General News
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Bosch launches new flow packer
11 March 2019Bosch Packaging Technology has launched the first machine of its next generation of flow wrappers on the European and Asian markets – the Pack 403, a fully-automated horizontal flow wrapper for medium to high speed wrapping. The narrow machine is ideal for wrapping bars and biscuits, as well as chocolate, cookies and crackers. It features a removable discharge belt, upgrades to the cross-seal and fin seal units, and a highly intuitive, user-centred design. “Our new Pack 403 offers mid- to large-sized manufacturers a fully-automated packaging solution that is exceptionally easy to operate, clean and maintain. This minimises downtime and increases Overall Equipment Effectiveness,” says Fransien de Ruijter, product manager at Bosch Packaging Technology in Schiedam, Netherlands. The Pack 403 is designed to produce up to 800 packages per minute at a film speed of 90 metre. Supported pack styles include pillow, gusseted and easy-to-open packs. User-friendly design User-friendly and easy operation was in focus for the Pack 403’s design. Clear signage, instructive decals and setting scales on each component facilitate changeovers between products and minimise waste and downtime caused by ‘trial-and-error’ adjustments. The cantilevered discharge belt is one of the Pack 403’s key features - being removable, it is easy to clean. Its detection function rejects faulty packages and automatically ejects them using compressed air. For even more user-friendliness, the film tower has an easy-to-adjust pivot arm and sequentially numbered film rollers for easy film threading have been added. The Pack 403 also comprises an automatic film splicer with clear instructions to secure fast and smooth film changes without having to stop the machine. Improvments Compared to the previous machine series, several updates were made to improve process efficiency and film control, including as standard the servo-driven power feed roller to optimise film tension and tracking. The new fin seal unit consists of pressure-controlled fin wheels to easily adjust the machine when running a variety of products with different films. Due to the cut-out deckplates each package now passes over the fin wheels more closely, which results in even tighter packages. “Operators are now able to remove the fin fold-over unit without tools and have full access to the cutting head area for cleaning and maintenance, which increases OEE,” says de Ruijter. The cross-seal unit in turn stands out for its narrow cutting head, which operators can manually open up for cleaning and clearing using a hand wheel. Air and fork gusseting is available for gusseted packages. In a final step, the mechanically driven overhead roller tightens the package seals on the discharge belt station.
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Volpak: Pouches at the forefront of the packaging revolution
08 March 2019Volpak, designer and manufacturer of horizontal form-fill machines for flexible pouches, says that pouches are at the forefront of the flexible packaging revolution, thanks mainly to their versatility. Pouches can be adapted for most products and industries, and various filling and packing technologies are employed in the production process of the pouches to guarantee full protection and freshness of the packaged product. They also ensure long-lasting freshness within the flexible packaging, while extending the shelf life. As pouches can easily include resealable options such as zip-locks and many others, goods may last longer even after they are opened by the customer. There are also plenty of exterior aesthetic options available - with pouching technology, the imagination can be stretched to create all sorts of unique shapes, sizes, materials and components. From the production to distribution processes, Volpak says that flexible pouches are by far the most cost-effective packaging solution, as well as being the more ecological one compared to cans, jars, bottles or boxes. For one, it says, the manufacturing process of flexible pouches is much simpler. It takes far less material to produce pouches compared to rigid packaging solutions, and thus has a much lower production cost. With the highest product-to-package ratio of any other packaging solution, pouches are more compact in space and lighter in weight than cans or jars. This makes them more efficient to transport, thus reducing both transportation costs and CO2 emissions. Even in cases where the packaging is not recycled after use, leftover pouch material still creates less landfill debris, since there was less material to begin with. Plus, efficient manufacturing technology enables less heat to be used in the production process, meaning the amount of energy is reduced from the get-go. While the packaging industry continues to push for the use of recyclable materials, Volpak has already developed the technology to operate with recyclable materials. Stability in the forming process, control of film stretching, precise settings and accurate control of sealing parameters (time, pressure and temperature) are key elements to producing good quality and leak-proof pouches, especially if made with down-gauge packaging films. Machines such as the SI 280 or the brand new SC+ are equipped with solutions for management of different packaging materials qualities. Moreover, all latest Volpak machines address the needs and requirements of Industry 4.0 and digitalisation, hence come with a set of ‘smart’ advanced devices such as an asset performance evaluation system, central data storage, web-based self-diagnosis system and plug and play interconnectivity. The company says that these features contribute to achieve a perfect result in forming and filling pouches, and also help in sustaining the environment, reducing waste both in terms of energy and materials.
