairy Foods | December 2011

The new TriSeal carton closer TSC-300z from Delkor is the latest addition to the Capstone Closer product line. Designed for lowto mid-range throughput at up to 60 cartons per minute, this carton closer requires less than 25 square feet of plant space and provides precision closing for a variety of preformed carton styles, such as TriSeal flap, single flap or side flap. Delkor Systems Inc. 800-328-5558 www.delkorsystems.com Continued on page 60

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. ®

æ3OUTHPORTæ2OADæsæ3PARTANBURG æ3#ææsæWWWEXOPACKCOM 4OLLæFREEææsæ%MAILæmEXPACK EXOPACKCOM

Touching Everyday Life

™

New Product Showcase Polypack unveiled its Clearprint Series shrink bundler, a high-speed, welded frame that creates pad-supported multipacks using both clear and printed film. This machine is capable of shrink wrapping large-sized bundles at a high rate of speed. And, the pad packing system incorporates stainless-steel washdown motors and a 4-fan tunnel. Polypack Inc. 727-578-5000 www.polypack.com

Lantech Lantech’s RL automatic stretch wrapper is an ultra highspeed ring straddle-style stretch wrapper capable of wrapping up to 200 loads per hour, whereas the SL automatic stretch wrapper is an overhead straddle wrapper with throughput capabilities up to 120 loads per hour. Both machines feature LeanWrap innovations, such as more film choices, higher operating speeds, improved productivity, reduced film breaks, less maintenance and lower cost per load. Lantech 800-866-0322 www.lantech.com

PDC introduced the 90-2 shrink sealer, which seals more than 400 containers per minute with true 24/7, downtime-free performance. It also can run as slowly as 100 cpm per head to synchronize with production. Standard features include a stainless-steel frame, NEMA 4 enclosures, an Allen-Bradley touchscreen and PLC, a static eliminator, a robust blade assembly with reliable spinning knives and sensors for low material and film feed for imprint and bar code verification. PDC International Corp. 203-853-1516 www.pdc-corp.com Bosch Packaging Technology Inc.

Harpak-ULMA

Harpak-ULMA’s extensive experience in the dairy industry includes a wide variety of packaging solutions, from packaging applications for cheese to yogurt and everything in between. Harpak-ULMA offers a complete line of primary, secondary and automated packaging solutions for sticks, blocks, sliced, stacked, shingled, wedge, yogurt, ice cream bars, novelty items, pouches, tubs and more. Harpak-ULMA Packaging, LLC 800-813-6644 www.harpak-ulma.com 60

Dairy Foods | December 2011

As part of the Sigpack RNx platform, Bosch Packaging Technology introduced Sigpack RNGS-6/KG3, a vertical flat pouch system that consists of a sachet packaging machine and cartoning unit for packaging, transport and grouping of powders, granulates, pellets and piece goods. It provides an output of up to 1,000 sachets per minute, and the integrated weight control system ensures 100% inline weight control. Bosch Packaging Technology Inc. 715-246-6511 www.boschpackaging.com

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Buyers Mart

PLANT EQUIPMENT Asep tanks from AsepTrans can aseptically transport liquid food products in bulk quantities (up to 24,000 liters), while delivering higher payload, greater efficiency and secure product integrity. AsepTrans 941-981-3886 www.aseptrans.com DuPont Qualicon introduced the BAX System STEC Suite, a trio of real-time PCR assays that enable food processors, reference labs and government labs to rapidly and reliably detect the Shiga toxin-producing E. coli (STEC) most frequently associated with severe foodborne illness. This suite of food safety tests was developed in collaboration with the Agricultural Research Service of the United States Department of Agriculture and is closely aligned with the testing approach used by the Food Safety and Inspection Service. DuPont Qualicon 302-695-5300 www.qualicon.com

day results, easy sample preparation, simple mix-and-measure protocols, detection of live bacteria, time saving, labor and consumables and removal of agar plates. Luxcel Biosciences +353 (0) 21 490 1447 www.luxcel.com Wahl Instruments released Heat Spy thermal imaging cameras. The z30 series “Detector” is designed for on-the-spot maintenance inspections and repair, features 11 languages, four color palettes, °C, °F or K measurement scales, hot/cold seeking, two fixed spot measurements and freeze frame for viewing the current image. The z50 series “Inspector” documents and prepares reports, including thermal and digital images, and features all the functions of the z30, but with additional 7-color palettes, built-in emissivity table for easy look up, measurement offset correction, digital camera and image storage via SD card. Wahl Instruments Inc. 800-421-2853 www.palmerwahl.com

