minister of trade & idiocy? - food & beverage reporter · the prize follows coca-cola’s...

SEPTEMBER 2017

Reporter

Processing Reporter

WHY IS ROB DAVIES LETTING THE EU DESTROY OUR CHICKEN INDUSTRY?

MINISTER OF TRADE & IDIOCY?

CONTENTSopinion

packaging & processing

Shoprite’s new Cape 23 DC is pretty awesome

CHEP gives Nando’s 31 the sustainable edge tna sets a speed record 33with its new case-packer

Reporter

&

Save our chicken industryfrom EU dumping frenzy 2Local pesticide limits are just not lekker 4

features

PLEASE PASS THE SALT 8 Why are we so obsessed withsodium reduction? It’s actually healthy, says a leading researcher

GUT GOODNESS

SA’s first yoghurt summit 18

Danone’s SA MD

on a mission to

combat malnutrition

16

FOOD SABOTAGE THINK LIKE A TERRORIST! 12

Africa’sbiggest

foodcompanies

21

September 2017

4 | SEPTEMBER 2017 | FOOD & BEVERAGE REPORTER www.fbreporter.com

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Publisher Bruce Cohen

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Reporter

&All this poultry dumping. And we’re chicken sh**

EDITORIAL

Bruce Cohen [email protected]

This month’s story on European Union (EU) chicken producers dumping their surplus on SA – and

Government’s inability to defend the local industry - is yet another depressing example of ANC policy failure when it comes to keeping the economy afloat, let alone moving it forward.

There are only two things that Trade and Industry Minister Rob Davies should be having sleepless nights over: 1) jobs 2) food security. And nothing better sums up Government’s policy cock-ups in these two critical areas like the chicken dumping saga.

Davies has been in his post since 2009, probably the longest-serving minister in a single portfolio in Jacob Zuma’s dizzying game of (ministerial)thrones. One would have thought Davies would be tough enough, experienced enough and confident enough to take

a stand against the EU and hold the line. Instead he plays chicken.

Now, I don’t doubt the minister’s integrity but I just couldn’t help myself Googling to see if, perhaps, the Guptas owned poultry farms in Holland, Germany or the UK, the worst dumping culprits, because that might have explained the unfathomable failure of the DTI to halt this dumping onslaught, the shedding of jobs and the destruction of a vital industry.

Google came up with nothing. So I’m left in a state of bewilderment.

It just makes no damn sense.

No country seems more determined to eliminate the scourge of single-use plastic

bag pollution than Kenya, which last month introduced the world’s toughest penalities: fines of up to R500 000 or 4 years in the chink!

The government says it won’t be hunting down grannies doing their weekly shopping, focussing rather on the bag manufacturers, but the message is clear: Kenya is sick and tired of the eco damage done by the bags, an issue which came into sharp focus recently with the revelation that Nairobi slaughterhouses

have been removing up to 20 bags from the stomachs of some cows.

Of course there’s going to be a price to pay, because Kenya is a major producer of plastic bags for the entire East Africa region. Job losses could be huge. But sometimes draconian measures are the only way to break a vicious cycle.

South Africa, on the other hand, has chosen the easy, lazy route to deal with our new national flower- tax the bags. So government pockets a billion or more each year and pretends it has taken a progressive stance for the public good.Sound a lot like the looming sugar tax?

Kenya sure knows how topunish plastic bag offenders

SUBSCRIBE TO FBR FOR JUST R250Make sure you get every issue of Food & Beverage Reporter

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THE GREEN ROAD: ARE YOU ON IT? South Africa’s food and beverage sector has shown commendable innovation and commitment to addressing environmental challenges in recent times.

From recycling and upcycling projects and solutions, to energy, water and waste efficiency programmes, the sector is increasingly addressing the impacts of global warming and pollution, as well as growing consumer demands for cleaner, ethical and sustainable food chains all the way from farm to fork. In the November issue of Food & Beverage Reporter we’ll be publishing a special supplement:

THE GREEN ROAD Pathways to Sustainability in SA’s Food and Beverage Sector

If you’re a supplier of green technologies, products and services to the industry, if your company has embarked on a sustainable journey it wants to share with the world, we really want to hear from you.

For all advertising/advertorial inquiries and editorial submissions, please contact Wendy Breakey [email protected]

Office: + 27 (0) 11 026 7311 Mobile: +27 (0) 83 653 8116Booking and editorial submissions by Friday 6 October, ad material by Friday 13 October.

Reporter

&

By Dr Eva Sirinathsinghji

Earlier this year the South African government issued draft amendments to its regulations governing the legal limits for pesticide residues on food crops. The proposed amendments expose the gaps in regu-lations to date, despite the cultivation of herbicide-tolerant GM crops for almost two decades.

As the African Centre for Biodiversity (ACB) team researched the proposed changes to Maximum Residues Levels (MRLs) for various vegetables and staple crops, it became clear that there is no established system or single database where information on MRLs can be found.

The incomplete information exposes the government’s inadequate oversight of our food system. Indeed, the oversight role is fragmented across 14 separate acts of parliament, with policy execution ham-pered by a lack of clear demarcation regarding mandates, responsibilities and accountability.

In contrast, the regulations on MRLs for international export are tightly regulated. This begs the question: why does our government regard testing to ensure safety of local foods of less importance than that of foods destined for international trade?

Such monitoring is crucial for protecting people’s health, especially with the latest evidence of the toxicity of widely-used pesticides, such

as glyphosate, at levels well within legal limits set in South Africa. Now we are facing the commercialisation of yet more GM herbicide-tolerant crops to replace the failing glyphosate-tolerant varieties that are succumbing to weed resistance, such as 2,4-D tolerant maize. This will only increase the chemical burden on our foods, water, land and health.

Since government monitoring of chemical contamination is clearly inadequate, the ACB commissioned laboratories to test for glyphosate residues in soy and maize products. Residues were found to be present in multiple foods.

Moving away from GM crops and placing a ban on glyphosate will help to convince the public that our health and that of our children is government’s top priority.

• An MRL is the legal limit for pesticide residues in foods. Each foodstuff has its own limit for each pesticide; an MRL for glyphosate on soy-bean may be different to

that for chicken or maize. MRLs are determined by

various factors that consider both agronomic use and the safe legal limits, or “accept-able daily intake” (ADI) set by regulators. ADI is based on long-term toxicity testing and, in theory, represents safe levels to consume over a life time. However, there is widespread scepticism over such regulations, since all data is provided by industry.

Source: African Centre for Biodiversity: acbio.org.za

OPINION

PESTICIDES: LOCAL LIMITS NOT LEKKER

www.fbreporter.com FOOD & BEVERAGE REPORTER | SEPTEMBER 2017 | 7

BRIEFS

Not long ago it was a rarity, something only those in the know knew about. Now cold-pressed juices are so flavour-of-the-moment that even the big guys are in on the game. Sir Juice recently announced the introduction of their cold-pressed range, which consists of three blends: Apple, beetroot, raspberry, orange, carrot and ginger; Carrot, apple, orange, granadilla and ginger; Apple, cucumber, spinach, kale and mint. “They are free from added sugar, preservatives, artificial flavours, colours or stabilisers. It is the king of juicing methods and rightfully so with the flavour and goodness it punches,” says Sir Fruit’s Brand Manager, Taryn van Zyl.

SIR JUICE JUMPS ON COLD PRESS TRAIN

COKE’S MILLION $ SWEETENER PRIZECoca-Cola have turned to researchers and scientists outside of the company to come up with a naturally-sourced, low-calorie sweetener that will taste just like, well, sugar. Whilst the R&D departments of other companies have been toiling away for years trying to find the perfect solution, Coke has put a major incentive on the table – a prize to the tune of $1-million up for grabs until October 2018. The prize follows Coca-Cola’s announcement earlier this year that they are evolving their growth model to focus more on consumers’ changing tastes, with a special focus on offering beverages with limited sugar. A little late to the party perhaps, but James Quincey, who became CEO of Coca-Cola in May, says: “We’re seeing what consumers want and making adjustments immediately. Because, at the end of the day, speed and agility are critical in this rapidly changing consumer landscape.”

SORGHUM GURUS TO MEET IN CTCape Town is the venue for the 2018 global sorghum confer-ence, “Sorghum in the 21st Century: Food, Feed and Fuel in a Rapidly Changing World.” The first conference of its kind in over 30 years, the event, from April 9-12, will bring to-gether hundreds of participants from around the world, includ-ing researchers, agro-process-ing players, industry represent-atives, business entrepreneurs, government representatives, development practitioners and more. As the world’s fifth major cereal, sorghum serves as a staple crop for millions of people in the harshest of climates while also offering countless opportunities in the area of bio-fuels, food product development and livestock nutrition. In a world of growing populations and mounting climate change, sorghum plays a key role both in food security, climate change, clean energy and environmental sustainability around the globe. For further information see https://21centurysorghum.com or contact Prof John Taylor, University of Pretoria on +27 (12) 42096 or email: [email protected]


PLEASE PASS THE SALT!NEW BOOK

IS ROCKING

THE BOAT

ON SODIUM

INTAKE

CONTROVERSY

A leading American doctor is advocating more rather than less salt, challenging the ruling

health wisdom of the last few decades. Is our health policy on salt reduction outdated?

