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New technologies and innovative ingredients

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The confectionery industry, like many other industries, has changed significantly: Mainly due to the ‘plant-based revolution’ that gathers pace right across the food and beverage sector.

As analysts note, the steady rise in vegan trends in recent years is not a mere passing foodie fad; and the pandemic has fuelled this perspective among many consumers. This dynamic growth is creating innovation opportunities across a wide range of new food categories, including sugar confectionery. The number of confectionery products with a vegan claim has grown by over 25 per cent in the last five years (CAGR 2016-2021). However, while confectionery products with plant-based claims have continued to show a strong surge in growth, such products aren’t always simple to produce.

To develop vegan/vegetarian confectionery, animal-derived ingredients such as gelatine, milk and egg white must be replaced: The alternative ingredients need to provide similar functionality. An important factor to consider is price volatility, which is currently a major issue in the egg industry, with the recent Avian Flue outbreak in Europe and the US causing a 52% surge in egg prices. Therefore, manufacturers are now looking for egg alternative solutions for confectionery applications.

Plant proteins offer great functionality and can be considered as a solution. The use of proteins, such as emulsifiers and hydrocolloids, is aimed at producing high-quality products without compromising their physical, functional, organoleptic, and nutritional characteristics and a choice of economically advantageous ingredients. The rise in raw material prices, together with that of energy sources, is pushing manufacturers to look for ingenious solutions to find ingredients that are economically competitive and have a lower environmental impact.

From this perspective, waste ingredients from fruit processing and air can be used as a key component for future formulations. Air, like gases in general, can optimise the consistency of food and at the same time induce a feeling of satiety, linked to a reduced use of fats and calories, by conveying aromas and modulating the volume and geometry of the preparation. This leads the consumer to believe that he has bought more product (see also the phenomenon of “shrinkflation”, consisting in the use of packaging to conceal changes in the weight of the article).

The pandemic has also influenced the market: consumers make more responsible and healthy choices, prefer a lifestyle based on low-fat foods and sweets, and therefore less associated with chronic diseases. The undisputed role of fats in the “texture” of a product, in its taste and aroma, has directed research towards alternatives to fats that have similar chemical structure, including rheological properties during cooking and mixing. Fat replacers and fat mimetics are the viable alternatives to emulate the ability of fats to contribute to stability, palatability, crispness, interaction with water and other ingredients, and flavour.

相比之下,fat replacers(e.g. Olestra and Salatrim) derive directly, through an enzymatic process, from fats, and are chemically different from them, whilefat mimetics来自蛋白质,淀粉,水状胶质牙龈,polysaccharides and cellulose. The fate of these products will be determined by their ability to retain their consumer acceptance in terms of taste and texture, and the possible reduction of adverse health effects.

In this respect, the ability to combine recipe formulations in terms of ingredients with related “claims” declared for advertising and health purposes will become increasingly crucial. In this regard, recent market surveys highlight the demand for products related to environmental sustainability and animal welfare, but also to the functionality of what is purchased, such as the ability to fight fatigue, strengthen the immune system, or the intestinal flora: in practice, the general well-being of the organism.

Expectations also include the search for new and quality products, with the willingness to spend more on products that guarantee or promise benefits or present themselves as niche products, and in any case have a satisfactory taste, without neglecting appearance and texture, transparency, and traceability.

Natural Food Colours

The enhancement of natural ingredients also involves the search for new food colours, as:·Brilliant blue given by Spirulina: it is a pigmented protein known as phycocyanin; from its extraction a blue pigment is obtained that is stable at high temperatures, fading and resistant up to pH 3.0;

  • Bright white from corn-starch: a new colour line offering a range of bright and stable whites to replace titanium dioxide (E171) which is being eliminated;
  • new yellow and green tonesfrom organic safflower.

Technology

Among the most important innovations on the market for sweet confectionery:scalesare the key to ensuring accuracy during any type of high-quality preparation; by optimizing the timing, keeping track of the recipe history, we also have control on traceability and inventory rotation. The pre-crystallization of tempering of cocoa butter is a crucial step in chocolate production and has a major impact on the quality and cost of final product production: The use ofhigh-power ultrasound(20 kHz to 100 W) increases the processing speed.

