Smart Manufacturing

Heat exchanger solutions for 5 challenging foodstuffs

Thermal treatments using heat exchangers, such as pasteurisation, heating and cooling, feature in the manufacture of multiple food and drink products. In this article we look at five of the most challenging foodstuffs in terms of thermal processing, and the heat exchanger solutions to help manufacturers handle them correctly. Highly viscous materials Highly viscous foods, including nut butters and other fat-based products, can be almost solid at low temperatures. This creates a number of challenges, including moving the material through the heat exchanger. Other considerations include preventing fouling and ensuring an even temperature. Nut butter can be one of the most difficult products to handle, and so a heavy duty rotating scraped surface heat exchanger (SSHE) is required. With its larger motor, bigger scrapers and extra mounting supports, the HRS RHD Series was specifically designed for such tough materials. Products containing pieces The challenge when dealing with pieces of product (from small, diced vegetables to large fruit pieces) is ensuring the mixture moves through the process at a constant speed without damaging the physical integrity of the product. The Unicus Series of reciprocal SSHE is perfect as the separately controlled hydraulic scrapers are available in a range of designs and are fully controllable. Thermally challenging products Some ingredients, such as eggs or chocolate, are very sensitive to temperature and must be processed at precise temperatures to avoid damaging the product. Liquid egg, for example, is extremely delicate as the proteins in egg are more sensitive to heat than other products, such as milk or juices. The white and yolk are distinct components with different compositions and behaviours: egg white is denatured at 58°C while yolk is denatured at 65°C. If not handled correctly, thermal pasteurisation can decrease protein content, change physical characteristics such as texture and colour, and increase product […]

Kerry drives dairy innovation with advanced lactase solutions

With rising lactose intolerance affecting an estimated 30-60% of the population in Australia and New Zealand, Kerry is meeting a surging demand for lactose-free dairy options in the region through its portfolio of advanced lactase solutions. Lactose intolerance remains a prevalent issue globally, with only a third of adults worldwide able to digest lactose effectively. By 2028, the Australia and New Zealand market for lactose-free dairy products and alternatives is projected to reach EUR938 million. This shift is not solely driven by lactose intolerance but also by a broadening interest in lactose-free options due to perceived health benefits. This has contributed to impressive growth rates — in 2024, the lactose-free market in Australia is valued at AUD602 million, with a projected 31% CAGR between 2019-2023. In New Zealand, growth is significant with 52% CAGR from 2019-2023 and current market value of NZD63 million. Lactose-Free Solutions for Better Dairy Lactases are naturally occurring enzymes that break down lactose, the sugar found in milk, into simpler sugars — glucose and galactose, which are easily digestible. This enzymatic intervention is critical for those who lack sufficient natural lactase enzymes in their digestive system, a common scenario among the lactose intolerant population. By adding lactase to dairy products, the lactose is pre-digested, making these foods accessible and enjoyable without the usual adverse reactions. The dairy industry has seen a revitalisation in its appeal, much of it thanks to innovations such as lactase enrichment. Traditional dairy products previously thought to cause discomfort are back on the menu, changing the dietary landscapes for many. With these innovative changes, lactose-free is now the fastest-growing dairy category, while low-sugar options are increasingly top of mind for consumers. Kerry’s newly expanded portfolio of lactase solutions includes the high-performing NOLA® Fit and Ha-Lactase™, alongside LactoSens®, a unique rapid residual lactose […]