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Barry Callebaut opens second Chocolate Academy in China
08 March 2019The Barry Callebaut Group has opened its new office and its new Chocolate Academy center in Beijing with customers and distribution partners. Both will provide better assistance to Barry Callebaut’s local customers with onsite training and application support. The company says that it latest investment reemphasises its continuous efforts in growing its presence in the region as well as an appreciation of the strategic importance of the Chinese market. China has been a key target market for Barry Callebaut for over a decade. Back in 2008, Barry Callebaut opened a chocolate factory and a Chocolate Academy center in Suzhou, followed by a relocation of the offices and the Chocolate Academy center to Shanghai in 2010. The offices in Shanghai, which will continue to be the company’s head office in China, are currently being expanded. The Beijing Chocolate Academy is the company’s 22nd Chocolate Academy globally. The Chocolate Academy centres are teaching and training centres for artisans and professionals who want to improve their skills in chocolate and learn about new trends, techniques, and recipes. In the last 10 years, more than 3,500 craftsmen in China have attended these events in the Chocolate Academy centre in Shanghai. In Asia Pacific, Barry Callebaut already operates nine chocolate and cocoa factories and employs more than 1,800 employees. In the last 12 months, the company has expanded its sales operations in Australia, Indonesia and also in the Philippines, in addition to its existing sales offices in India, Japan, Malaysia, Singapore, and Thailand. Its second chocolate factory in Indonesia is currently being built in Rancaekek (near Bandung). Chef working at Barry Callebaut Chocolate Academy Beijing
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Cocoa market to reach $10bn by 2026
07 March 2019The global cocoa market is expected to reach $10bn by 2026, growing at a compound annual growth rate (CAGR) of 3.4%, according to Beroe Inc. With the market for cocoa derivatives such as cocoa butter surging, and climatic conditions threatening cocoa production in West Africa, the ability to meet growing global demand remains uncertain and prices are projected to rise. "Worldwide, we've seen demand for cocoa increase year over year for the past 10 years," said Nagarajan S, Team Lead, Agro Commodities and Food Ingredients at Beroe Inc. "This demand, coupled with unfavourable cultivation conditions, is slated to drive up cocoa prices. Climate change is having a profound impact on crop yields, and cocoa has been one of the crops hardest hit. With insecure cocoa production on the horizon, procurement organisations must adopt assertive strategies to ensure the long-term sustainability of cocoa supply chains." Demand for cocoa is projected to increase 30% by 2020, with chocolate production continuing to serve as the chief driver of global supply needs. Strong forecasts for cocoa derivatives are further bolstering market demand; the US and Europe comprise the top consuming countries for both cocoa powder and cocoa butter, reflecting high market consumption of chocolate products. In addition, cocoa liquor is positioned to experience accelerated growth at a CAGR of 4.5% until 2020, credited to its diverse utilisation and rising preference of its use in chocolate production. Global demand The ability of cocoa producing regions to meet booming global demand remains uncertain. West Africa is the top cocoa producing region, with the Ivory Coast, Ghana and Nigeria holding nearly 70% of global production. As climatic conditions threaten cocoa yields across Africa, estimated production is questionable through 2020. Compounding this issue, labour shortages and the rising cost of labour are driving up the expenses associated with harvesting cocoa - leading many farmers to exit the cocoa farming business entirely. Strengthening co-operatives presents one viable option for incentivising cocoa farming while ensuring cocoa price sustainability - by eliminating intermediaries in the supply chain, a focus on co-operatives has the potential to save 10-12% in cocoa procurement costs. "Without empowering and investing in small-scale farmers, the cocoa industry will struggle to produce sufficient supply," added Nagarajan. "Investing in co-operatives is a win-win - it ensures farmers get a fair price for their yields while enabling procurement organisations to ensure the stability of cocoa prices and their supply needs over the long-term." Major trends governing the cocoa industry include a strong focus on organic cocoa and its nutritional benefits - both driven by global consumer preference. While the market for organic cocoa is increasing, the smaller yields of organic cocoa farms are fueling a shortage in organic cocoa supply.