Catherine Knight reports.

Dr James DiNicolantonio’s book, The Salt Fix, is causing a stir in global health and nutrition

circles by going up against the medical establishment and the World Health Organization with his claims that we can consume salt without worrying about our hearts and blood pressure, and that too little salt can endanger one’s health.

DiNicolantonio has impressive creden-tials. He is a cardio-vascular researcher at Saint Luke’s Mid-America Heart Institute in Missouri. He is also an associate editor of Open Heart, a joint publication of the BMJ (British Medical Journal) and the British Cardiovascular Society.

He sits on editorial boards of other medical journals and has contributed extensively to health policy and medical literature. He has published a number of articles in the peer-reviewed medical literature specifically on salt: “The History of the Salt Wars” in the American Journal of Medicine in May 2017, and “Is Salt a Culprit or an Innocent Bystander in Hy-pertension? A Hypothesis Challenging the Ancient Paradigm” in the August issue.

DiNicolantonio has also co-authored a few articles with Dr Zoe Harcombe, who has written extensively on the paradox of obesity and has also come under intense criticism by the medical establishment for her views.

But back to the book. The Salt Fix: Why the Experts Got it All Wrong — and How

Eating More Might Save Your Life argues that there is no credible evidence that a salt-restricted diet lowers blood pressure in the vast majority of people, and more significantly, that it does not lead to heart disease or stroke.

In fact, the author suggests that salt restriction is harmful and seems to pre-dispose us to such conditions as insulin resistance, Type 2 diabetes, elevated cho-lesterol and triglycerides, abnormal work-loads on the heart, and kidney disease.

DiNicolantonio is of the view that salt is the wrong little white crystal to blame for chronic illness. He says the real culprit when it comes to high blood pressure, cardiovascular disease and kidney disease is sugar.

His approach to the role salt plays in health and illness is fairly straightforward, embracing both current scientific knowl-edge and simple common sense. Salt en-sures that we have enough blood volume to sustain life. Our bodies have a natural and automatic “thermostat” that signals the brain to seek more salt when we need it and to stop when we have enough.

Salt intake is thus a negative feedback system in which the body, at some point, tells itself to reduce intake (salt taste receptors actually switch from providing positive to negative sensations).

DiNicolantonio points out that, for those of us with normal blood pressure, our kidneys are an incredibly efficient mechanism that excretes salt when

levels rise above very tightly-regulated upper limits (normal kidneys can filter the equivalent of over 1 teaspoon of salt every five minutes). When salt is restricted, on the other hand, our body regards this situation as life-threatening and initiates a cascade of hormonal and metabolic rescue operations that, themselves, have negative side effects, including increases in heart rate and elevated serum levels of insulin, cholesterol and triglycerides.

The book takes the reader through the history of the scientific basis to the original calls in the 1950s and 60s for salt-restric-tion and the fact that public health author-ities were under pressure to deal with an epidemic of cardiovascular disease (CVD).

Following on from the headway that had been made in curing other diseas-es by examining “lifestyle factors”, the search was on for those contributing to CVD. Modifying the diet was an obvious extension of that process and DiNicolan-tonio posits that it was this process that resulted in salt becoming a convenient enemy: rats fed a high-salt diet were seen to have elevations in blood pressure and researchers knew that hypertension was a primary risk factor in the etiology of heart attacks and strokes.

In 1977 when the US Government launched its Dietary Goals, Americans were told to restrict their salt intake on the grounds that a low-salt diet would prevent age-related increases in blood pressure. Yet even then, the US Surgeon


General admitted there was no evidence to support it, DiNicolantonio writes.

He also notes that the first systematic review and meta-analysis of the effects of sodium restriction on blood pressure only came out in 1991 - a full 15 years after the salt as culprit messaging was

initiated.And while the anti-salt forces have won the day when it comes to “official” dietary guidelines, the scientific debate has been ferocious, and The Salt Fix provides readers with a smart and interesting account of it.

Science & nutrition author Gary

Taubes, himself an iconoclast when it comes to the role sugar plays in the diet, describes it this way: “The controversy over the benefits, if any, of salt reduction now constitutes one of the longest run-ning, most vitriolic and surreal disputes in all of medicine.”

“South Africa has become the first country to legislate salt reduction, and the Heart Stroke

Foundation (HSF) accepts the mandate to conduct the national awareness campaign”

– CEO of the HSF, Dr Vash Mungal-Singh

It’s highly unlikely that the views of Dr James DiNicolantonio will be given much attention by the authorities here. In fact, the South African Department of Health and other organizations

concerned with public health have made sure that SA has become a world leader in salt reduction strategies.

The quote above from the Heart and Stroke Foundation’s (HSF’s) 2014 annual report followed a high-level Salt Summit it hosted in March of that year, which brought together national and international opinion leaders and experts, the government, industry and other key stakeholders.

During the summit, the Deputy Minister of Health, Dr Gwen Ramokgopa, noted that regulations alone would not be sufficient and that SA needed education and health promotion efforts to reduce salt intake.

As a result, the Salt Watch initiative was then launched as a multisectoral coalition, supported by the National Department of Health, and SA became a member of World Action on Salt and Health.

The National Department of Health also contributed R5-million to fund a public awareness and education campaign run by the HSF to encourage South Africans to reduce their salt intake. The national campaign was launched in 2014, and included TV and radio advertisements combined with distribution of pamphlets, newspaper editorials and a low-salt recipe book.

Another high-level Salt Reduction Consultation was held in Cape Town last September, hosted again by the HSF. This was just three months after the first phase of South Africa’s anti-salt legislation came into effect following a three-year lead-in period. Facilitation was coordinated by the World Health Organization

(WHO) and the University of Wollongong in Australia, in collaboration with North-West University.

The regulations set maximum salt level targets for a basket of commonly-consumed foods, including bread, breakfast cereals, margarine and butter, savoury snacks, crisps, processed meats/sausages, soups and gravy powders, instant noodles and stocks. The salt content per two slices of bread, for example, was reduced from 650mg to 400mg‚ while breakfast cereals must now contain less than 500mg per 100g serving. Stricter limits will kick in from 2019.

The Department of Health wants SA to reach a WHO target to reduce the mean population intake of salt to less than 5g per day.

Processed foods are, unsurprisingly, the key target of the SA legislation, given the fact that this is the source of 60% of average salt intake. But the 2016 Salt Summit highlighted the need to extend the number and involvement of industry partners to a broader range of food manufacturers and to include the catering and fast

food sectors as well, given the fact that an increasing proportion of food is eaten out of the home.

Data presented by University of North West at the summit showed that 66% of the population consumed more than 6g of salt per day. Another study conducted under the auspices of the WHO showed that 40% of younger adults in SA have very high salt intakes - above 9g per day.

Will these salt-reduction strategies work?One sceptic is Professor Riette de Kock at the University of

Pretoria’s Food Science Department, who has done research into people adding salt to food at the table via her sensory evaluation lab. “Our own research has shown that salt reduction strategies by the food industry may lead to some consumers simply adding salt back at the table or compensate in other ways which would negate the health effects. Nutrition communication and education about salt intake is key to ensure health benefits for consumers,” she notes.

MEANWHILE, BACK ON THE HOME SALT FRONT…

THE SALT FIX

CONTROVERSY


Albany’s new facility in Bellville, Cape Town is a very impressive addition to their

portfolio of bakeries.Launched last month at a cost

of R350-million, the “new” bakery is in fact a serious upgrade of the existing facility along with the building of a brand-new plant. The original Bellville bakery was commissioned back in 1970 and has come to service 5 000 outlets mainly in the Cape Metro area.

Pretty much everything at the Bellville plant has or will double - the new building occupies 6 884 square metres compared to an area of 3 766 square metres in the old bakery.Pro-duction capacity will also be doubled over the next five years, significantly contributing to small enterprises locally.

The launch event was MC’d by Marc Lottering, who clearly has a history with the brand, given the “insider” jokes he shared. His larger-than-life running commentary was matched by some impressive figures delivered by Tim Harris, CEO of Wesgro, who spoke of the significance of an investment of this nature to growing the economy of the Western Cape and South Africa.

Harris also commented on the environmental impact of the new facility. “It is a great example of determination to innovate and modernise. Indeed, we in particular appreciate your efforts to introduce green technology when you do so – it is the responsibility that we all need to share in building a sustainable economy for all.”

The “green factor” was picked up on later by Albany managing director Matshebela Seshibe: “For the upgrade, we took the environment into account and have increased our emissions efficiency by reducing the factory’s energy consumption and also placed emphasis on improving safety measures.”

Energy-efficient lights, motors, coolers and ovens have been installed,

a saving of 4000 litres per week is now possible and the truck wash water is also being recycled. “Our revamped high-tech bagging system is another aspect that adds to the overall efficiency,” noted Willie Marais, Albany Bakeries’ supply chain executive.

Two Tweedy mixers, backed by British technology, add to the output capacity from 6 000 loaves per hour to 12 000, “effectively doubling the output we were able to achieve before,” said Seshibe.

Marais elaborated: “With measured proportions of flour, water and yeast, the machine turns 300 kg of bread dough per batch in six-minute cycles. This facilitates 10 mixing cycles per hour and illustrates the efficiency of the high-speed Tweedy mixers.