The future of vegan sugar confectionery

In this context, moving towards novelplant protein sourcessuch as hemp, fava bean, sunflower and chickpea could allow the discovery of new aerating and gelling properties. Fermentation is also being investigated for its potential to develop clean label, better tasting plant protein ingredients with more performing properties.

Also, healthy snacking and functional gummies are a trend that continues to grow, as are the integration ofvitamins, prebiotics, and probiotics. The use offruit powders such as limeis continuing to expand. They are used in hundreds of applications, including confectionery, plant-based food and filling. These are fine, normally highly soluble powders with long shelf-life, making them ideal for use in food manufacturing.

Chocolate

The growth of the chocolate industry has always been promising since it is aimed at all age groups and social classes. For more than a decade, the chocolate confectionery market has been growing steadily thanks to various innovations in the sector: Vegan chocolates, healthier ingredients, innovative aromas, and the use of high-quality single-origin/premium chocolate. The use of healthy ingredients in the production of dark chocolate, such as stevia, honey, lactose-free ingredients, usage of nun-hydrogenated fats, and others, have attracted the most fitness-conscious population, while flavours like Chili, turmeric and ginger are the innovative flavour blends in the industry.

The new flavours include citrus flavours, vegetables, nuts, cereals, unusual fruits, rare cocoa, and florals. Although still niche, the usage of vegetables in chocolates is gaining popularity in Asian countries especially China. One of the vegetable-chocolate combinations are potato chips and chocolate. This excellent snacking option provides a salty flavour. Similarly, edamame and chocolate, wasabi and chocolate, and purple sweet potato and white chocolate are some of the popular vegetable chocolate combinations in the Asia Pacific region. Manufacturers are reducing the use of chemical additives such as emulsifiers and preservatives in the cocoa products.

Many companies are utilizingsunflower lecithin, which is a healthier and cleaner ingredient in chocolate products. For the consumer who prefers less processed food, usage ofraw cacaois trending, obtained by slow roasting of cocoa and cold pressing it. This way all the nutritional content is preserved. The placing on the shelves of sweets (particularly chocolate bars and tablets) presenting formulations with an increased protein intake (a crucial trend in the food sector in general) and a reduced sugar content is constantly increasing: the recipients particularly interested in buying them are athletes, diabetics and persons on ketogenic diets.

这包括使用乳清港eins and sweeteners such as erythritol, whose costs are decreasing, allowing for wider use, and whose organoleptic similarity to sucrose makes it easy to include them in recipes without changing the formulations. The use of new ingredients must necessarily face the difficulties of producing defect-free products at a sustainable cost. However, consumers who are interested in quality sweets are prepared to pay a higher price. Chocolate tablets, for example, are ductile nutrient vectors unlike yoghurt, cheese and smoothies, which require refrigerated storage and therefore have a different shelf-life.

Sugar reduction

Health-conscious consumers are actively seeking to limit their consumption of sugar. As new regulations and health initiatives increase pressure on the food industry.Erythritolhas a sweetening power of 60% compared to sucrose and is poorly absorbed by the intestine causing nausea, irritability, and laxative effect in excessive daily doses.Alluloseis found naturally in fruits such as figs, kiwi, and raisins, but only in very small quantities.

It is available as a crystalline powder and melts easily in water. The sweetness of allulose is about 70-80% of that of sucrose, with only 10% of the energy intake (0.2 kcal/g). The FDA has approved its use in America since 2012, and it is also permitted in Mexico, Japan, Singapore, and South Korea. In Europe, EFSA is awaiting its inclusion among the Novel Foods.

Oleogel

Also, in the context of chocolate-based products trends, there is the experimentation of oleogel emulsions, in particular in spreadable creams and fillings, to replace cocoa butter, palm oil and coconut oil. The research is focusing on the progressive reduction of saturated fats, which are technologically important to give creamy, succulent, and lucid appearance: Oleogels are the result of a conversion of vegetable oils into more or less solid textures, using waxes, monoglycerides and ethyl cellulose.