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Moo Free Chocolates unveil six premium vegan free-from bars
07 March 2019Moo Free Chocolates has expanded its recently launched ‘marvellously moreish’ premium range, with six exciting 80g vegan chocolate bars. The family-owned chocolatier’s new additions include, trendy Sea Salt & Caramel, zesty Sea Salt & Lime, classic Original and a crunchy Cinder Toffee, which is a larger variant of their most popular small bar: the Mini Moos Bunnycomb bar. Mike Jessop, Moo-Free Co-founder, said, “This is one of the greatest innovations in Moo Free’s history. These are the premium chocolate bars consumers have been waiting for. Six new bars with bold, exciting flavours made with premium inclusions and ethically sourced ingredients”. The premium, ethical chocolatier also makes its debut in the luxurious world of dark chocolate with a Dark 65% and a Dark 85% bar, both made with single origin cocoa mass. Mike Jessop, adds, “The fruity flavours of the single origin Dominican cocoa mass really come through with our brand new dark bars. Our bars are also guaranteed to be vegan and free from dairy, gluten and soya, as we don’t have those allergens in the factory. Not all manufacturers can say the same!” The demand for Moo Free’s vegan chocolates has grown rapidly since it’s founding in 2010, with its chocolates now available in the UK’s leading multiples, including Sainsbury’s, in all great UK independents, and in over 38 countries. The six new bars in the marvellously moreish range enable Moo Free to continue its impressive growth, which is due to both its quality chocolates and its awards including, the Queen’s Award for Enterprise: International Trade and, for the sixth time in 2018, Best Vegan Chocolate at the VegFest Awards UK.
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Turning cocoa bean waste into electricity
06 March 2019A project led by the University of Nottingham is developing new green technology to generate electricity from discarded cocoa pod husks. The technology is set to benefit African farming communities currently with little or no access to grid power. The project aims to spawn an entirely new bio-fuel industry that would also improve socio-economic stability for cocoa producers in rural Ghana. “Ghana is the second highest producer of cocoa in the world and every ton of cocoa beans harvested generates 10 tons of cocoa pod husks. In the past, this waste material was underutilised,” explains principal investigator, Jo Darkwa, Professor of Energy Storage Technologies in the Faculty of Engineering. “However, feasibility studies indicate that cocoa pod husks could be converted into valuable bio-fuels; an important energy supply for rural areas that have only 15% electricity coverage at present. If successful, this new bio-energy infrastructure would support the Ghanaian government’s aim for universal access to electricity by 2030.” The Implementation of Bio-Rural Energy Scheme (IBRES) project, backed by the UK Government’s Global Challenges Research Fund, aims to makes practical and economic use of the discarded cocoa pod husks. In addition to energy production and distribution, local jobs would emerge for the collection and transportation, treatment, storage and processing of this potentially lucrative byproduct. A community energy cooperative model will also help the farmers to make money from their new bio-energy source and hence reduce poverty. The main tasks of the project are to: Characterise the four different types cocoa pods commonly farmed in six regions of Ghana for their use as bio-fuels Design, build and evaluate a small-scale bio-power electricity generation unit that burns cocoa pod husks - a waste product in production - in a gasification system, which includes a gasifier, a 5kWe diesel generator set, a solar drier and pelletiser Develop guidelines for setting up full-scale bio-energy schemes and their integration into rural communities Investigate stakeholders’ perceptions of the bio-energy scheme Develop community co-operatives and governance structures for cocoa-producing regions In addition to Professor Darkwa, the Nottingham-led project team involves: Dr John Calautit, Dr Mark Worall, Dr Yuehong Su and Nii Nelson, of the Buildings, Energy and Environment (BEE) Research Group; Dr Alison Mohr, from the Institute of Science and Society; Dr Karen Robertson from the Advanced Materials Research Group; and the School of Chemistry’s Professor Robert Mokaya. Nottingham academics are also collaborating with the Centre for Energy, Environment and Sustainable Development (CEESD) Ghana, Ghana Cocoa Board (COCOBOD) and Kwame Nkrumah University of Science and Technology (KNUST) in Ghana where the bio-power unit will be installed and monitored by researchers.