Seshibe pointed out the implications of this increased output: “As a result of our increased capacity, we are now

planning to increase the number of outlets to reach previously unserved parts of the Western Cape. These range from large supermarket chains to independent retailers and spaza shops.”

Efficiency was not the only consid-eration in the design of the new facility. In terms

of safety, Marais, said they were very proud of the low incident rate in the past few years. Improved safety measures include SANAS-approved walkways to eliminate unsafe crossing of conveyors and isolators installed at all conveyors and electrical panels to ensure lockout procedures are adhered to. In addition, there is a water drenching system installed at coolers to prevent fire damage, and fire detection monitors are installed at key points around the plant. “We have also optimised the use of natural light with a raised roof to create an ergonomically friendly environment,” said Marais.

* As part of the celebrations around the new facility, the Albany Bellville team have taken care to include the local community by identifying six schools in the area which will be visited by the Albany Love Lunch Squad, who will entertain and educate children about healthy eating, and dispense lunch packs and stationery.

BAKING

Thumbs up for the new greener, safer facility.

UP TO 12 000 LOAVES PER HOUR FROM

ITS NEW R350M BELLVILLE BAKERY

Albany boosts

Cape capacity


CHICKEN

There’s a tide of anger and frustration rising over

Government’s failure to support the local chicken

industry, allowing huge imports of cheap foreign

poultry to devastate the sector and destroy tens of

thousands of jobs, putting SA’s food security (chicken is

our No 1 source of animal protein) at risk. Bruce Cohen

reports on a campaign to defend the sector

CAMPAIGNS

SAVE OUR INDUSTRY!

Initial concerns about dumping focused on the impact of cheap American chicken imports as part of

the Agoa trade deal between the two countries, but it’s now become clear that the No1 culprit is in fact the European Union (EU).

Among the voices mobilising against the EU is the FairPlay Movement, established late last year (it’s patron is Judge Richard Goldstone) to campaign against predatory trade practices.

At the helm of FairPlay is Francois Baird, the former Africa head of the world’s largest PR group, Edelman. Now based in the USA, Baird has been mobilising an international network of industry bodies and NGOs to expose dumping, and has his sights set firmly on EU chicken.

Baird says that despite their predatory activity, the EU has been in denial. “There has been no admission that what they have been doing has plunged the local chicken industry into crisis,” says Baird. “It has cost thousands

of jobs and threatens many thousands more if dumping continues.

“There has also been no promise to stop this practice and no undertaking to support those rendered jobless by heartless EU actions. All there has been are half-truths and misleading statements designed to hide the facts.”

Dumping happens when countries export goods below the cost of production or below the normal selling price in their home country. This predatory practice is frowned upon and is considered immoral, if not illegal.

Local producers, however efficient (and South African producers are very efficient, as has ironically been proved by EU-based research, says FairPlay), cannot compete, eventually having no option but to shut down.

Baird says the EU has become a “serial evader” on the issue of chicken dumping, “It has no option but to concede that dumping has occurred in the past because three countries — Germany, the Netherlands and the UK —

were subjected to antidumping measures in 2015 after being found guilty, But the EU will not concede that the practice has continued.”

FairPlay says EU consumers prefer chicken breasts and wings, and the left-over dark meat is dumped in foreign markets – often sent in frozen bulk, without a specific end consumer in mind. It is these dumped leg quarters, 80% of which came from the EU in 2016, that have precipitated the crisis in the local industry.

Baird also accuses the EU of “grossly misleading” statements about the massive EU subsidies, which give its producers a huge advantage, particularly against farmers in developing countries. Billions and billions of euros are spent on direct and indirect producer subsidies, which are the single largest item in the EU budget.

Says Baird: “Putting a stop to dumping, from the EU — or anywhere else — is required urgently if the South African chicken industry and the

Francois Baird ... founder of FairPlay


thousands of people whose jobs depend on it are not to suffer further constriction.

“The South African chicken industry needs to grow. It can only do so if it is not threatened by dumped imports. The EU’s professions of concern for the South African industry would be a little more convincing if it would admit its role in the industry’s decline and the thousands of jobs that have been lost because of dumping.”

To give a voice to the thousands of chicken industry workers either axed or threatened with job losses, FairPlay recently launched a Cry for Action campaign.

It says that over the past six years, few industries, if any, have been as badly affected by retrenchment, closures and liquidations as hasthe poultry industry. It is not only central to SA’s food security, it is also a leading agricultural employer with 110 000 direct employees and as many as 20 000 indirect employees.

It points out that SA’s poultry industry has been proven by the world-renowned agricultural research institute at Wageningen University in the Netherlands to be one of the most competitive in the world. It is ranked number six and is ahead of all European countries.

“So, when we talk about closures and liquidations, it is not because of uncompetitiveness due to

bad management, ineptitude, poor strategic vision or laziness — it is because dumping is making it virtually impossible to survive

In the long run, it is impossible to survive when all the rules of fair competition have been set aside and kicked into the long grass. And that suits the dumpers because no local survivors means a market with no competition.

“What the dumpers conveniently forget is that after an industry contracts – once the production facilities are closed and the farms sold, the workers laid off – there is no way back.”

FairPlay has appealed to President Jacob Zuma and Trade and Industry Minister Rob Davies to intervene and “put an immediate stop to this abhorrent practice that is destroying individuals,

families, entire communities and businesses that are key to SA’s economic and social wellbeing”.

The organisation says its Cry for Action campaign aims to ensure that those people who have lost their jobs will not also lose their voices, their self-esteem, their value, importance and significance to their families, communities and to society. They will not be set aside, abandoned, forgotten or made anonymous in the miserable pit of unemployment statistics.

“The Cry for Action appeal to Zuma and Davies is a cry from the heart of people who are suffering because of an activity that is unlawful, preventable, abhorrent.”

FairPlay founder Francois Baird says: "We are very hopeful that Zuma and

Davies will respond urgently to our Cry for Action and in so doing, bring a momentum of hope to the many people who are feeling abandoned.

"SA has one of the highest unemployment rates in the world and latest figures show it just keeps rising. Dumping is adding to the millions of South Africans already unemployed, creating jobs in places like the EU, while killing jobs in SA.”

Adds Baird: "Dumping imports misery and SA simply cannot allow it to continue. Zuma and Davies can stop it, firmly and immediately, and we call on them to do just that."

Chicken sector workers and FairPlay march on the EU offices in Pretoria earlier this year. The EU, says FairPlay, has simply ignored the plight of the industry.

CAMPAIGNS

“Dumping imports misery

and we cannot

allow it to continue”


THINK LIKE A TERRORIST!Know your TACCP from your HACCP and VACCP

By Linda Jackson

To say that these are uncertain economic times would probably be the understatement of the decade.

An unstable economy brings to light additional risks for food manufacturers. Job losses and rumours of retrenchments impact on employees’ morale. Increasing costs of production and the pressure of having to keep the costs of living as low as possible for the consumer can tempt manufacturers to cut corners and adulterate food products as a cost-cutting mechanism.

Both of these risks are not adequately addressed in our traditional HACCP-based food safety programmes. According to the FAO, the hazard analysis process should list all the hazards (biological, chemical or physical) that may be reasonably expected to occur at each step from primary production, processing, manufacturing and distribution until the point of consumption. The premise being that the introduction of these hazards would be largely unintentional.

However, food fraud in the form of substitution of ingredients, passing off of one foodstuff for another, false or misleading statements for economic gain that could impact public health, product tampering, fake or incorrect labelling etc, is a deliberate act and therefore needs a slightly different departure point. You need to start thinking like a terrorist.

In order to strengthen current food safety management systems, the Global Food Safety Initiative has defined the Food Safety Management Umbrella to include HACCP (hazard/ Food Safety), TACCP (threat/ Food Defence) and VACCP (vulnerability/ Food Fraud). These are defined as three separate pillars that will need to be addressed individually. This allows building on the very familiar HACCP concepts since it is widely accepted and implemented (The HACCP abbreviation

stands for HazardAnalysisand Critical Control Point system).

So how do I implement a TACCP plan?

Step 1. Know thine enemy

The image below shows where the threats may come from and the obvious knock-on effect that these incidents can cause. While managing extremists may be a tall order, keeping a close eye on those closer to home is essential.

According to a recent article in foodprocessing.com.au, the FBI warn that most threats are likely to come from within. “The insider threat is that person [who] knows the facilities, processes, distribution network and can cause the greatest impact,” says Special Agent Scott Mahloch.

He advises that the motivations of a disgruntled employee can stem from multiple issues, including financial problems, destructive behaviour or personal issues at home. It is in the company’s best interest to monitor their staff carefully and look for any unusual behaviour such as photographing processing operations, unscheduled deliveries or unattended packages.

Understanding the threats posed by employees and implementing systems to mitigate these threats will go a long way in curbing external threats.