Omega Engineering Psion’s Workabout Pro 3 is a handheld computer that delivers the choice of numerous hardware add-ons, from biometric scanners to RFID readers, as well as software applications and upgrades. Its rugged, flexible design enables workers to get the job done faster, and its ergonomics and user-friendly features provide comfort for operators. Psion 800-322-3437 www.psion.com The Thermal Imager OSXL160 from Omega Engineering offers a temperature range of -4° to 2,192°F. Plus, it is equipped with voice annotation, analysis software, flash memory storage, USB connection to PC and a colored thermal image with sounds and alarms. Omega Engineering Inc. 203-359-1660 www.omega.com Luxcel Biosciences released the GreenLight range of food safety tests, which allows for easy, same-day detection and enumeration of bacteria in food and beverage samples. These tests measure bacterial oxygen consumption and equate it to microbial load. Other benefits include same62

Dairy Foods | December 2011

The new BenchMix Model OPLB-400 from Admix combines power, speed and versatility into one unit. The BenchMix handles up to 15 liters and provides complete versatility with multiple high-shear heads, low-speed impellers and props. It comes with 3 HP at 12,000 RPM, a low batch level adapter and an adjustable beaker clamp. Admix Inc. 800-466-2369 www.admix.com Parker Hannifin now offers a line of stainless-steel filters designed for areas that are frequently exposed to aggressive washdown chemicals. These filters remove 99.9999+% 0.01 microns of oil, water, rust, bacteria and other viable organisms from

compressed air and other gases. Filters are available in ¼- to 1-inch line sizes with flow capacities over 700 SCFM. Parker Hannifin Corp., Filtration & Separation Division 800-343-4048 www.balstonfilters.com

SPX Flow Technology

SPX’s new APV cavitator, which is exclusively licensed from Hydro Dynamics Inc., Rome, Ga., sends shockwaves produced from the collapse of “controlled cavitation” bubbles and works by taking fluid into the machine housing that passes through a controlled cavitation field created by the reactor’s spinning rotor. This advanced technology is said to be used for a multitude of sanitary applications, ranging from pasteurization to low-pressure homogenization. Its benefits include improved process efficiencies, enhanced product quality, yield and/or raw material savings, extended process run times, elimination or reduction of process downtime from maintenance requirements, smaller footprint, easy disassembly, fully CIPable and meets 3-A standards. SPX Flow Technology 800-252-5200 www.spxflowtechnology.com The new AEGIS Shaft Voltage test kit from Electro Static Technology and Fluke Corp., Everett, Wash., makes it easier to measure and document damaging VFD-induced voltages. The kit includes a replaceable probe tip that contains highdensity conductive microfibers for highly accurate voltage readings on rotating equipment. The tip and extension rod may be held or used with an optional magnetic base. Electro Static Technology 866-738-1857 www.est-aegis.com

Buyers Mart

R&D INGREDIENTS Gelita presents body function-stimulating bioactive collagen peptides Verisol for “beauty from within” and Gelita RXL (reduced cross-linking) gelatine for improved shelf life and stability of hard and soft capsules. Verisol is produced from native collagen and is said to maintain an excellent bioavailability. It can be easily incorporated into indulgence products such as chocolate or instant coffee. Gelita RXL gelatine enhances the availability of actives by increasing dissolution properties and improving shelf life, especially at high temperatures and humidity. Gelita USA Inc. 712-943-1692 www.gelita.com

blossom, chamomile, mimosa, iris, rose, hibiscus and chrysanthemum. Wild Flavors Inc. 859-342-3600 www.wildflavors.com