Technology can address food wastage challenge in India’s foodservice industry

Food wastage remains a critical challenge for India’s foodservice industry, not only eroding restaurant profits but also intensifying environmental concerns in a country where millions suffer from undernourishment and malnutrition. Leveraging technology offers a dual advantage by mitigating food waste and promoting sustainable practices, thereby enhancing efficiency and supporting long-term industry growth, says GlobalData, a leading data and analytics company. Parthasaradhi Reddy Bokkala, Lead Consumer Analyst at GlobalData, comments: “Many restaurants struggle with operational inefficiencies that lead to excess food preparation. This includes challenges in accurately predicting customer demand, which can result in over-preparation of meals that ultimately go uneaten. Moreover, small- and medium-sized restaurants often have limited resources and experience, making it difficult for them to negotiate with vendors for better pricing or to find quality services that can aid in waste reduction. “In addition, financial challenges are particularly acute for smaller eateries, which often lack the capital to invest in waste-reduction systems or processes. Additionally, the dynamics of the food delivery market, such as shifting consumer preferences, create challenges in maintaining predictable and efficient inventory management.” This unpredictability often results in food waste as restaurants may prepare items that do not sell. Given the increasing oversight by the Food Safety and Standards Authority of India (FSSAI), restaurants face a dauting task to minimize wastage and losses. Francis Gabriel Godad, Consumer Business Development Manager at GlobalData, adds: “The evolution of technology has ensured that even smaller outlets can benefit from it. For instance, Zomato launched a new initiative, Food Rescue, which will help restaurants address the challenge of food wastage to some extent. This initiative allows customers living near restaurants to purchase these cancelled food orders at significantly reduced prices. The feature not only helps in minimizing food waste but also provides an economical option for consumers, thereby contributing […]

Thailand foodservice industry shifts to cage-free eggs

The growing ethical awareness among the consumers has led the Thailand foodservice industry to increasingly adopt sustainable practices. Many foodservice operators are opting for cage-free eggs and restaurants are placing greater importance on animal welfare. This shift not only addresses the evolving consumer expectations but also aligns with global food standards, reflecting the industry’s commitment to ethical sourcing and sustainability. Consumers believe animals deserve respectful treatment, with the confined, restrictive conditions of battery cages widely deemed cruel. In contrast, cage-free systems provide hens with more freedom to move and express natural behaviors, aligning with ethical values. Cage-free systems can have a smaller environmental footprint when managed responsibly. Consumers prioritising sustainability consider cage-free eggs to help reduce environmental harm and support sustainable farming. Moreover, sustainable feed practices and reduced reliance on antibiotics contribute to a healthier ecosystem and lower overall resource usage. Restaurants adopting this standard are not only supporting the humane treatment of animals but are also contributing to healthier food production processes. Capitalising on these trends, various foodservice operators in Thailand, such as Tap Home Cook and Zen Corporation Group have committed to only use eggs from cage-free hens. Cage-free environments are believed to help produce healthier eggs with a lower risk of contamination, particularly salmonella, than eggs from caged systems. Consumers often associate better animal welfare practices with higher food quality and safety.

Suomen Lantakaasu invests in Kiuruvesi biogas plant project

Suomen Lantakaasu Oy’s biogas plant to be constructed in Kiuruvesi, Finland will produce renewable liquefied biogas from cattle farm manure in Upper Savo and from other agricultural and food industry byproducts. The investment covers the construction of the biogas plant and the liquefaction unit. The preparatory groundwork phase has already been finalised and construction of the biogas plant will begin this winter. The plant will be completed in 2026. The Kiuruvesi biogas plant is part of the Upper Savo complex that includes the industrial-scale, centralised liquefied biogas production plant in Kiuruvesi as well as three smaller satellite plants in Lapinlahti, Sonkajärvi and Nurmes. The total value of the investment in the Upper Savo complex is around EUR 100 million. The project has been granted EUR 19.2 million in funding from the EU Recovery and Resilience Facility (RRF investment aid). This aid is critical for realisation of the project. The final decisions on construction of the satellite plants are still pending the completion of the environmental permitting and zoning processes. The biogas plant under construction in Kiuruvesi will make efficient use of local livestock manure. The plant will be able to receive manure from about 100 farms locally, i.e. around 400,000 tonnes of manure per year. The biogas plant will also receive manure-based compressed biogas from other biogas plants in the hybrid complex for liquefaction. The plant will liquefy about 125 GWh of biogas per year, which is equivalent to the estimated annual fuel consumption of 250 heavy-duty vehicles. “Manure biogas production has a major role in reducing emissions not only from heavy transport, but also from agriculture. With the binding supply agreement we have signed with more than one hundred agricultural entrepreneurs in Upper Savo, the biogas plants will have a very broad impact on Upper Savo’s agricultural emissions and […]

