SAAFoST Lecture

Food Factory of

the Future

Sahar Nikouie Adl Beatrice Conde 31 July 2014

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Challenges in nourishing the world within the limits of our planet

30 % food

losses and waste

High Cost of Foodborne

illnesses Need to increase

food production

by 70 % in 2050

High profile

food safety scares

Need to develop affordable

technologies for affordable

products Double burden of

undernutrition and

overnutrition

Increasing population

and urbanization

Complex global trade

and supply chains Changing

consumption habits Agriculture under

climate change stress

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The factory of the future needs to…

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Process food more efficiently requiring less energy

Apply new affordable technologies for affordable food products

Deliver food that is nutritious and meets local taste and culture

Ensure high food safety standards

Operate intelligently

Create new job opportunities

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Energy Efficiency

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How good

understanding of food

material can lead to

energy efficient drying

processes

A case study on pasta

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Pasta drying is key for stabilizing pasta and adjusting the cooking properties of pasta

Pasta drying

Is key for pasta stabilization and for

adjusting the cooking properties

Typical drying is done at 80 to 90 °C for

up to 8 h.

Energy-intensive process step

Wheat Pasta:

Produced by mixing durum wheat

semolina and water (approx 30 % )

and shaping it

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Traditional pasta drying allows early setting into glass state

Te

mp

era

ture

[°C

]

Moisture content [%wb]

Rubbery

state

Glassy

state

Glass transition curve

Allows a fast setting of the

outer layer into the glassy state

- build up of moisture

gradients

- glassy outer layer slows

down drying

- long drying (stabilization) to

prevent cracks

Pasta dough Dry pasta

pasta core

outer layer

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Novel pasta drying allows drying in the rubbery state

Te

mp

era

ture

[°C

]

Moisture content [%wb]

Rubbery

state

Glassy

state

Glass transition curve

The drying concept dries in the

rubbery state along the Tg curve

- low moisture gradients

- higher drying rate

- more efficient drying

Pasta dough Dry pasta

pasta core

outer layer

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New drying concept allows 30 % energy savings of 115 kWh/t

This means around 1 % lower production costs

Labor cost packaging line 8%

Logistics 5%

Maintenance packaging line 4%

Depreciation others 3%

Energy others 1%

Total cost w/o sales 100%

Raw material 60%

Packaging material 10%

Depreciation pasta line 3%

Energy pasta line 3%

Labor cost pasta line 2%

Maintenance pasta line 1%

Cost structure Pasta production: Pasta line w/o packaging & building:

400 kWh/t total consumption

115 kWh/t total savings

30% less energy consumption

- 40% thermal 100 kWh/t

- 20% cooling 15 kWh/t

- 10% electrical 10 kWh/t

1% lower Pasta production cost

green label pasta / less CO2

15 kWh/t

electrical

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Food processing

along different steps

and shortcuts can

make processing

more efficient

Breakfast cereals

Chocolate

raw materials raw materials

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Grains

Sugar Solution/

Vitamins

Drying

Batch cooking

Packaging

Drying/Toasting

Coating

Drying

Cooling

Syrup/Flavor/

Lecithin

Flaking

Diagram for Batch Cooked and Indirect Expanded Flaked

Products – Corn Flakes, Wheat Flakes

Tempering

Water/Steam

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Diagram for Extrusion Cooked and Indirect Expanded

Flaked Products – Corn Flakes, Wheat Flakes

Feeding

Preconditioning

Mixing

Sugar

Solution

Cereal

Flour

Drying/Tempering

Extruding

Packaging

Drying/Toasting

Coating

Drying

Cooling

Flaking

Syrup/Flavor

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Batch versus Continuous Cooking

Data for relative comparison purposes only, effective

figures are prepared on case-by-case consideration Batch Continuous

Processing time: ~ 5 h ~ 0,5 h

Production start/stop ramp: > 5 h > 0,5 h

Tuning of process:

Required moisture level: 30 % H2O 23 % H2O

Energy consumption: 460 kW 195 kW

Investment cost: So Expensive Reasonable

Raw material cost: 100 % 75 ... 125 %

No. of operators required: 2 1

Comparison of main parameters (based on 800 kg/hr)