Wild Flavors developed a line of floral flavors for teas, functional drinks, energy drinks, juices and water. The lineup includes jasmine, lavender, cherry blossom, orange

International Dairy Ingredients released cheasing’up, which avoids the processing of by-products and reduces the number of manufacturing steps (no

Spirax Sarco released phase 1 of its pressure-reducing valve (PRV) module. Based on suggestions and user feedback, the module was enhanced to incorporate additional features and benefits. For instance, the visual product range selection option allows full product descriptions and code numbers to be viewed, making it unnecessary to use sizing charts. Additional features include velocity and noise predictions, automatic pipe sizing and more. Spirax Sarco Inc. 800-575-0394 www.spiraxsarco.com Thermo Fisher Scientific’s Xpert C400 easily detects metal, glass, dense plastics and other contaminants in packaged food. It can also analyze an X-ray image to estimate weight, fill and count or assure that objects are inside a packaged item. The system’s highly sensitive detectors are available in multiple resolutions, and its suite of algorithms can find small contaminants in complex images with few, if any, false rejects. Thermo Fisher Scientific Inc. 800-678-5599 www.thermofisher.com

International Dairy Ingredients Inc.

Softtrace introduces a suite of tracing software solutions. Softtrace cheese can determine daily production and yields, respond immediately to any production problems, provide a plant balance of milk by volume and composition across all products and processes, verify the quality and grade of each pallet of cheese and reduce waste. Softtrace liquid milk integrates with plant ERP and automation systems to provide real-time performance analysis and traceability for milk production. It determines daily production costs and yields by volume across all processes, offers precise product monitoring and control of wastage, establishes optimum production levels and provides full production traceability. Softtrace dairy is a fully integrated enterprise-quality management system that addresses and solves deficiencies and ensures product quality, physical traceability and product safety with maximum product yield. Softtrace Ltd. 866-739-0913 www.soft-trace.com

curd cutting, draining or brining). Plus, it delivers gains on operational costs and investments. Cheasing’up is applicable for hard, soft, fresh and processed cheese. International Dairy Ingredients Inc. 419-738-4060 www.idi-ingredients.com Cargill introduced Vitex AYS stabilizers, a customizable functional system that enables dairy food manufacturers to manage raw material costs in yogurt while still providing consumers with the same creamy products. Vitex AYS features modified food starch and hydrocolloids to create a cost-effective alternative to gelatin without affecting the flavor or texture of yogurt. Cargill Inc. 952-742-6360 www.cargill.com

Ross tray sealers from Reiser produce modified atmosphere packages from preformed trays of almost any size or shape. These sealers package all types of fresh and refrigerated cheese at a full range of output rates in leak-proof, tamper-evident packages with greater seal integrity and extended shelf life. When the tray is in the sealing station, the package evacuation and gas flushing are done using pressure. This ensures the same level of evacuation and gas in each tray on every cycle. Reiser 781-821-1290 www.reiser.com Dynamic Conveyor presents a new line of DynaClean custom food conveyor systems. Designed and built to meet NSF, FDA, USDA and BISCC standards, these systems are fabricated with stainless steel and heavy duty plastic segments that quickly connect with each other. Plus, they utilize belt lifters that can be placed anywhere, ensuring easy cleaning without tools or belt removal. Dynamic Conveyor Corp. 800-640-6850 www.dynamicconveyor.com www.dairyfoods.com

63

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].

AUCTION

EQUIPMENT FOR SALE

AUCTIONS

2001 Modern Packaging SL 1x2 Filling Machine Model Number: MP714

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Currently in operaƟon. For sale due to move to larger Įller.

• 2006 Marel Automated Steak Trimming/ Portioning System & Trim Table Systems • (12) 2009-2007 Formax Patty Formers • (26) Multivac & other Vacuum Sealers • (2) 2010 30’ Microwave Thawing Tunnels • Safeline X-Ray Inspection Systems, (14) Metal Detectors, Labelers, Cartoners • (15) Weiler & other S/S Grinders • (12) MTC & RMF S/S Mixers & Blenders • Tumblers, Slicers, Vacuum Stuffers • Extensive Conveyor Material Handling Systems, General Plant & Trailer Fleet • Both Facilities Available for Turn-key Sale!