Oleogels therefore allow the replacement of saturated fat quantities by increasing doses of polyunsaturated fatty acids in formulations, solving the technical and rheological difficulties of preparing creams by inserting water into a three-dimensional crystalline matrix. Further studies will be needed to test the viscoelastic characteristics and the extent to which the water activity of these products may influence microbial growth and consequently affect its stability, safety and saleability.

References

www.fortunebusinessinsights.com/thoughtleadership/top-4-innovations-in-chocolate-ingredients-products-10258

www.gamberorosso.it/notizie/food-tech-startup-innovazione-cibo-salutare

www.alimentinews.it/tecnologia/packaging-tracciabilita/142-innovazione-nella-produzione-del-cioccolato

www.confectioneryproduction.com/news/40847/research-shows-alternative-confectionery-ingredients-and-vegan-markets-continue-to-show-global-growth

New drying and microbial inactivation technologies for the tomato processing industry

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The purpose of a recent study carried out by a group of international researchers (Al-Hilphy et al., 2021), was to explore the impact of halogen drying temperature (varying between 60 and 80°C) on drying kinetics and some sensory and physical properties of tomato slices. In addition, experimental data was used to develop a new predictive model, whose performance was compared with that of previously proposed models.

The study shows that increasing the drying temperature from 60 to 80°C reduces the drying time from 150 to 106 min., but increases energy consumption. Furthermore, it was noted that, under all conditions tested, the drying rate is not constant during the process, while the effective moisture diffusion varied between 7.96 x 10-9and 1.07 x 10-8m2/s.

The samples with the best sensory evaluation were those treated at 60°C. The authors point out that the color parameters (L*,a*,b*,a*/b* and ΔE) were significantly affected by drying temperature. The browning index and mass transfer coefficient increased significantly with the increase of the drying temperature.

In conclusion, considering its ability in saving energy consumption, reducing drying time and producing high-quality products, this innovative process – even if it needs further study – showed a good potential for upscaling compared with conventional technologies.

Microbial inactivation in tomatoes with an innovative water-assisted Ultraviolet C light technology

The purpose of a recent study, carried out by a group of Spanish researchers (Abadias et al.,2021), was to assess the efficacy of a new ‘clean’ technology for the disinfection of fresh tomatoes and processing wash water. In particular, this technology is based on the combined use a water-assisted UVC light device (WUVC).

First, wash waters with different turbidities were inoculated withListeria innocuaand treated in the WUVC device at different dosages. Secondly, fresh tomatoes, inoculated withL. innocuaand non-inoculated ones, were treated using the WUVC device containing wash water of different turbidities for different times.

The results show that the reduction ofL. innocuapopulations was influenced by turbidity: lower reduction values were observed at higher turbidities. It has also been observed that washing tomatoes with tap water with UVC lamps off significantly decreased theL. innocuapopulations on the surface of the fruit, but not to those that end up in the water.

Contrarily, when UVC lights were on,L. innocuapopulation in wash water after treatment significantly decreased.In conclusion到目前为止,获得的结果非常有前途的or the development of a new ‘clean’ technology to be used for disinfection in tomato processing, but further research is needed to improve the performance of the proposed system using water with a certain degree of turbidity.

References

A.R. Al-Hilphy et al.,Journal of Food Process Engineering, 44, 2021, e13624;Abadias et al.,Food Microbiology, 94, 2021, 103631.

X-ray detection of foreign bodies

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Xnextdeveloped XSpectra, a non-disruptive inspection system for real-time detection of non-conformities in industrial products.

In particular, in the area of food safety, it helps to improve food quality by detecting contaminants such as plastics, bones, cartilages, insects, woods and rubbers that would otherwise not be detected by traditional inspection systems.

The system can detect contamination directly on the production line, in milliseconds. It performs a multi-spectral analysis of the product in real time, comparing the energy absorbed by any contaminants and thus declaring the compliance or non-compliance with the required quality standards.

