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Edition 3/2015

performancePLUS: Effectiveness up, costs down

combidome 500 ml: perfect package for on-the-go products | Save time and costs with FDA master fi les | Malt beverages: energy without caffeine | From glass jars to carton packs: Waitrose opts for retortable carton pack

IMPRINT /// SIG COMBIBLOC MAGAZINE 3/15 Published by SIG International Services GmbH Rurstrasse 58; D-52441 Linnich Editors Carolina Boni, Ingo Büttgen, Beatriz Callanta, Margarita Maier, Luciana Galvão, Hanno Geissler, Claudia Lopez, Claudia Meza, Bianca Roßkopf, Heike Thevis, Areerat Wongsa-oun, Taube Zhou Concept and design SIG International Services Pictures SIG Combibloc Wolfgang Flamisch, René Schiffer Lithography Appel Grafik, Frankfurt Print Appel Grafik, Düsseldorf Contact T: +49 2462 79 -0 [email protected] Internet www.sig.biz SIG Combibloc Magazine is published in German, English, Spanish, French, Italian, Portuguese, Polish, Russian and Chinese. All rights reserved. Articles indicated as being contributed by other writers do not necessarily reflect the views of the publisher. No part of this publication may be reproduced or electronically distributed without the prior permission of the editorial team.

Dear Readers The demands on a modern fi lling company are growing – and as a result so are the demands placed on us as a manufacturer of machines and packaging material. It’s about much more than installing a machine, delivering the packaging material and servicing the machine as needed or providing spare parts. It has always been our aim to work in partnership with our customers and to be more than just a supplier of fi rst-class technology. This objective has prompted us to adjust our service portfolio in line with the current needs of the food industry. One result is our new, performance-based service agreement performancePLUS , which we present to you in this issue of our magazine. performancePLUS is a service and consulting package tailored to the individual needs of each customer, which makes our customers' production streams more transparent and more plannable, uses modern `lean' methods to enhance equipment efficiency, and lowers fi lling costs. Just a few months after starting, tangible results and noticeable cost reductions can be achieved. A further highlight from which our customers benefit is the new Stork UHT equipment in our combiLab. This highly-flexible system is ideally suited for trialling and test fi lling of new products in the aseptic carton pack. Using the service in our combiLab gives customers the perfect setting to develop and manufacture innovative product concepts under real conditions, and test the process and packaging technology in combination. We hope you’ll enjoy reading about this and other topics. Markus Boehm, Chief Market Officer SIG Combibloc

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Contents

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Perfect for on the go: combidome 500 ml Extaler-brand mineral water in combidome 500 ml.

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First nectars with fruit pieces in Latin America Brazilian company ebba launched drinksplus products in combiblocMini 200 ml.

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Save time and money with FDA master files Filling machines from SIG have ‘FDA master files’ – the best conditions for rapid acceptance by the FDA.

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From glass jars to carton packs: Waitrose opts for retortable carton pack Private label passata range now available in combisafe.

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Energy without caffeine: Malt beverages Beverage concepts with malt are gaining in popularity.

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Dos Pinos: First SIG customer in Costa Rica Central America’s largest cooperative opts for filling technology from SIG.

06 COVER STORY

performancePLUS – the performancebased service contract from SIG

With performancePLUS , SIG Combibloc offers a service package that boosts performance in its customers’ production operations and helps them achieve their targets.

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New UHT unit expands the possibilities in the combiLab A new heat exchanger unit supplied by JBT Corporation’s Stork Food & Dairy Systems, has been added to the equipment in the filling machine pilot plant.

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From the tree back to the tree US company ‘Drink Maple’ launched maple water from Vermont in combifitMidi.

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CO2- bonus for product and package: lupin drinks in carton packs Protein from sweet lupins as a GMO-free alternative to soybeans.

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News

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Perfect for on the go: combidome 500ml volume combidome, the carton bottle from SIG Combibloc, is available in a package volume of 500 ml – a perfect size for ‘on-the-go’ products. The company riha WeserGold Getränke GmbH & Co. KG now offers Extaler-brand mineral water in combidome 500 ml.