2. If we fail to plan we plan to fail

The best line of defence is attack and inthis case the best line of defence is to

Continued on next page

Food & Beverage Reporter has partnered with Food Focus to bring you enhanced coverage of food safety/compliance issues. Launched last year, Food Focus addresses the full range of compliance factors which South African food businesses have to face, including occupational health and safety hazards, environmental demands and corporate social responsibility. Find out more at www.foodfocus.co.za

WHAT IS VACCP?“Food Fraud Vulnerability Assessment: The standard shall require that the organization [company, manufacturing plant, food processing operation, warehouse, etc.] have a documented Food Fraud Vulnerability Assessment in place to identify and address Food Fraud vulnerabilities.” (Ref: GFSI FFTT).

MALICE & SABOTAGEThe TACCP concept was introduced and implemented in the British Standards institute’s Public Available Standard 96 Food Defence. The document scope states: “The main generic threats are malicious contamination with toxic materials, sabotage of the supply chain and misuse of food and drink materials for terrorist or criminal purposes. A successful attack could disrupt business and undermine brands, and could lead to illness and death.”

Psychological Impacts

Adverse EconomicImpacts

• Disgruntled Employees

• Counterfeit/ Diversion/

Tampering• Economic Adulteration

• Outside Contractors

• Foreign and Domestic

ExtremistsWidespreadPublic Fear

CatastrophicPublic HealthConsequences

Loss of Confidence

in the Safetyof Food

Potential Sources & Impacts of Intentional Adulteration


expect an attack and have a functional plan to combat a potential attack.

According to the USDA Food safety inspection service, A food defence plan is functional when it meets all four of the following conditions:1. Developed – the plan is documented

and signed2. Implemented – food defence practices

are implemented3. Tested – food defence measures are

monitored and validated4. Reviewed and maintained – the plan is

reviewed at least annually and revised as needed

These requirements are now echoed in the version 4.1 of FSSC 22000:

Sec 2.1.4.3. Food Defence

2.1.4.3.1 Threat assessment 1) The organization shall have a

documented and implemented threat assessment procedure in place that: a) identifies potential threats, b) develops control measures, and c) prioritises them against the identified threats.

2) To identify the threats, the organization shall assess the susceptibility of its products to potential food defence acts.

2.1.4.3.2 Control measures he organization shall put in place

appropriate control measures to reduce or eliminate the identified threats.

2.1.4.3.3 Plan1) All policies, procedures and records

are included in a food defence plan supported by the organization’s Food

Safety Management System for all its products.

2) The plan shall comply with applicable legislation: http://www.fssc22000.com/documents/graphics/version-4-1-downloads/part-ii-requirements-for-certification-v4.1.pdf

The food defence plan should be written or documented to identify mitigation strategies and protective measures that will be implemented within your facility. Vulnerability assessments help to inform where mitigation strategies are needed. Additional documentation is unavoidable but the good news is that the HACCP methodology will work and your TACCP plan can be developed along similar lines and integrated into internal audits, management reviews and existing SOP’s.

3. The devil is in the detail

Fortunately for us, a lot of work has gone into developing food defence plans in the USA since the attacks of 9/11 and this provides us with great resources to learn from. A literature review suggests you should consider the following as a minimum in a robust food defence plan:• Management and supervisor

involvement in food defence• Inventory of hazardous materials on

site, including maximum allowable quantities, MSDS, secure location

• Controlled issue and traceability of hazardous materials on site

• Recall procedure• Procedure for investigating suspicious

behaviour• Review and evaluation of the food

defence plan• Screening and identification of

employees, visitors, contractors• Restricted access and access controls• Training in food defence and

communication with the necessary confidentiality for sensitive details

• Facility access control and security measures

• Laboratory security measures• Security of water and utilities• Security of final products• Security measures in transit• Cyber security measures to protect

data, networks etc• Evacuation and response procedures

Should the food safety team tackle food defence?

There are advantages to applying the

HACCP principles to food defence: • Your plan should be science-based.• Effective HACCP systems are easy to

use and to understand and this should be the case with your TACCP plan too.

• It must be practical and implementable. • It will need to be reviewed to ensure it

stays current.• The plan should be comprehensive

including suppliers, contractors, manufacturing employees, transporters, distributors, and all partners along the food supply chain. If all hazards are not considered in a HACCP plan, it will not be effective. Similarly, with your TACCP plan.

• Validation and verification are essential for the best HACCP plans, which

should include external assessment as well as internal record keeping

and audits. • Employee training and support is a

critical element of the best plans. • Periodic simulations may be a useful

element of this training as well as a detailed strategy for communication within and without the organization.

But …

The ideal situation in a HACCP plan is to be able to design out the hazard, thus removing the risk completely. In food defence, security may therefore be even more important than the science. Given the scope of food defence measures, it is clear this CANNOT be tackled by the food safety co-ordinator and even the food safety team alone as it is unlikely they have the correct expertise. Additional input and leadership in the form of security consultants and insurance professionals will be essential. Avoiding duplication is, howeve,r paramount as the economic pressures we started this article with should dictate that we work smarter and not harder.

Want to know more:https://www.fda.gov/food/fooddefence/http://www.foodsafetymagazine.com/magazine-archive1/aprilmay-2008/the-value-of-the-food-defence-plan/https://www.fsis.usda.gov/wps/portal/fsis/topics/food-defence-defence-and-emergency-responsehttps://meathaccp.wisc.edu/additional_info/assets/Guide%20Food%20Processing.pdfhttps://www.food.gov.uk/sites/default/files/pas96-2014-food-drink-protection-guide.pdf

Image source:

www.fsis.usda.gov

TESTIMPLEMENT

DEVELOP

REVIEW &MAINTAIN

BRANDS


THOUGHT FOR FOOD

GUT GOODNESS

Hendrik Born, 4th from left, at the Yoghurt Summit with Dr Ruairi Robertson, Queen Mary University, London, Marlinie Kotiah, Senior R&D and Science Manager, Danone Southern Africa, Prof Yanga Zembe, Institute of Social Development, UWC,

Dr Friede Wenhold, Dept of Human Nutrition, University of Pretoria, and Prof Harry Sokol, Saint Antoine Hospital, Paris.

DANONE SA’S MD IS ON A MISSION TO GIVE YOGHURT IT’S RIGHTFUL PLACE ON THE SOUTH AFRICAN PALATE

How would you describe your philosophy about life?

To lead and inspire people you first have to be well-grounded yourself. To do this, having a sense of purpose is important. Having worked in many impoverished communities, my passion is to provide meaningful food solutions. To do this, I have to be with the community and not

behind a boardroom desk. This means you will often find me in the townships, in the factory and in the stores.

I get my energy from hearing from people and it is people that inspire me … people who eat our yoghurt, people who do not eat our yoghurt, moms, dads, children, key opinion leaders and our Danoners - the people I work with.

I cannot imagine a more powerful

reason to wake up every morning than to bring health through food to as many people as possible.

You are a triathlete. How has extreme sport influenced your approach to life?

By the nature of what triathlons do, it’s an endurance exercise. Each day at the office is a test of my mental and physical

Hendrik Born, appointed MD of Danone SA earlier this year, has spent much of his career searching for solutions to the nutritional deficiencies facing poor communities around the world. Born is determined that Danone, through initiatives like the recent Yoghurt Summit held in Johannesburg, makes a powerful health-through-food impact in this country. Bruce Cohen interviewed him after the summit.


stamina and as much as I enjoy the everyday work, pushing myself during a triathlon gives me a new sense of achievement; these are personal goals and are different from the goals of turnover and profitability.

I am better at cycling, okay at running, and not so good at swimming, so competing in a triathlon reminds me I have some strengths and some weaknesses and this reminds me that there are some things in my life that still need polishing.

How would you describe your manage-ment style? Are you a maverick?

Maverick? No. Cautious? No? Instead, I would describe myself as taking informed steps. With many years of experience at Danone, I have the skill to help people navigate but I do not solely control the GPS. There is no way I can be an expert on everything, I rely on the people who have lived here and who have worked hard in their respective areas.

To make sure that people feel free to express themselves when they are around me, the first thing I do when I am in the office is to greet everybody, eye contact provides connection. Then my day has started. This means that when we meet later on in the boardroom I am in the moment and people feel valued and know that I am listening. You will also rarely find me interrupting someone when they speak. Beside this, I strongly believe in the power of ONE team: collective success has to stand above the individual one.

What are you most passionate about in the Danone group?

The great people I work with. We are called Danoners. We are moving closer and closer to fulfilling our mission of health through food to as many people as possible, and this amazing journey drives me. The opportunity in South Africa to achieve this is huge but it will be complex.

Food, as we found out at the 1st Yoghurt Summit in July, is a powerful way for people to express their culture. Unpacking what this means will be stimulating because what we do in Europe will not necessarily work for South Africa. Danone is flexible like that. As a business, there is latitude and, in

fact it is encouraged, that we provide healthier solutions that are community relevant and that consumers can have a superior taste experience. The teams that I work with are committed to this goal.

You have worked for Danone in places like Cuba, Saudi Arabia, various countries in Africa and Iran before coming to SA. How has this influenced your approach to doing business in South Africa?

It goes without saying that the cultures and food practices are different everywhere in the world. For example, achieving health means different things to different people. However, there are some universal insights when it comes to eating and parenting.

Danone is able to assist many emerging markets like South Africa keep people grounded in healthier eating. During a transition period into urbanization, when fast foods are more attractive, we can offer a modern food like yoghurt that keeps the same virtues of a traditional product like maas. The good news is that at Danone we have both, maas and yoghurt. The former is nostalgically loved but we need to make people connect with it again, because it’s much healthier than, for example, something fried.