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HARRY

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Email [email protected] for more details and video of Įller in operaƟon. Please write “MP714” in subject line. Contact for pricing.

EMPLOYMENT

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A D V E R TI S E H E R E Contact Suzanne Sarkesian at 248-786-1692

64

Dairy Foods | December 2011

EMPLOYMENT

EQUIPMENT FOR SALE

PRODUCT SAVER The Unpackager.... Reclaiming Machines.... Product Saver technology differentiates our system from all the rest. Our high throughput design will process products quickly and efficiently. Compacted containers are product-free. Reclaims products from off-spec packaging. Will process free-flowing liquids and viscous products. Powder reclaim systems available as well. Free product testing and demos.

Product Saver 40A Stonehill Road, Oswego, IL 60543 • T: 800-547-9370 • F: 630-554-7805 E-Mail: [email protected] • www.productsaver.com

HENSON PARTNERS, INC. SPECIALIZED EXECUTIVE SEARCH

EXCEEDING EXPECTATIONS AS YOUR SEARCH PARTNER Our mission is to earn the privilege of becoming our client’s exclusive recruitment resource for key search activity. We do this by LISTENING to our clients needs to develop an understanding of the ideal candidate. We FOLLOW-UP throughout the entire recruitment process with conscientiousness and a respectful sense of urgency. We reliably DELIVER freshly recruited, qualified and interested candidates to fill our client’s positions. Our pursuit of excellence and our dedication to the Food Processing Industry, has earned our firm a reputation we are proud to have, and one that you can trust. To learn how your business can benefit from our extensive industry knowledge and experience, contact us today.

HENSON PARTNERS, INC. Phone / Fax: 866-898-9911 Web: http://www.hensonpartners.com

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Call CXR COMPANY • Warsaw, IN 800-817-5763 • fax 574-269-7140 www.cxrcompany.com

Advertise in our Classified Section. Contact Suzanne Sarkesianat 248-786-1692 or check out www.dairyfoods.com! www.dairyfoods.com

65

EQUIPMENT FOR SALE

ICE CREAM DOLLY “The Original Ice Cream Dolly” els New Mod in Available e! id Tall and W

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66

Dairy Foods | December 2011

3/7/11 10:17 AM

EQUIPMENT FOR SALE

SOFTWARE

Owl

“Serving the Dairy, Beverage & Food Industries for over 78 years.” STORAGE TANKS (1) 25,000 GALLON WALKER SILO (1) 50,000 GALLON MUELLER SILO (1) 40,000 GALLON CREPACO SILO (1) 40,000 GALLON DCI SILO (2) 3,000 GALLON DCI ROUND HORIZONTAL TANKS (2) 6,000 GALLON WALKER ROUND HORIZONTAL LARGE STOCK OF 1000 - 10,000 GALLON HORIZONTAL STORAGE TANKS STAINLESS INTERIOR

Software Program Product Development Nutrition Labeling Reformulation Least Cost Formulation Batching Reverse Engineering

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Information About Ingredients For Frozen Desserts “Frightful Weather, Delightful Desserts” (beginning on page 26) refers to ingredients used in frozen desserts. Contact these companies for more information. • Frozen Greek yogurt. Danisco USA, www.dansico.com • Bakery and confection concepts. Kerry Ingredients & Flavours www.kerry.com • Savory flavors for ice cream. Pecan Deluxe Candy Co. www.pecandeluxe.com

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Ad Index

Company Name

Page No.

Company Name

Page No.

Company Name

Page No.