Current inspection systems are capable to perform a 1- or 2-level energy analysis. XSpectra, instead, thanks to the combination of three high-level innovations, such as photonics, nuclear electronics and artificial intelligence, is capable of detecting the full energy spectrum of the incident radiation, up to 1024 energy levels.

This allows to obtain more information on the composition of a product. The technology can be applied to all food sectors and to many products, including stuffed pasta, legumes or processed and bulk meat.

Bench and stand-alone dough sheeters

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Z.matikhas 40 years of experience in the manufacture of dough sheeters, workbenches, mixers and cutting rolls in AISI 304 stainless steel. Since this year, a revolution has begun, while respecting tradition, starting with the manual bench and stand-alone sheeters.

These machines are now more compact and ergonomic, with mechanics that retain some key points, but have been revamped to provide less routine maintenance and greater strength. The sheeter is suitable for a wide range of applications in bakery products.

Existing optionals have been enhanced, starting with the thickness detector that allows to calibrate the lowering of the cylinders to precisely control the thickness of the dough. This device is equipped with a larger and more accurate colour digital display. The company is certified according to the TÜV Süd – ISO 9001 quality system; it complies with all food-contact standards and sanitizes each product before packaging.

The quality and sustainability of packaging in the wine industry

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Defranceschi to showcase a comprehensive range for the industry: from winery design and technology to Bag-In-Box solutions that deliver market-leading sustainability, plus a versatile modular range of FLEXI-KUBE labeling machines that are perfect for the wine world.

The29th edition of Simei– theInternational Enological and Bottling Equipment Exhibitionto be held atFiera Milano from 15 to 18 November 2022– will focus on the union ofenologyandecology.SACMI Beveragewill offer visitors an opportunity to get a close look at the full range: a range that combines winery engineering – which aims to create an ‘experiential’ place of technology and design – with complete Bag-In-Box packaging solutions, the most sustainable on the market, now with important new features. And then there’s the highly versatile labeling provided by the Flexi KUBE range, specially designed for this industry… and already a recipient of awards from the main Italian and international wineries.

Designer tanks and autoclaves, all the latest in the Defranceschi range
Defranceschi– the SACMI brand that specializes inwinery engineering and architecture– will be exhibiting at Simei 2022 following an exceptional two-year period in which it completed major projects in Italy and abroad and further developed its products. At the heart of the Defranceschi range lie itsvertical twin-compartment, segmentedand dual-material (steel and concrete)designer tanks, intended for wine-making and maturation.

Offering stylish features such as exclusivepigmented steel, they’re now available inmicroporous ceramic. Their outstanding design transforms wineries from simple places of production to ‘experiential’ places where customers can play an active role. On the technical front, the new vertical twin-compartment, multi-cell tanks with layered domes revolutionizetank accessibility, allowing staff to work ‘from the ground’ andstore different musts where space is limited.

Built meticulously, these tanks can incorporate eye-catching design elements, such ascooling jacketsmade of pigmented steel, giving the Defranceschi range a stylish touch of exclusivity. The new ‘segmented’ tanks are particularly appreciated: patented by Defranceschi, these all-new tanks can even be designed around the structural elements (i.e. columns) of a winery building, thusoptimizing use of space.

Defranceschi incorporates the steel or ceramiclayered domes访问框架,使坦克本身a ‘walkway element’. This makes cleaning easier and, more importantly, provides advantages in terms of ‘hospitality’, as customers can now be welcomed into a place that was once a strictly technical environment to experience thewine maker’s unique heritage.

The year 2022 sees the launch of the very first 32hl ceramic tank prototype, the result of SACMI’s vast expertise in this area. This tank exploits the extraordinary properties of ceramic to refine the wine viamicro-oxygenation. That process has been carefully performance-evaluated by Defranceschi, and the market has already responded positively with purchases.