What is the Nutriplanet project?

Nutriplanet is an assessment of the local nutritional and health status. It has already been completed in 53 countries. Under my responsibility we did 12 in Africa. It begins with an analysis of the desktop scientific literature consolidated with local experts’ opinions.

In Morocco, for example, we realized that nutrition education was a key requirement, so we partnered with the department of education to make nutrition training compulsory for one week per year in the school curriculum.

South Africa has also been part of the Nutriplanet project. The data consolidation was last done in 2006. In SA, when we established the various vitamin deficiencies, we set about

improving the nutrient density of our brands. For example, we have Danino that has 260mg of calcium per 100g vs full cream milk which has 120mg calcium, so Danino has twice as much calcium as milk. This is an important innovation from Danone to address the calcium deficiencies documented amongst children from 1-9 years old.

Recently, Danone’s Nutriday, the largest yoghurt brand in SA, added 11 Vitamins (vitamins A, a selection of B vitamins, vitamin D and E).

Since 2012, we have also been active in teaching nutrition in South African primary schools. We reach 2 000 primary schools, 1.5 million

learners and 70 000 teachers every year. The nutrition modules are written by trained syllabus writers and the workbook is Curriculum and Assessment Policy Statement (CAPS) aligned.

We are currently in the process of updating the Nutriplanet data. We are also in the field with a research study on the sociological analysis of eating habits. Professor Yanga Zembe from the University of Western Cape, who has been commissioned to complete this, presented some preliminary findings at

Continued on Page 20

THOUGHT FOR FOOD

We are moving closer and closer to fulfilling our

mission of health through food to as many

people as possible, and this amazing

journey drives me.


The First Yoghurt Summit in South Africa took place in Johannesburg recently with the mission of sharing unbiased scientific data about the nutritional impact of yoghurt.

A high-powered group of international and local speakers offered fresh insights into the numerous health and nutritional benefits of regular yoghurt consumption, in particular the tight links between gut and brain.

The summit, attended by a contingent of dieticians and health professionals, is a project of the SA Yoghurt in Nutrition Initiative, an independent thinktank with backing from Danone SA.

Dr Ruairi Robertson, from Queen Mary University Hospital, London, told delegates that the human intestinal tract harboured a complex microbial community which played a central role in health. It has been estimated that we are more bacterial cells than we are human cells. It was now apparent that our gut microbiome co-evolves with us and that the right diet has a positive effect on creating diversity of the bacteria in the gut.

Robertson said the modern Western diet was destroying this microbe-human relationship, with negative outcomes on the many physical and biochemical connections between the gut microbiome and the central nervous system, which are directly connected via the vagus nerve.

Highlighting the gut-brain axis, he

pointed out that a large proportion of serotonin is produced in the gut. Serotonin is the “feel good” chemical because of its ability to impact mood, anxiety and happiness, among other functions.

“Feed the gut, feed the body, feed the brain,” said Robertson.

He described the pioneering work of Russian immunologist, Élie Metchnikoff, which opened the way for research into the benefits of yoghurt.

Metchnikoff studied a group of people in Bulgaria who were living exceptionally long lives and noted that their diet included the consumption of large quantities of sour milk. He

subsequently began research to examine how maintaining a healthy balance of bacteria in the gut could help stave off disease and prolong life.

Professor Harry Sokol, a gastroenterologist from Saint Antoine, France, described how, during vaginal delivery, the microbes in the mother’s birth canal helped build the infant’s immune system.

Each person, he said, has his or her very own composition of gut microbiota, like a unique fingerprint and it was critical to maintain gut health because it played a key role in important body functions, including metabolism, building the immune system and even brain function.

Sokol explained the concept of dysbiosis (alteration of gut microbiota composition) and how it was involved

in many illnesses, including inflammatory bowel disease, obesity and neuropsychiatric diseases.

Professor Yanga Zembe, a social anthropologist at the Institute of Social Development at the University of the Western Cape, emphasized that eating well is not a simple idea.

Most people, she said, have the intention to eat healthily but are strongly influenced by culture and psycho-social needs, and all of these factors complicate the decision-making process. For example, although maas is a healthy food choice with strong traditional ties, it is now associated with hardship or seen as “non-modern”.

FEED THE GUT. FEED THE BRAIN

THOUGHT FOR FOOD


From Page 17

the 1st Yoghurt Summit. She provided some insights into food choice conundrum South Africans are faced with. People do not only eat food to satisfy their hunger but use food also as a means to show social inclusion, love and self-esteem.

This new dimension to our under-standing of the consumer will allow us to deliver food solutions that fulfill these needs. This is more and more about being community relevant, not providing a one-size-fits-all solution to consumers but rather to become their ally, empathizing with their concerns that eating healthily is not an easily understood and practiced principle.

Danone is very active internationally in areas like infant nutrition and water, but in SA you are essentially a yoghurt business. How come you have not opened the SA market for your other business units?

You are correct. Danone is active in 130 countries, including 40 African countries mainly through fresh dairy and baby products. In South Africa, we operate mainly as a dairy business; and locally we have a small and growing medical nutrition business called Nutricia. They make products like Forticare that is used and respected by many health professions for ailing patients.

We still have a large amount of work to do with special focus on the dairy business. Compared to the rest of the world South Africans consume very little yoghurt (less than 5kg per year) vs the Netherlands and France that consume 23kg and 21kg per year respectively. My first goal is to get people to eat one yoghurt every day to receive the benefits of good health. The role of the 1st Yoghurt Summit was to give the key opinion leaders the science that supports the role of yoghurt in providing dietary diversity for good gut health.

Your global CEO Emmanuel Faber recently launched Danone’s One Planet, One Health mission statement. What does this mean, especially, for countries like SA which have high poverty and malnutrition levels?

The One Planet, One Health statement is a single idea that brings our vision,

mission, values and social intentions together. It embodies the values of our business approach. People want good and real food that is locally sourced.

In SA, we will continue to pay special attention to our sourcing, learning from our pilot projects with the WWF for water preservation, reducing waste, working to provide healthier food solutions and supporting community projects.

Are you not concerned about the high, especially added, sugar levels in your products?

I am very proud of our formulations. In the dairy sector, we set ourselves clear Danone Key Performance Indicators (KPIs) for our 2 categories; Essential Dairy Dailyness and Chilled Pleasure. These KPIs go beyond just sugar thresholds and include nutrients to encourage, such as protein and calcium, and nutrients to discourage, like saturated fat and total energy (kilojoules). Nutriday and Yogisip are classified as Dairy Dailyness products and they both already fulfil the 2020 target of less than 7% added sugar.

Most of your yoghurt products are low fat. Does Danone still believe that high fat dairy is unhealthy? Do you have plans to increase fat content?

Yoghurt is inherently perceived and valued by consumers to be a low-fat category. We did extensive research on this, and although there is a trend for high fat products, this remains very small and niche. The merit of dairy fats cannot be discounted, and for those wanting a high fat product, Nutriday has a double cream plain yoghurt.

What is the background of the Yoghurt in Nutrition project and what do you hope to achieve?

The South African Yoghurt In Nutrition Initiative intends to evaluate the science that supports the benefit of eating yoghurt. There is growing interest in the role yoghurt plays in providing good health and the 1st Yoghurt Summit drew attention to gut health.

Independent and credible experts presented their view on the gut-brain interaction and concluded that the gut and brain are interlinked and if you feed the gut, you feed the body, you feed the

brain. What is clear is that a diversity in diet helps to create diversity in gut microbiota. Yoghurt helps provide dietary diversity.

We are in a state of political turmoil and economic meltdown, hardly a conducive environment for a multinational to operate in. What are the biggest obstacles to doing business in SA and, given the above, does Danone have any plans for expansion?

Danone is in South Africa to build a healthier community. To do this, we must work within the challenges of the local context. We need to be agile with formulations to have products that preserve the goodness of dairy and that could lend themselves to unique foods for the

local community. We also cannot demand the same margins from the portfolio we sell into community projects. Our aim is to provide health through food to as many people as possible, not just those who can afford to do a grocery shop in a mainstream store.

Our expansion in the community using bicycles is in its pilot phase. This is to make sure that we encourage healthy products as close to doorsteps as possible.

People do not only eat food to

satisfy their hunger, but

also as a means to show social inclusion, love

and self-esteem

THOUGHT FOR FOOD


LEADERSHIP

Africa’s Top 50 in consumer productsDeloitte study highlights the clout of SA manufacturers

Despite a much-discussed slowdown in the African economic growth story, Africa’s consumer

products industry is demonstrating a resilient and positive growth path when viewed in local reporting currencies.

That’s the conclusion of consulting firm Deloitte, which recently released its inaugural African Powers of Consumer Products report.

It shows that the Top 50 African listed Consumer Product (CP) companies are concentrated in 15 countries, with South Africa, Egypt, Nigeria and Morocco accounting for 64% of the companies with just above 80% of their total revenues.

This concentration reflects the size

of their respective economies, their level of development and economic diversification, but also the low degree of capital market development in other African countries.