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Fazer builds €40m xylitol factory in Lahti, Finland
06 March 2019Fazer is investing €40m in an oat hull based xylitol manufacturing facility in Finland to enter the xylitol market. In Fazer’s oat milling process, a substantial amount of oat hulls are derived as a side stream. Oat hulls contain xylose which can be used to produce xylitol, a sweetener which is used in chewing gum and pastilles. “We have at hand an innovation where we combine patentable new technology, healthier options to consumers and an excellent example of an innovative circular economy solution,” said Christoph Vitzthum, President and CEO, Fazer Group. “We believe that xylitol from a plant-based Nordic raw material with a Nordic origin will create interest also outside Finland and the Nordic countries, even globally. We plan to expand the xylitol production to our mill in Sweden, too. I’m proud of this example of the fearless creativity at Fazer, and we are excited about the new opportunities ahead of us.” Fazer says that producing xylitol from oat hulls is a true innovation with totally new technology. The production process is unique due to the raw material which, until now, has not been commercially utilised. Currently, oat hulls are used mainly for energy production. The xylitol factory will be built next to Fazer’s oat mill on the Lahti site and will be the first fully backward integrated xylitol manufacturing facility in the world capable of producing many forms of xylitol, supporting the market needs of the food, cosmetics and pharmaceutical industries. Growing market Modern consumers are seeking healthier options to replace refined white sugar and xylitol offers potential for future product development. The xylitol market is growing and Fazer aims to be the only xylitol manufacturer producing xylitol from a plant-based raw material with Finnish origin. Furthermore, xylitol is an important ingredient for Fazer’s confectionery business - Fazer is the only company producing chewing gum in Finland. The Lahti investment will take place in 2019-2020 and will create 30 new jobs. Works at the site began in February 2019. Fazer is also developing its business and product portfolio with special focus on growth and consumer trends. The company’s aim is to transform into a modern sustainable food company and is targeting further expansion in Northern Europe and beyond. Over the last three years, Fazer has invested approximately €195m in total, of which €136m have been invested in Finland.
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Barry Callebaut to reduce carbon footprint
06 March 2019Solar panel company REDAVIA has been chosen by Barry Callebaut to establish a solar farm at their factory in Tema, Ghana. REDAVIA will deploy six solar units at a total of 504kWp at the Barry Callebaut factory in the Free Zone Enclave in Tema. Jo Thys, Vice President of Cocoa Africa, said, "At Barry Callebaut, we want to make sustainable chocolate the norm. Already, 14 out of 59 (24%) of our Group's factories are running on 100% renewable energy. The solar farm at our factory in Tema is another important step in our long history of investing into a sustainable value chain." Erwin Spolders, CEO and founder ofREDAVIA, stated, "We are thrilled to partner with a market leader on their sustainable energy initiative. REDAVIA offers businesses the win-win of cost-efficiency and clean energy that allows them to save money and achieve their sustainability targets at the same time." In 2016 Barry Callebaut launched a program called Forever Chocolate to make sustainable chocolate the norm by 2025. Under the Forever Chocolate program, the company has committed to four targets to address the biggest sustainability challenges in the chocolate supply chain: To eradicate child labour from the supply chain; to lift more than 500,000 cocoa farmers out of poverty; to use 100% sustainable ingredients in all products; and to become carbon and forest positive. In order to become carbon positive, Barry Callebaut does not only look at the carbon footprint created by its own operations and energy use, but also takes into account the carbon footprint of the entire supply chain, including the production and processing of all raw materials and related land use changes.