Sacmi Line for Bag-In-Box

Sustainability and performance: Bag-In-Box opportunities
SACMI Beverage has been developing a complete Bag-In-Box range for several years. Its tried and tested solutions are appreciated worldwide. Yet why go for Bag-In-Box? This will be the topic of SACMI’s talk at Simei, to be given on 16 November, from 1 to 1:30 pm, taking place Sala Convegni – Pad. 3 titled“One-stop-shopping approach to BIB technologies: a complete approach to sustainability & performance in packaging-beverage sector”.

It begins with a description of the outstanding properties of BIB packaging, which optimizes the storage, transport and pouring of bulk wine. From a sustainability perspective, the first advantage is that this type of package holdsthe maximum effective quantity of product, thus reducing use of packaging materials while optimizing logistics and transport. Above all, modern BIB solutions preserve the product’sorganoleptic qualities. Both at the filling stage and after opening, special design featuresextend the shelf-lifeby preventing contact with air and, therefore, the risk of oxidation.

With the SACMI solution, for example, the amount of oxygen the product comes into contact with is, even after opening, below0.75 ppm(parts per million). BIB by SACMI can processany type of bag on the market. Ultra-highconfigurabilityand numerous options ensure solutions can be adapted to the needs of the specific process and product. Excellentfilling precision(<0.3%) makes SACMI BIB ideal forpremium products. From a quality and performance viewpoint, the design allows – in addition to preventing post-opening product oxidation –几乎完全consumption, thus avoiding the problem of high levels of non-consumable residue that typically affect traditional BIBs.

SACMI BIB solutions have also been specifically designed to reducemaintenance costsand make management and changeovers more flexible. These product features go hand in hand with high-added-value assistance, such ascustomized maintenance plansand advanced technical, training and spare parts services. BIB draws on the uniqueSACMI Beverageability to providecomplete automationsolutions for every part of the packaging line. From this perspective, customers canfully integratethe lines thatfeed, form and fill the bagsand the line that inserts them in the boxes (which are also formed automatically).

Sacmi FlexiKube

FLEXI KUBE, precise labelling, versatility, ‘plug&play’
One technology, an infinite variety of labels: this is SACMI’sFLEXI KUBE, developed to meet a vast range of industry-wide needs. Offering output rates as high as25,000 applications per hourand installable on mixed packaging lines (self-adhesive, hot melt, cold glue), FLEXI KUBE lets bottlersget the most from their products, starting with a marketing and communication tool that is crucial in the wine industry: the label.

A modular framework lets customers configure the labeler according to their exact needs. This is done by installing optional devices – specifically designed for different product-container types – suitable for self-adhesive or cold glue applications. Wine-specific advantages includeshorter changeover times, thus allowing the efficient management of small batches and diversified sizes via the use of adjustable starwheels or motorized axes. Precise and user-friendly,the system makes setting the container size and shape easy.

This is done directly via the HMI, which controls the motorized carousel axes positioning and adjustment system. The advanced control system also lets userssavethe differentrecipeson the machine and recall them as needed. Alongside streamlined settings and shorter changeover times, which maximizeflexibility,this solution also has minimal maintenance requirements thanks to easy machine access andergonomicdesign.

SACMI’s innovative platform design, based on aplug & play approach, means that FLEXI KUBE is designed to allowincremental investments over timeaccording to specific production requirements. Using thesame platform, customers can, in fact, optimize the configuration by installing additionalmodules and/or optional devices, or reconvert them to suit different production needs.

FLEXI KUBE is available with an integratedbottle orientation systemandLVS(labeling vision system) software, developed entirely by SACMI. This makes the labeler ideal forpremium products因为它可以确保total quality control. It also means purchasers have asole providerfor all assistance and support services before, during and after the sale.

Get your free ticket
Visit the SACMIDefranceschistand at Simei 2022![Pad. 03 stand N.12].
Click here to sign up for the workshop(16 November from 1 to 1:30pm at Sala Convegni – Pad.2).

Volumetric dough divider for Panettone and Pandoro

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选择工业也和欣赏artisan field, SVP boasts precise and accurate pasta breaking thanks to the internal cutting system.