Deloitte say that while the overall African growth story might have stuttered recently (mostly due to the commodities decline), the prospects and opportunities for consumer goods companies still reflect a generally positive growth opportunity. For instance, Sub-Saharan Africa’s (SSA) GDP per capita in purchasing power doubled to US$3 831 between 2000 and 2016.

While several oil-producing countries have seen faltering investment, East

African economies that are less exposed to commodity markets are growing at rates of 6% per annum or more.

On average, the year-on-year revenues of the Top 50 declined by 7.5% in US$ and grew by 4.7% in local reporting currencies. When measured over a five-year period from 2011 to 2015, the average of the Top 50 Compound Annual Growth Rate (CAGR) in US$ was 3.5% and 12.5% in local currencies.

“Although African economies have seen their currencies depreciate sharply against the US$, making

Continued on Page 22


From Page 21

imported goods more expensive, companies which produce goods locally and are able to ramp up facilities have an opportunity to grow their market share,” said Andre Dennis, Deloitte Africa Consumer Products leader.

The report considers the performance of Africa’s Top 50 listed consumer product companies in financial year 2015 (year ending up to and including May 2016), as calculated according to revenue in US dollar terms.

It focuses on African domiciled companies which are listed on African

stock exchanges, with manufacturing as a core business.

South African and Nigerian companies dominate the Top 10 of Africa’s largest listed consumer products, although their size in volume is not reflected in profit margins – 4 of the most profitable (best profit margin) companies are from North Africa, 4 from East Africa and 2 West Africa. In FY15 48 of the Top 50 companies recorded positive profit margins, with 16 earning at least 10% profit margins.

It is interesting to note the emergence of Northern Africa, with some of the fastest growing CP companies on the continent coming from this region:

including five from Egypt, one from Morocco and Tunisia with the remaining three from Southern Africa.

“Positive economic prospects linked to accelerating urbanisation, a growing middle class, and Africa’s young population, along with improvements in infrastructure and technological developments, has attracted the expansion interests of a range of African and international multinational companies in the CP sector. We anticipate seeing increased investments in this sector as it continues to grow on the continent,” says Dylan Piatti, Snr Industry Chief of Staff at Deloitte Africa.

Top 50 are resilient businesses

TIGER BRANDS IS THE LION OF AFRICASouth African and Nigerian companies monopolise the Top 10 of Africa’s largest listed consumer products companies.

In Financial Year 2015, eight of the Top 10 by revenue were listed on the Johannesburg Stock Exchange and the other two were listed on the Nigerian Stock Exchange. Seven of the Top 10 companies had annual revenues of more than US$1bn.

In FY15, the total revenue of the Top 10 companies was about US$15.3bn, which was 6.5% lower than in the previous year. All the Top 10 companies in FY15 were also in the Top 10 in FY11.

Tiger Brands was in the number one position

throughout this period. Between FY11 and FY15, RCL Foods was the strongest growth performer within the Top 10, and moved up eight positions in the rankings, from #10 to #2.

The South African companies in the Top 10 have a more widespread geographic footprint compared to their Nigerian counterparts, whose operations and investments are restricted to their domestic market.

On average, the South African companies have manufacturing facilities or other investments in four countries.

Tiger Brands has the largest manufacturing and investment footprint, with a presence in 6 African countries.

LEADERSHIP


Shoprite’s run of success is the envy of the food retail sector, and there seems to be no stopping the supermarket giant as it powers its way across Africa with the promise of “everyday low prices”.

Whilst its stores capture public attention, behind the scenes Shoprite has been developing a massive distribution centre (DC) network, now totalling a whopping 750 000 m2 (almost 100 covered rugby fields) across 33 sites. The most recent addition to its network was the opening in August of the company’s new Climor DC in Brackenfell, Cape Town.

Totalling 123 000m², Shoprite says Cilmor is one of the most technologically-advanced distribution centres on the African continent and consolidates the activities of five different DCs spread throughout Cape Town. It will hold around 35 000 line items from over 1 500 suppliers.

Shoprite CEO Pieter Engelbrecht at the opening of the group’s new Climor DC in Cape Town

Processing Reporter&SHOPRITEADDSMEGA DCMUSCLE


Metal Tank Industries, an East Rand-based company in close proximity to OR Tambo International Airport, can now present its clients with not only the vessel, but also all other components that make up a complete process plant.

Using new technologies enables Metal Tank Industries to construct storage vessels, steel walkways, platforms and gantries, pumps, pipelines, control panels, electrical cabling, load cells, cooling towers and boilers that are used at food and beverage production plants.

With 20 years knowledge and experience Metal Tank Industries offers turnkey, end-to-end solutions, can design, build and install entire production lines for a broad spectrum of industries.

“Vertical tank building technology, tig welding, laser alignment and orbital pipe welding are all new technologies that we are using to increase the speed and quality of our products to various industries,” says Metal Tank Industries

MD Rob MacGregor.Full lines are pre-fabricated in kit format on thecompany’s 29 000m² factory floor. This has made a significant

impact in terms of costing controls for both parties. “We call it a knockdown format,” MacGregor explains. “Everything we build is designed to come down in pieces that are transportable. It has really worked to our clients’ advantage. They now have quicker turnaround times, reduced time on site and more control over costing as the bulk of the work is done at our facility, not on site”

MacGregor says the company is seeing positive growth in the various sectors for which it is constructing new plants in to which it supplies its products. “We are confident that we can meet the growing demands throughout the continent and we are striving to be a supplier of choice with regard to turnkey process solutions.”www.metaltank.com

METAL TANK NOW OFFERS TURNKEY SOLUTION

German processing equipment giant GEA has teamed up with local player Bacchus Equipment

in a knowledge-sharing programme for clients.

GEA, one of the largest food pro-cessing equipment manufacturers in the world with a headcount of 18 000 globally, offers solutions across every single F&B sector one can imagine, and there are some stats that are little short of mind-boggling: 1/4 of all milk processing in the world occurs in GEA equipment, as does 1/3 of instant coffee processing and 1/3 of all chicken nugget manufacturing.

GEA’s South African business was established approximately 30 years ago.

Bacchus Equipment, on the other hand, has been quietly building itself up in the wine industry since starting life in Paarl in 2007. Having just celebrated its 10th anniversary, the business is now expanding from its origins to engage with the fruit growing sector.

At the helm are two men with many years of experience in the olive, wine and beverage industries. Barry Hanna runs the technical support team, whilst Gerrit Human looks after marketing and sales. The pair are also involved in the sister business called The Olive Specialists, which Barry started around 15 years ago.

Both their companies are now actively involved with GEA, helping the German giant deepen its presence in SA. Human says the companies share a very strong service ethos, and run technical support teams 24/7

Supported by GEA’s body of know-ledge on separation, Hanna says they are now in a position to drive into markets outside of olive and wine production, such as tomatoes, fruits and nuts. “Our relationship is still in its infancy and this, coupled with a severe downturn in the wine industry, means we need to explore as many opportunities as we can together, not only in our existing markets, but also into new markets,” says Hanna.

One such element of the combined “attack” is a series of seminars the two companies are hosting. Aimed at sharing global best practice with existing and potential clients, the seminar in Elgin

covered a variety of topics, from worldwide equipment trends to GEA’s cleaning technology and waste management solutions.

Jaco Coetzee, regional sales manager for GEA, is clear on the mutual benefits: “GEA will bring the process engineering know-how with specialised equipment in food processing. Bacchus and The Olive Specialists will give us access to the wine and olive industries as they are the market leaders.”

www.gea.comwww.bacchussa.co.zawww.olive-wine.co.za

BRIEFS

GEA & BACCHUSGET IT TOGETHER ...

Delegates at a recent seminar in Elgin organised by GEA and its local partners, Bacchus Equipment and The Olive Specialists.


tna has launched ropac® 5, a ground-breaking, ultra-high-speed case packer for flexible bags that is capable of industry-leading speeds of up to 300 bags per minute.

Part of tna’s performance 5.0 packaging system, the ropac 5 is the first side-load case packer to use tna’s patented semi-rotary bag stacking technology to quickly and efficiently pack small to medium, pillow-style snack bags into secondary containers.

With its innovative, highly-compact design, the new ropac 5 more than doubles the industry’s average case packing speeds, offering snack food manufacturers unprecedented levels of throughput, exceptional equipment reliability and one of the smallest machine footprints.

Unlike most case packers that employ vacuum pick and drop technology, the ropac 5 uses continuously revolving horizontal platforms that can accommodate multiple rows of bags. tna’s proprietary system is able to quickly and efficiently form, lower and side-load vertical stacks of bags into a secondary container such as a box. As a result, the ropac 5 is capable of packaging up to 300bpm, making it the world’s fastest case packer for flexible bags. The stacking system also prevents bags being dropped by vacuum heads, minimising the risk of product breakage and missed bags.

The ropac 5 features semi-automatic, tool-less changeovers that take less than 10 minutes to complete, offering manufacturers complete flexibility over bag and case size. Together with the overall simplicity in design of the case packer featuring a small number of moving parts compared to competitor models, tna’s innovative technology ensures that there is less wear and tear of components.

The ropac 5 also requires minimal power and air due to the

small number of pneumatic actuators and the semi-rotary action that avoids reciprocating motion. As a result, operating costs are reduced significantly and manufacturers are able to achieve more sustainable production.