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Increasing line efficiency through new processing routes New strategy for chocolate mass production for growth markets

Mixing Prerefining Refining Conching

light conching ball miling mixing

Traditional

process

Alternative

process:

Ingredients:

cocoa liquor

sugar

milk powder

lecithin

cocoa butter

premium

chocolate

affordable

chocolate for

growth markets

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Nutrition

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The factory of the future needs to focus on nutritional value of food

Global view of undernutrition

http://www.fao.org/hunger/en/

Two billion people in the world suffer from various forms of malnutrition

The most common micronutrient deficiencies are: iron, iodine, zinc and Vit A

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Rice is the main staple in the world but generally consumed as white rice depleted of bran micronutrients

Data FAOSTAT, 2012

490 Mio tones of white rice

-32 % removal of husk

and bran

720 Mio tons

global paddy rice production

Global rice production and consumption

www.knowledgebank.irri.org/

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Although brown rice is richer in micronutrients from the bran most consumers prefer white rice

Neutral taste and appealing texture & color

White rice is shelf stable (brown rice becomes rancid)

White rice cooks quicker than brown rice

Removing the bran reduces contaminants (heavy metals, myxotoxins, etc. )

Tradition and eating habits

...although white rice is depleted from micronutrients.

Fortification is a possible solution to increase nutritional value.

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Fortification with micronutrients is one solution to improve rice nutrition

NutriRice™: recomposed fortified rice

developed in partnership with DSM

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But promoting underpolished rice would be a more sustainable solution for better nutrition

rice

kernel

Images published by Nadina Mueller-Fischer in ‘Nutrient Focused Processing of Rice.’ In: Agricultural

Sustainability. Eds: Gurbir S. Bhullar, Navreet K. Bhullar. Oxford, Academic Press 2012, pp 197 – 220,

50 µm

bran endosperm

severa

l w

hitenin

g &

polis

hin

g p

asses

to in

cre

ase

hig

h d

eg

ree

of

po

lish

(w

hite

ne

ss)

target today

white, but little

micronutrients

target in future?

less white,

but partial

retention of

micronutrients

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The factory of the

future produces

traditional food that

meets urban lifestyle

Imparting convenience

to maize

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Maize: most abundant cereal, but little direct use for food

(Ethanol, oils, etc.)

Global production

870 Mio t in 2012

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Imparting convenience to a traditional South African food

The goal:

A shelf stable flour,

but with 10 times

shorter cooking time

The traditional dish

Maize-based product

obtained by cooking of

coarse maize flour for

30 – 40 min

The challenge:

Industrial process to

add convenience to a

traditional product

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Traditional maize meal requires approx. 30min. 40 minof

cooking.

Instant / Quick Cooking maize meal requires approx.

3min. of cooking.

Shelf life > 6months; steaming at high temperatures during

process results in top Food Safety

Same texture, elasticity and mouthfeel as traditionally

prepared maize meal.

Initial target market

Urban middle class consumer with high quality

awareness.

In Africa for Africa

Instant / Quick Cooking Maize Meal. A Buhler Innovation (patented technology)

+ =

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Maize cleaning

Degerminator

grits

conditioning

Tempering

Drying + Cooling

Grinding

Packaging

Flaking

Steaming

Quick Cook / Instant Maize Porridge Process Flow.

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Flour Intake

Mixer

Feeder to Extrusion

Extrusion

Grinding

Sifting

Mixing Nutrients

Drying & Cooling

Packaging

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Food Safety

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Food Safety is the

game changer for the

factory of the future

From hygienic processing

environments of solutions

for making food safe

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Food Safety challenges and trends

Salmonella in dry food

Myxotoxins due to fungal infection New regulations

Changing food habits

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Food Safety concerns all factors along the value chain Pressure to act builds up from the end product / consumer side

Farmers Traders Agro-food Food Retailers Consumers/

convertors processors Society

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The big food & feed safety hazards

Pathogenic bacteria like Salmonella, Listeria, E. Coli, etc. that may lead

to food-borne diseases

Pest like insects, mammals, birds, etc.

Spoilage microorganism that lead to losses and waste.