Proposed byMF Italywith a hydraulic closed circuit system and heat exchanger, the machine allows to adjust the pressing depending on the type of dough used, guaranteeing a medium or high production without stressing the dough. The divider is oil-free, i.e. It works without a mechanical lubrication.

The E-Receipt 4.0 package includes a storage software that allows following customizations: production speed; initial pressing (important to reduce as much as possible the stress on the dough); the speed of pieces rejection and activation of the divider (for soft doughs to prevent overlapping of the layers); the speed of the belts with adjustment of the thin oil layer deposition (for sticky dough); customization of the recipe, with loading of the production batch; product image and weight; automatic customization of weights.

The EasyOpen head allows cleaning of the inside of the dividing machine without removing any mechanical parts. Thanks to all these parameters the machine falls within Industry 4.0.

Radio-frequency pasteurization for pasta, gnocchi, sandwich bread

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STALAMoffers multiple solutions in sanitation and pasteurization by demonstrating the effectiveness of radio-frequency treatment on bulk and packaged solid products.

The benefits of this technology are minimal thermal impact on food and organic chemical-free treatment. The machines provide high energy efficiency and short process time. With radio-frequency the heating process is fast, uniform and controlled, therefore product deterioration is minimised.

The picture shows Sanipack+, an RF pasteuriser ideal for packaged products such as fresh pasta, gnocchi, sandwich bread. Thanks to the fast and selective heating process carried out by the RF field, the energy is directly transferred into the product without losses in the surrounding ambient The RF equipment requires less floor space compared to the traditional systems, for the same production output.

WiFi monitoring of temperatures and humidity

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In a world of endless digital possibilities, often temperature and humidity are still monitored with outdated and expensive methods. For example, by means of spot measurements with thermometers, whose measurement values must then be reported manually in a list with ample possibility of error.

When dealing with fresh and easily perishable food, however, it is essential to guarantee optimal climatic conditions. WithTestoSaveris 2 WiFi data loggers this is possible, because the measured temperature corresponds exactly to the expected values at all the main cold measuring points.

The instrument consists of a data acquisition system with WiFi data logger, which can be configured with maximum flexibility according to customer needs and easily integrated in an existing network. What to measure and where is not a problem: there is a wide range of temperature and humidity data loggers available, and an even wider range of probes.

All values measured with the integrated probe are transmitted to the Cloud, where they are automatically stored and analysed. Thanks to the access to the Testo Cloud, all measuring values and analysis functions can be accessed anywhere and anytime via smartphone, tablet or PC; the alarm function sends immediate warnings when limit values are violated.

CIP washing systems

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Sfoggiatechhas been designing and building machinery for the food industry for more than 50 years. These include CIP washing systems which guarantee the cleanliness of machinery used during production processes.

The washing steps of these machines can be summarized as follows: Cold rinse, hot wash with basic detergent, hot rinse, cold wash with acid, final rinse. The company offers several customized solutions: CIP systems with two, three or four tanks with various capacities and process management in semi-automatic or fully automatic mode.

Thanks to simple and user-friendly software, CIP systems can interact with all the machines in the production process: Fillers, tanks, multi-purpose machines etc.; they can be remotely controlled.

Recycling plant for dough scraps

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Pasta factories that produce scraps need to grind and reuse them without compromising the quality.

TheAntenore Visentinplant can transform them into a product with calibrated particle size, and characteristics like the original semolina used.

In particular, the plant respects the grain size of the product, with minimal presence of fine dust. It consists of two groups of machines connected to each other by a pneumatic conveyor which lifts the product and transfers it to the MCR roller mill, a real miniature mill for grinding the dough.

在这里,条纹的面团辊磨碎required size, producing a product very similar to semolina. The turbo sifter TS20.65 intercepts larger fragments of dough, which are automatically recirculated through the vacuum transport line (zero dust emissions to the environment). The fan that ensures transport from the hopper-pre-crusher unit to the mill-turbo-sifter also sends the produced semolina to the storage silos.