“The snacks market is booming and food manufacturers need equipment that is able to deliver the speeds and

efficiencies they need to respond to the ever-increasing demand for packaged snacks,” comments Michael Green, group general manager at tna.

“With speeds of up to 300 bags per minute, our new case packer has the potential to double manufacturing throughput overnight, completely redefining industry standards. When combined with our complete portfolio of high-performance turnkey solutions, this means that snack manufacturers can source all their production line equipment from a single supplier, from pre-processing equipment at the start of the line all the way to case packing solutions for the end of the line.”

The ropac 5 can be seamlessly integrated with

any upstream and downstream equipment, including check weighers, case erectors and top sealers. With a width of only 1220mm, it was specifically built to fit in line of the VFFS system, enabling manufacturers to place a case packer after every single bagger. It even allows for the installation of two case packers in twin configuration for the most efficient use of factory floor space.

To find out more about the new tna ropac 5, visit tna at Propak Cape, booth 1/A17 between October 24-26www.tnasolutions.com; Tel: +27 (0) 11 466 8577

INNOVATION

Blistering speed ..tna’s ropac 5

tna’s ultra high-speed flexi packer is industry leader ...


LOGISTICS

Nando’s switch from cardboard boxes to CHEP’s reusable plastic crates (RPCs) has allowed the

group to reduce its environmental impact significantly while achieving bottom-line improvements, according to Eli Golovey, Head of Logistics and Commercial at Nando’s South Africa.

In a recent presentation at SAPICS 2017 with Debbie Wehmeyer, Retail Director at supply chain and logistics solution provider CHEP, Golovey said Nando’s was collaborating closely with CHEP and third-party logistics provider Vector to streamline its supply chain – proving that it is no longer necessary to choose between “profit” and “planet” when designing business strategy.

“This project shows that there are always opportunities to create value for both the environment and the business,” said Golovey. And Wehmeyer agreed: “Moving Nando’s onto our reusable plastic crate solution had substantial benefits in terms of hard and soft costs, as well as environmental impact.”

In terms of hard cost savings, Wehmeyer highlighted total packaging savings. “The RPC can hold 30% more chicken per crate compared to the cardboard box Nando’s previously used. This in turn means that you can fit more chicken on a pallet, which immediately improves your truck utilisation. But, ultimately, it allowed Nando’s to improve their pallet utilisation by 60%, which translates into substantial savings.”

Though the soft cost savings, such as better utilisation of space at the back door of the stores, the improved structural integrity of the crate and better temperature control are impressive, environmental impact is the real head turner.

This project has seen a reduction in CO2 emissions of 60%, water usage decreased by 60% and waste-to-landfill lowered by a whopping 85%. “The benefits speak for themselves,” said Wehmeyer. “We love working on projects where we can ensure that both business and the environment benefits.”

But both Golovey and Wehmeyer agreed that the project was not without its challenges. Golovey highlighted that all three companies involved had to commit to make the new arrangement work, noting that creating meaningful partnerships is part of the way Nando’s operates.

The change-over was significant from a systems perspective, as the RPCs represent an asset that must be tracked over the journey of the product. While the boxes holding the chicken would previously have been the store’s responsibility to dispose of, now there was the ownership of an asset to be considered – which had to be transferred from CHEP to the chicken manufacturer.

“Vector, who play a critical role in getting product from the manufacturers to our 300 restaurants country-wide, needed to adapt its system to manage

this,” Golovey said. “At the same time, each Nando’s needs to change ownership of the crates when they take delivery and when they give the crates back.”

Golovey said the CHEP RPCs also accommodated the commitment Nando’s has to quality through the use of fresh, rather than frozen, chicken in all of its products. “Research has shown that a fresh product is much better quality than a frozen one, and this quality is a key part of our commitment to the end-customer.”.

The RPC’s higher strength allows for more product to be stored – making transport more efficient while reducing inventory costs. Previously, the logistics supplier would have had to keep stock of packaging material as the demand for chicken could change on a daily basis.

“Under the new arrangement, they do not have to make an investment in stock,” said Golovey. “Rather, they can just get these crates from CHEP as required.”

Concluded Wehmeyer: “When people share and reuse the same platforms to move their goods – such as our RPCs – less platforms are required, less natural resources are consumed, less waste goes to landfill, and less CO2 enters the earth’s atmosphere. We ensure that our customers no longer have to trade off profit or planet, it simply is no longer a compromise.”

www.solutions.za.chep.comwww.sapics.org.za

CHEP’s reusable plastic crates give Nando’s a sustainable edge


Protecting brand reputation has become a critical factor for all businesses, as it can take years for a company to build up a brand but just a single quality issue can

seriously damage it, particularly if it is related in any way to consumer safety.

The cost implications can be immense as well – from loss of sales to fines imposed by the retailer and the logistics in arranging a product recall, not to mention the possibility of legal action.

Retailers are also hugely aware of the importance of protecting their image, particularly in terms of anything that impacts on consumer safety. The result is that there is an increasing focus on the value of X-ray inspection systems with one leading UK retailer starting to insist on the use of X-ray machines among its suppliers to meet its stringent sensitivity requirements.

The debate has of course arisen as to the relative values of metal detection versus X-ray inspection technologies. In reality, many food companies will require both systems, depending on differing needs within the production environment. In terms of preventing contaminants in products, X-ray inspection systems have the versatility to spot a much wider range of foreign bodies, including glass, plastic, stone and rubber and there are now specialist X-ray inspection systems available that can detect bones in meat fillets.

Investing in the appropriate inspection and detection technology is a vital part of protecting brand reputation, explains Ciaran Murphy, Quality Control Business Manager, Ishida Europe. “One of the challenges for achieving effective quality control is the increasing automation throughout the processing and packing operations, which in itself is vital to maximise efficiencies and minimise costs. This leaves fewer opportunities for human intervention to spot any problems on the line.”

To this end, Ishida Europe has just launched a new range of X-ray inspection systems to help companies comply with global safety standards and meet the demands of quality and safety-conscious manufacturers and retailers. Their new X-ray (IX) series raises the bar in performance and usability with a range that meets all local territory standards. Offering customers easy maintenance and stress-free operation, the equipment includes a robust, failsafe system that prevents a contaminated product reaching the consumer in the event of a power outage or breakdown, helping to minimise the potential for costly recalls.

“With the IX range, we have harnessed the latest advances in imaging technology to create industry-leading X-ray inspection systems that meet the specific needs of our customers across all markets and sectors, offering unrivalled detection of foreign body contaminants,” says Murphy. The new range consists of three advanced X-ray systems: • The IX-EN series. Ideal for manufacturers requiring an

affordable but highly accurate entry-level inspection solution, offering a reliable machine that balances impressive

sensitivity with minimal operating costs to deliver an excellent return on investment

• The IX-GN series. Ideal for manufacturers looking for the highest level of certainty and the best possible performance for a wide range of products. Able to detect pieces of stainless steel as small as 0.3mm in diameter, plus aluminium, glass, stones, rubber, dense plastic and shells at high speeds. Suitable for a variety of packed and unpacked products, and includes a compact, built-in air conditioning unit

• The IX-G2 series. This series is able to provide the highest level of quality assurance to processors and manufacturers of complex products. Its dual energy sensor detects what other inspection systems miss, providing highly effective X-ray detection of low-density objects, even in varying thickness or overlapping products.

The IX series also offers products that are specifically designed to cater for large packs or bottle applications.

Both the GN and the EN ranges use Ishida’s patented Genetic Algorithm (GA) image processing to deliver superior,

accurate inspection with many standard GA settings already stored in the machines for a range of products and possible foreign bodies.

Although all IX systems offer the highest performance in the market, they are designed with ease of use in mind, with the availability of touchscreen interfaces that have intuitive software. Everything within the new range has been designed to offer the maximum performance with the minimum cost in personnel training, to ensure producers can rapidly gain the benefits of their investment.

For more information contact Torsten Giese of Ishida Europe Ltd on +44 121 607 7700 oremail: [email protected]

INNOVATION Ishida’s X-ray solutions protect reputations


For 20 years, food companies around the world have relied on the award-winning BAX® system for accurate,

reliable pathogen detection. Today, food companies and government agencies use Hygiena’s award-winning BAX® system to detect unwanted organisms in raw ingredients, finished products, and environmental samples to help keep our food safer.

With certifications and regulatory approvals, the BAX® system is recognized globally as one of the most advanced pathogen testing systems available to the food industry.

BAX® systems break down samples at the genetic level and provide rapid results that help you make product release decisions with confidence.

As part of your quality control system, it can have a tremendous impact on operations — reducing false positives and minimizing retesting.

Often referred to as the “gold standard” in DNA-based pathogen detection by those familiar with it, the BAX® system is the most widely adopted and referenced platform in its market.

Whether you are looking for the power of polymerase chain reaction (PCR) in a small footprint or a high-throughput solution for your laboratory, Hygiena’s BAX system offers powerful technologies with two convenient options.

The BAX® system X5 and Q7 instruments feature two types of PCR detection technologies - real-time and end-point assays.

The BAX® system Q7 offers speed, accuracy and ease of use for up to 96 samples at a time.