Mycotoxin in food & feed due to mold growth

Undeclared allergens like gluten, nuts, soy, milk protein, etc. in food

Natural toxins like lectins in dry beans or glycocyanids in cassava

Chemical contaminants from environment, food contact material,

processing or adulteration

Foreign matter like glass, metal, plastic, wood, etc. in food

biological

hazards

chemical

hazards

physical

hazards

biological

hazards

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Controlling pathogenic bacteria in food processing

Stop

entrance

Avoid

growth

Avoid

transfer

• Hygienic design

• Keep dry (war on water)

• Cleaning & disinfection

• Factory design & zoning

• Air/ water/ waste management

• Hygienic design

• Packaging

• Personnel hygiene

• Process validation

• Cleaning & disinfection

• Hygienic design

• Raw material control

• Facility Design from

roof to drain

• Control access

Inactivate

or remove

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Hygienic design allows the timely and effective cleaning of the entire manufacturing

asset (equipment, infrastructure, building,…) and minimizes risks of product

contamination during the whole working life.

Hygienic Design from factory, over equipment to people

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Mycotoxins – the silent food & feed safety threat

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Mycotoxins :

Toxic to humans and animals

Found on 25 % of food crops

Relatively heat stable

legal limits

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Stabilization by drying

Field

Harvest

Collection Points

Drying

Transport

& storage

Mill

reception Milling

Food & Feed

Processing

optical sorting

Analytical monitoring

Mycotoxin control requires action at all stages of the value chain

? no decontamination

available to date

Safe storage

conditions

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Intelligent Processing

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1st industrial

revolution

4th Industrial Revolution

End of

18. Century

Introduction of

mechanical

production lines

2nd industrial

revolution

Begin of

20. Century

Mass production

of goods

3rd industrial

revolution

From 2020 Mid 70s

4th industrial

revolution

Automation with

PLC and

miniaturization

Autonomous control

and decision

making networks in

real time

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Intelligent Processing – On line Sensors

Online Particle Size Measurement.

Combines laser diffraction and image processing in one system.

Continuous online monitoring of particles in the range of 10-5000 microns.

Monitoring and control of grinding processes and product granulation.

Finished products with a consistent particle size distribution.

Detection of oversize grains.

Optical Sorting.

Optical sorting is used to remove defective material from good product.

Typical products: Cereal grains, pulses, nuts, dried fruit, frozen vegetables,

confectionary, seeds, coffee, plastics.

Types of defects: Colour, spot defects, geometry, near-infrared.

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Sensors • On-line

• In-line

• At-line

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Intelligent Processing – On line Sensors

NIR Multi Online Analyzer

1 spectrometer for up to 6 measuring

points (optical multiplexer).

cost reduction per measuring

point.

Parallel analysis of the raw

material, intermediate and end

products. Allowing smart and

continuous control of ongoing

production.

Applications:

Coffee online Degree of Roast

Hydroken sensor in Cocoa bean roaster

FineFilm / FineSense sensors on 5th roll

of 5Roll Refiner in Chocolate production

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Electronic evaluation system

PLC

Rpm control

Fineness

set value (µm)

actu

al finen

ess

Calculated rpm (min-1)

FineSens

1

2

3

4

5

Vario drive

Electronic evaluation system

PLC

Rpm control

Fineness

set value (µm)

actu

al finen

ess

Calculated rpm (min-1)

Electronic evaluation system

PLC

Rpm control

Fineness

set value (µm)

actu

al finen

ess

Calculated rpm (min-1)

FineSens

1

2

3

4

5

1

2

3

4

5

Vario drive

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Education

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Summary of Training opportunities

ON THE JOB TRAINING

TERTIARY INSTITUTION

SETA SPONSORED TRAINING

(JOINTGOVERNMENT/BUSINESS INITIATIVE)

SOCIAL RESPONSIBILITY TRAINING

Process core skills/ competencies

Process core skills/ competencies

Apprenticeship practical training

Lean Manufacturing Principles (theoretical and practical implementation.

Legal compliance training modules

Buhler Global/ DNA training (at overseas at benchmark plants)

Plant tours - academic students in Engineering etc, school-goers for practical insight into their studies.

Student programmes (joint y off-site theoretical and on the job practical blocks.

Process core skills/ competencies

Business-relevant tertiary qualifications (sponsored by Buhler)

Apprenticeship Theoretical training

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