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New heat-sealing robot for Flowmodul
05 March 2019In order to be able to use the heat-sealing film even more flexibly when packaging in flowpacks, Schubert has developed a new heat-sealing robot for its Flowmodul. The flow-wrapper’s new cross-sealing unit allows constant sealing times with variable chain speed and a wide control range of the film. Confectionery manufacturers can now gently package a large range of products in flowpacks with the cost-efficient heat-sealing film. This also includes highly sensitive products such as chocolate. Compared to cold-sealing, Schubert says that the packaging of products in flowpacks with heat-sealing technology offers various advantages. The heat-sealing film is inexpensive, can be stored for a long time and leaves no adhesive residue when the packaging is opened. To ensure a high-quality seal, three factors – temperature, pressure and time – must remain constant during the sealing process. Additionally, not every product can withstand the heat. And until now, this has limited flexibility in the packaging process. Schubert’s patented sealing technology enables customers to use the heat-sealing film for an even wider range of products. The Flowmodul’s two sealing units were developed specifically to achieve this. First, the flowpack’s longitudinal sealing unit is equipped with ultrasonic technology. The heat is generated directly in the heat-sealing film and is not distributed as usual onto the tools and machine parts. Therefore, heat-sensitive products such as chocolate also remain flawless during longitudinal sealing. Furthermore, ultrasonic technology ensures consistent seal quality at different speeds. Secondly, instead of a conventional fixed cross-sealing unit, the new heat-sealing robot is used in the flow-wrapping unit. The moving component breaks the rigid mechanical connection between the chain and the cross-sealing process: when the chain’s speed changes, the sealing unit moves either with or against the direction of product flow. The duration of the sealing time is therefore independent of the feed rate and can be programmed to milliseconds. The new cross-sealing unit adapts to the variable speed of the upstream pick and place robots for each individual flowpack, therefore guaranteeing consistent sealing times. The flying cross-sealing unit can be integrated into any Flowmodul and combined with other sealing techniques. By switching from cold- to hot-sealing technology, Schubert says it is possible to save up to 17% in film material costs. Many different products including biscuits, chocolate and marzipan are already being packed with the combination of a flying cross-sealing unit and an ultrasonic longitudinal sealing unit from Schubert.
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Mondelēz expands deforestation program
05 March 2019Mondelēz International has announced plans to protect and restore forests in cocoa-growing regions, in an effort to secure a sustainable future for cocoa by making farms more resilient to climate change. The plans cover the company’s two largest cocoa-sourcing markets, Ghana and Côte d’Ivoire, as well as Indonesia. As one of the world’s largest chocolate makers, the company has been using its scale to drive change in the cocoa supply chain for many years and launched its 10-year, $400 million Cocoa Life program in 2012 with the aim to reach more than 200,000 farmers across six countries. “Our plans to combat deforestation in cocoa include a commitment to map 100% of the farms that supply Mondelēz International’s Cocoa Life program by the end of 2019,” said Cedric van Cutsem, Associate Director, Operations, Cocoa Life. “Mapping and monitoring farms will give us a deeper understanding of farmers’ needs so we can help drive effective change. In addition, our plans include financial incentives that will encourage farmers and communities to protect and renew forest areas.” In 2015, Mondelēz International was the first company to raise the issue of deforestation in the cocoa industry at the COP21 summit in Paris and the first chocolate maker to sign Memoranda of Understanding (MoUs) with the governments of Ghana and Côte d’Ivoire. As a founding member of the Cocoa and Forests Initiative (CFI), the company's action plans align to the CFI’s three focus areas of Forest Protection & Restoration, Sustainable Production & Farmers' Livelihoods and Social Inclusion & Community Engagement, and feature the following commitments: The company is one of the first chocolate companies to commit to map 100% of the farms in its Cocoa Life program in key origins by end of 2019 to ensure that farmers are not operating in forested land. Seventy per cent of these farms are already mapped, using Global Forest Watch to assess the risk of tree loss. Mondelēz is the first organisation to introduce incentives in the form of Payment for Environmental Services (PES) agreements to a cocoa-farming context, encouraging farmers to protect and restore forests. The company aims to have agreements with 33,000 farmers by 2022. By 2022, nearly 1,300 cocoa communities will have active forest restoration and protection programs through Cocoa Life. “Mondelēz International is to be congratulated for recognising the key role natural resource conservation plays to ensure sustainable livelihoods and the need for active community participation to protect local natural resources,” said David McLaughlin, Senior Advisor Strategy at Conservation International and a Cocoa Life advisor. “Landscape restoration is clearly going to be a vital element in confronting climate change and our hope is that others will follow their lead.” For more information and details on Mondelēz' Cocoa Life Deforestation Action Plans, click here. The World Cocoa Foundation has also published the industry’s joined action plans, which can be viewed here.
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