The BAX® system X5 handles up to 32 samples at a time with the reliability and performance you can trust.

At Hygiena, we believe that science offers the potential to help ensure the safety and quality of our global food supply. Our innovative science can help you perform fast, accurate food safety and quality testing to address a broad range of challenges — so you can get products to market faster and help ensure the safety of the foods people enjoy every day.

Hygiena delivers rapid microbial detection, monitoring, and identification solutions to a wide range of industries, including food and beverage, health care, hospitality, pharmaceuticals, and personal care.

Utilizing advanced technologies and patented designs, Hygiena provides industry-leading adenosine triphosphate (ATP) monitoring systems, PCR-based foodborne pathogen detection, DNA fingerprint molecular characterization systems, allergen tests, environmental collection devices, and more.

Hygiena is committed to providing customers with high-quality innovative technologies that are easy-to-use and reliable, backed by excellent customer service and support.

For further information contact Frances Renwick Tel. (011) 553 2300e-mail : [email protected] Website: www.microsep.co.za

TECHNOLOGY

HYGIENA’S BAX® SYSTEM:Fast, accurate pathogen detection

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PETCO BEATS TARGET - AGAIN!PETCO, the organization responsible

for fulfilling the South African PET plastic industry’s role of Extended

Producer Responsibility, recently announced that their 2016 recycling figures had exceeded their targets, for the second year in a row

Their figures show an increase in the annual PET recycling rate from 52% of post-consumer bottle PET in 2015 to 55% in 2016. The organisation recycled an additional 22% of post-consumer bottles in comparison to the previous year, with the total PET market growing by 14.8% to 241 269 tonnes.

“PETCO is delighted with the latest figures,” says CEO Cheri Scholtz. “Through the remarkable network of people, companies and organisations we work

with, 2 billion PET bottles were collected for recycling across South Africa during the course of 2016, creating some 62 000 income opportunities for small and micro-collectors, and changing their lives and those of their families in immeasurable ways.”

The voluntary recycling fee paid annually by PETCO members on every tonne of raw material purchased has enabled the payment of a total of R1.9 billion by PETCO contracted recyclers to collectors for baled bottles since the inception of PETCO in 2004, resulting in almost 800 000 tonnes of carbon and over 3 million m3 of landfill space saved to date.

Chandru Wadhwani, Joint Managing Director of Extrupet (Pty) Ltd. and PETCO

board member, adds: “PETCO’s achievement of collecting 90 749 tonnes in 2016 was beyond remarkable. For those of us who have long memories in this industry, it is extraordinary to have crossed the 90 000 tonne mark so early on in PETCO’s young evolution.

“One further needs to consider what was the lay of the land at the beginning of 2016, when there were only hurdles and obstacles which had many of us believing that the collection figure for the year would have gone backwards from the previous year.“

www.petco.za

RECYCLINGList your business in our

2018 Supplier Directory


BARPRO STORAGECape Town Tel: +27 21 552 9190 Johannesburg Tel: +27 11 450 [email protected]

Double your warehouse and cold store capacity without adding another square metre.

Storax mobile racking is designed to fit in either new or existing warehouses and cold stores where space is at a premium. Mobile racking can double pallet capacity while still allowing immediate access to every pallet position.

Barpro has offices in both Joburg and Cape Town, can manufacture locally, has spares and trained technicians on hand.

COLD STORAGE SOLUTIONS

DINNERMATES Tel: +27 11 462 0020 +27 11 032-8600Fax: +27 11 462 [email protected]

Suppliers to the hospitality and food industries of quality portion-controlled, chilled, frozen and dried meat products. Service excellence, innovation and flexibility give Dinnermates the edge in providing meat and chicken products tailored for special applications in the food industry.

PHT-SA TRADING INTERNATIONAL Tel: +27 861 777 [email protected]

PHT, your partner for hygiene and technology; plans and offers hygiene, food safety and technology solutions for food and beverage companies of any size; personnel hygiene equipment, change room equipment, drain technology, cleaning machines, foam cleaning technology, consumable goods, ergonomic handling systems, doors and components, deboning conveyor and racking systems, stunning and slaughter systems, water treatment systems, smoking and cooking systems, wood, pan releasing agents, speciality ingredients.

AROMATECH FLAVOURS Tel: + 27 10 010 6147 + 27 11 452 1760 [email protected] www.aromatech.co.za

For the past 30 years, Aromatech has specialised in the development and manufacture of flavours for snacks. However this has changed, and today besides snack seasonings we, with the co-operation of some of the world’s finest French flavour chemists, now offer flavours for the whole of the food, dairy, pharmaceutical and beverage industries.

We are also able to offer single vitamins and vitamin pre-mixes, of the highest quality.

Aromatech will not compromise on quality, and offer extremely competitive prices, low minimum order quantities and outstanding technical and personal service.

We are passionate about what we do. Make us your next flavour partner.

LAKE FOODS Unit 2 Galaxy Office Park, 17 Galaxy Avenue, Linbro Business Park, SandtonTel +27 11 409 5000www.lakefoods.co.za

Lake Foods is the exclusive representative for leading international manufacturers and suppliers of specialty ingredients and commodities, offering products and services into the dairy, beverage, wine, meat, poultry, bakery, health and nutrition industries.

Offering a full service to their customers, Lake Foods has a well-equipped pilot facility at Linbro Park, Sandton, which enables the technical department to assist customers with new product innovation, development and product improvements. Products in our portfolio include bacterial cultures, enzymes, natural colours, test systems, phosphates, stabilisers, emulsifiers, baking powders, brines, spice blends, marinades and various other food ingredients.

VEOLIA Tel: +27 11 974 8161Fax: +27 11 974 [email protected]

Veolia Water Solutions & Technologies SA is a specialist provider of complete water and wastewater treatment solutions and is active throughout southern and sub-Saharan Africa. As a subsidiary of the multinational Veolia Water, the company offers a full range of products and services to a variety of industries including food and beverage, petrochemical, mining, municipalities, and numerous others.

Veolia employs leading technology for disinfection, filtration and general purification, including environmental protection. Solutions are completed by in-house capacity to provide a speciality chemical treatment range - Hydrex™ - as well as SABS-approved hygiene products and services.


CCSS LOGISTICS-LINEBOOKER PO Box 686, Cape Town, 8000Vrystaat Road, Paarden Eiland Cape Town, South AfricaTel: +27 87 350 [email protected] www.linebooker.co.za

Linebooker is not a brokerage. Linebooker is an online business where customers have easy access to the majority of transport companies is South Africa. How it works: the customer would publish a load request on our platform and multiple pre-approved transport companies would bid for your load. Our customer can then choose to accept the lowest bid. We take care of the rest. Transporters on the other hand have access to more customers, thus more loads which assists in lane balancing and reduces the need to subcontract. We pay the transporter within 15 days and take care of all admin.

PRODUCT SOLUTIONS & SERVICE SUPPLIER

M&L LABORATORYSERVICESTel: + 27 (0)11 661 7947E-mail: [email protected]: www.bureauveritas.com

M&L Laboratory Services (Pty) Ltd, a Bureau Veritas groupcompany, is a fully-accredited Food Testing facility, providing clients with an extensive array of specialised analytical capabilities.

Our state-of-the-art facilities and equipment allow usto streamline sample flow through our labs in order toincrease productivity, project efficiency and provide highquality data as per your specific requirements.M&L Laboratory Services prides itself in meeting theneeds of the customer, on international, national and locallevels with exceptional servicefrom experienced technicalstaff as well as project management support.

M&L Laboratory Services is an ISO 17025 accredited facility

Email [email protected], Tel: 083 653 8116

ABB SOUTH AFRICA (PTY) LTD ABB Campus, 2 Lake Rd,Longmeadow Business Estate (North),Modderfontein, 1609Tel: +27 10 202 [email protected]/africa

ABB’s food & beverage solutionsPlant-wide solutions to optimize productivity, efficiency and uptime.

ABB’s broad digital portfolio enables increased control and visibility for better optimisation and productivity with less energy and water, realize improved food safety and traceability, and minimise waste. ABB can help you build the flexible, cost effective production systems needed to manage your risks and gain the most from today’s trends. ABB use the Internet of Things, Services and People to help you get the most out of your assets and improve uptime. Find out more about our full range of solutions at www.abb.com/food&beverage, or contact your localABB office.

CSS LOGISTICS PO Box 686, Cape Town, 8000Vrystaat Road, Paarden EilandCape Town, South AfricaTel +27 87 350 7350www.ccslogistics.co.zawww.linebooker.co.za

As the largest cold store operator in Africa, operating since 1971 and a 100% subsidiary of the Oceana Group, CCS Logistics owns and operates eleven modern refrigerated facilities in the major centres and harbours of South Africa, Namibia and Angola. Collectively, CCS offer 140 000 tons of multi temperature controlled storage and handling from ambient to minus 60 degrees.

Dynamic warehouse management systems incorporating radio frequency technology and integration capabilities support our range of services that include picking, blast freezing, bonded facilities, bulk vessel quayside operations and stevedoring. Customised services range from container consolidation, cross-docking, palletisation, transport and facilitation of clearing and forwarding.

PRODUCT SOLUTIONS & SERVICE SUPPLIER

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