NZ’s low-carbon beef production to accelerate following new study

New Zealand’s low-carbon beef production is set to accelerate following the release of a new study that found younger dairy cattle produce almost half the greenhouse gas emissions of older steers. The move could help address a significant ethical and environmental concern for the New Zealand dairy sector which sees nearly two million, four-day-old bobby calves culled annually – a practice facing a potential ban by 2030 due to animal welfare concerns. The new AgResearch report found that dairy-derived beef raised to 10-18 months has a carbon footprint 29-48% lower than the average for mixed beef cattle in New Zealand. The researchers found that in dairy production, the total greenhouse gas emissions are allocated between milk and live weight sold for meat. This means that only a portion of the emissions are attributed to the beef, while the rest are allocated to the milk. In contrast, beef systems only produce live weight, so all the emissions are allocated to the beef. Daniel Carson (Ngāi Tahu), founder of Māori-owned agribusiness Mīti, which commissioned the research, says their mission is to transform young dairy calves, usually slaughtered at four days old, into a sustainable and profitable food source. He says by extending the lifespan of these calves by up to a year they are able to create a new market for a viable low-emission protein source while adding value to the dairy and beef industries. Carson says it is hoped the research will support the creation of a new low-carbon, young beef category called Mataora, specifically designed for manufacturing into added value products, and lead to more efficient utilisation of New Zealand’s meat processing infrastructure as well as a low-carbon leather for the high-end fashion sector. “At the moment young bobby calves are considered surplus to requirements and the current system treats […]

Breakthrough Victoria invests in company turning waste into animal feed

Breakthrough Victoria is announcing a $2.5 million investment in Viridian Renewable Technology Pty Ltd, a pioneering Melbourne based company, addressing food wastage and creating a circular economy through sustainable insect protein manufacturing. Viridian is already operating its first commercial plant in Derrimut and will significantly increase factory capacity in the following 12 months, creating 15 direct jobs and producing 1,300 more tonnes of protein ingredients every year. Future plans include building two more plants in Gippsland that will be situated in food and agricultural industry hubs to support local businesses. Viridian also has links to Victorian universities and engineering businesses and intends to collaborate on future research projects to directly benefit Victoria’s innovation sector. The company specialises in developing and deploying technology aimed at creating insect-based protein ingredients for pet and animal feed with a nutritional quality greater than many traditional protein sources and a considerably lower environmental impact. Viridian also produces fertiliser products used across Australia to support regenerative agriculture. Australians waste about 7.6 million tons of food each year across the food supply chain. This represents a huge economic cost, waste of natural resources and around 3 per cent of our greenhouse emissions. At the same time, we need new ways of producing enough high-quality protein to feed ourselves, our pets and our livestock. Viridian addresses these challenges by building highly automated insect protein factories that can substitute traditional proteins in pet food and animal feed with affordable, consistent and nutrient-rich products, providing a commercial solution to this global issue. This approach reduces the amount of food materials wasted in landfill and the emissions associated with food, feed and fertiliser products. Insects require minimal land, water and feed to produce protein-rich biomass, making them an incredibly efficient food source. The company’s innovative technology elevates this efficiency further with […]

Confidence grows in solutions for processing plant-based foodstuffs

By Antonio Guillermo Jara Ponce, Systems Sales Manager, HRS Heat Exchangers The last two years have seen a slowdown in investment by the global food and drink industry, particularly in terms of products containing added sugar. However, plant-based drinks and alternative proteins have continued to grow as a sector. There are a number of reasons that food and drink manufacturers have postponed investment over the last 24 months. Some were waiting for interest rates to fall to make investment finance more attractive and reduce the price of raw materials, while others appear wary of the effects of proposed legislation by Western governments to tackle public health issues such as obesity and diabetes, which could see the introduction of taxes on sugar and fat, for example. Yet at HRS Heat Exchangers we’ve seen a difference between some of our traditional markets, such as those making juices, sauces and carbonated drinks, where investment has definitely slowed – and the plant-based and health-food sector where, despite some market readjustment, confidence has been noticeably higher. We are definitely seeing more demand from manufacturers of plant-based drinks, and not just those using traditional ingredients like soy and oat, but others such as coconut or rice. From our perspective, the actual ingredient is less relevant than its properties. From a design point of view, the material’s viscosity, thermal conductivity and how it flows are more important. Once we’ve established those parameters we can design an efficient heat exchanger. The ultra-heat treatment (UHT) of soy-, nut- and oat-based milk alternatives is fundamentally the same process as for dairy and, given our experience in dairy processing (together with the increasing use of our systems for handling meat products), makes us well placed to provide solutions both for plant-based drinks and alternative proteins. One of our particular specialisms is […]