ADM Cocoa ...........................................................27

GEA Niro Soavi NA.............................................. 7

Parker Hannifin Corporation ...................... 53

Admix, Inc. ............................................................. 15

GEA Tuchenhagen North America ........ 41

Robert Reiser & Co. ..........................................57

Bentley Instruments........................................... 6

Gram Equipment ............................................... 16

Burkert Fluid Control Systems ..................37

H.S. Crocker Company, Inc.......................... 18

Robertet Flavors, Inc. ...................................... 25

Rocket Products, Inc. ...................................... 33 Chr. Hansen, Inc. ................................................... 3

Huhtamaki ..........................................................IFC SensoryEffects ................................................... 19

Clear Seas Research ...................................... 55

Hydrite Chemical Company ....................... 39

CP Kelco ................................................................ 29

International Dairy Foods Association........ 43

DSM Nutritional Products, Inc. .................. 31

iTi Tropicals ....................................................12, 17

Exopack ................................................................. 59

MilkPEP .................................................................. 21

Flow Products, LLC.............................................. 6

Mintel International .......................................... 69

Virginia Dare ........................................................BC

FOSS North America ......................................... 4

Neogen....................................................................... 9

Weber Scientific ................................................. 13

SPX Flow Technology Segment............ IBC

Sudmo North America, Inc. ..........................11

Tindall Packaging, Inc..................................... 49

ACCELERATE YOUR

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

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69

Inside Perspective

Nestlé’s DSD Model Opens New Retail Channels uch like the rest of the beverage industry, retailers and distributors of dairy beverage products are faced with the challenge of having to meet the needs of increasingly discerning consumers who are short on time and constantly on the go. Key issues — like the reduction of spoilage, transportation and storage costs and the ease of access to products — are significant industry-wide challenges for all distributors. To address these challenges, many retailers have created directstore-distribution (DSD) models to help ensure the efficient and convenient delivery of products to consumers. Here at Nestlé, our DSD model, which launched in 2009, has ensured the availability of Nestlé products wherever and whenever consumers want them, thereby allowing the company to continue broadening its distribution base into non-traditional, alternative locations. Recent DSD sales successes within non-traditional channels such as military bases, colleges, universities and recreational centers, demonstrate DSD’s substantial potential of expanding the availability and convenience of our DSD beverages (including Nesquik and Nestlé Aguas Frescas) to previously untapped audiences. It is also important for all beverage companies to invest in technology and operational processes that will enable the wider and more efficient distribution of products. Back in 2009, Nestlé invested resources toward designing a state-ofthe-art manufacthe-a turing facility in turin Anderson, Ind., And which is now wh the first in the

M

Joe Culella

United States to receive approval from the U.S. Food and Drug Administration for PET (polyethylene terephthalate) aseptic production capabilities. (See “Nestlé LEEDs the Way,” January 2011, page 104.) It’s been an essential investment as aseptic production is a key enabler of the DSD model, which allows distributor partners and customers to save on refrigeration costs during distribution and storage.

The aseptic treatment that supports the DSD portfolio demonstrates significant benefits for retailers and distributors by increasing the potential for rising category sales without taking up valuable refrigerator space. For example, the technological capabilities of the Anderson facility, which produces the entire Nesquik ready-to-drink line, allows shelf-stable Nesquik to be stored up to 105 days without refrigeration. Of course, the entire line is made with real milk, but the aseptic treatment process (which uses ultra-high temperatures) kills both milk-borne and spoilage organisms. The aseptic treatment that supports the DSD portfolio demonstrates significant benefits for retailers and distributors by increasing the potential for rising category sales without taking up valuable refrigerator space. This helps retailers and distributors to free up back room storage and lower their transportation and storage costs. At Nestlé, we believe in addressing these industrywide challenges by working closely with our distribution w network partners. DSD distributors have extensive netn works of accounts that they service with a variety of bevw eerages. Because they also have an established history of building and supporting beverage brands, working with b tthese distributors allows consumers to access Nesquik aand other beverages in the DSD portfolio at a growing number of trusted locations. Nesquik now has access to n more stores than at any point in the brand’s history. m In 2012, we look forward to fostering and strengthening our existing distribution partnerships and hope that other o beverage companies will adopt and enhance their own DSD b models to effectively address the needs of retailers and dism ttributors and ultimately, our dairy beverage consumers.  JJoe Culella is a brand manager for Nesquik at Nestlé USA, Glendale, Calif. G Dairy Foods seeks essay from dairy processors. Contact D [email protected].

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Dairy Foods | December 2011

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