Dr-Aaron-Low-Chief-Technical-Officer-amaea-working-at-their-RD-lab-in-Hamilton-New-Zealand FI

Molecularly imprinted polymers successfully remove smoke taint in wine

Wine science researchers from the University of Adelaide have found that a tailor-made polymer developed in New Zealand could hold the key to removing smoke taint in wine. A billion-dollar problem, wildfires are an ongoing threat to vineyards. Wines made from grapes exposed to smoke result in an acrid, ashy aroma, taste and mouthfeel that compromises quality and reduces value to the point that it is oftentimes unsaleable. Ideally, to remediate smoke tainted wine, the molecules responsible need to be reduced, without removing desirable elements that contribute to the wine’s composition, colour and flavour. Professor of Oenology, Kerry Wilkinson and her colleagues have successfully tested a method to lessen smoke taint in wine, validating the use of molecularly imprinted polymers (MIPs) to target removing the volatile phenols responsible for the smoke taint. Researchers added MIP beads to smoke-impacted wine which selectively bound and removed the target compounds, ameliorating the wine’s sensory profile. MIP specialists, amaea developed the MIPs used in the Australian Government funded study. Professor of Oenology, Kerry Wilkinson said: “The selectively of MIPs made the science worth considering as a method to reduce volatile phenols. We exposed the wine to MIP beads imprinted with billions of binding sites complementary to the target compound’s molecular properties, such as size, shape and chemical characteristics – which allows the MIPs to specifically target, capture and remove the offending phenols.” The research showed the MIP technology was successful at removing 35−57% of the volatile phenols from the sample wines which included guaiacol, 4-methylguaiacol, cresols, and phenol. The findings were recently published in ACS’ Journal of Agricultural and Food Chemistry: Amelioration of Smoke Taint in Wine via Addition of Molecularly Imprinted Polymers during or after Fermentation. Dr Aaron Low, Chief Technical Officer amaea said: “Removing smoke taint from wine has long been a […]

Sidel whitepaper shows how beverage industry can harness the growing consumer trend for variety packs

Following the booming interest in beverage variety packs among North American consumers, many beverage producers are now considering implementing this packaging strategy in other markets. Sidel has distilled its expertise in variety packs into a new whitepaper to support producers and brewers in their decision-making. The launch of Sidel’s new variety pack solutions whitepaper will aid brewers and other beverage manufacturers looking to capitalise on this surge in popularity of variety packs. The comprehensive and objective whitepaper has been designed to explore and address the pertinent issues faced by decision-makers when designing their variety pack packing strategy, from market value and industrial challenges to the transition to an inhouse solution. Growing demand for Variety Packs Variety packs of flavoured alcoholic beverages increased by 833 percent from 2016 to 2020 demonstrating consumers’ increasing search for variety, novelty and customisation, a trend mirrored by the huge increase in popularity of hard seltzers amongst young adults. First appearing in 2013 in the US, the demand for hard seltzers grew into a market worth more than $2 billion by 2021, with more than sixty brands[2]. Variety packs offer consumers a way to sample new products, cater to different tastes within a social group, present potential value for your money and are convenient to carry and store. With increasing promotion, interaction and now online sales, they also allow breweries the potential to offer on-demand Variety Packs, allowing consumers to create their own packages according to their personal tastes. Transitioning to in-house solutions Approaches to packing solutions for variety packs can vary significantly depending on the beverage company’s production need and technical choices, from manual to automated repacking lines with WIP storage or even a ‘mega accumulation’ on-the-line production model. When the variety pack trend first started, beverage producers relied on contract packagers to avoid large […]

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