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Picture credit: Markus Blaickner

eople’s mobility behaviour has an impact on their consumer buying habits. What’s in demand right now is convenient ‘on the go’ products that people like because they taste good; that are healthy and nutritious and give consumers the good feeling that they have not been eating junk food. The packaging helps showcase products such as these to best effect. In this respect too, combidome does it all. combidome is ideal for drinking straight from the carton pack, because the 28 mm single-action screw cap is positioned centrally on the top of the pack – this creates the perfect angle to make drinking from the carton easy. Magarita Maier, Product Launch Manager Europe at SIG Combibloc: “Convenience remains one of the big issues for consumers when it comes to food packaging. Besides protecting the product, packaging needs to be easy to use, secure and give consumers peace of mind that they contribute to a sustainable environment. These are becoming increasingly important all over the world as more people are on the go, more often – whether it’s for work or leisure”. 4

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Message on a carton

The four display surfaces and the distinctive dome of the carton pack, which is made entirely from a cartonboard composite, can be fully printed, and thus used for the right ‘message on a carton’. This gives beverage manufacturers plenty of scope to communicate information and to attract consumers’ attention to the product. In this way, the design on the printed surface becomes the perfect complement to the unique shape.

riha WeserGold Getränke GmbH & Co. KG now offers Extaler-brand mineral water in combidome 500 ml.

Flexible as usual: one for all

A single combidome fi lling machine can be used to fi ll carton packs with volumes of 1,000, 750 and 500 ml. A volume change takes just a few minutes, offering manufacturers the option of positioning products in quantities that are tailored precisely to the intended target audience. Alongside this volume flexibility, the combidome fi lling machine, which can fi ll up to 12,000 carton packs per hour, also offers the design and product flexibility that customers have come to expect from SIG Combibloc fi lling machines. The product flexibility of the combidome fi lling machine provides the basis to implement modern concepts for products with low and high viscosity levels, right in line with current consumer trends.

Margarita Maier: “We believe combidome 500 ml is the ideal volume size for ‘on-the-go’ products – whether a manufacturer is looking to bring out breakfast drinks, premium organic products, smoothies, energy drinks or perhaps products targeted at specific groups such as health-conscious women or ‘Best Agers’ – it can be done efficiently, effectively, in a form that is readily marketable”.

Ideal volume size for on-the-go: combidome 500 ml. /// SIG COMBIBLOC MAGAZINE 3/15

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Picture credit: Empresa Brasileira de Bebidas e Alimentos

In September 2015, ebba started a comprehensive marketing campaign with TV-commercials and advertisements. 6

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First nectars with fruit pieces in Latin America Brazilian company Empresa Brasileira de Bebidas e Alimentos (ebba) launched fruit nectars containing real fruit pieces in combiblocMini 200 ml – an innovation for the South American market.

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ectars containing pieces of real fruit, packaged for long life in smallformat beverage cartons, are completely new in Brazil. “People have a totally new drinking experience when they try the nectars of the new ‘Maguary Pedaços’ product range. With every sip, consumers experience the unusual texture of the drinks. Real fruit pieces give them a particularly intense flavour”, says Fábio Levalessi, Commercial Director at ebba, the owners of the Maguary brand. The new nectars are available in Peach, Apple and Mango. The drinking straw, which can be used to drink the beverage straight from the carton pack, has an extra large diameter so the fruit pieces flow through perfectly. The products, available in major markets and supermarkets in Brazil, are rich in vitamins, making them a healthy alternative to snacks such as chocolate bars. The beverages are also perfect for carrying along and drinking on the move, and meet the tastes of children and adults. The market launch of the new products included a promotion and tasting at the PoS.

“Beverages with perceptible bits are attracting attention right around the world. With the drinksplus technology, beverage manufacturers are able to quickly and flexibly add healthy extras such as pieces of fruit and vegetables, coconut flakes or cereal grains to their beverages – matched perfectly to the tastes of modern consumers. These days, people want to eat a healthy and balanced diet, but they’re also looking for new taste experiences, moments of pure enjoyment and unusual textures. So beverage concepts with perceptible extras really tickle consumers’ tastebuds”. Maguary is one of the most popular brands in Brazil. The brand has been around for more than 60 years, and is Brazil’s market leader in the product segments juice concentrates and not-from-concentrate juices. With the market launch the brand is expected to win a notable share in the segment of ready-to-drink beverages.

Health and enjoyment

The Maguary products with real fruit pieces are made possible by the drinksplus technology from SIG Combibloc. Luciana Galvão, Head of Marketing at SIG Combibloc Americas: /// SIG COMBIBLOC MAGAZINE 3/15 

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performancePLUS – the performance-based service contract from SIG For a modern filling company in the food industry, the demands are growing all the time. With performancePLUS, SIG Combibloc offers a service package that boosts performance in its customers’ production operations and helps them achieve their targets.

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his is no ‘off the peg’ service offer, but a service package individually tailored to the customer’s needs, with the aim of increasing efficiency and reducing TCOs. With performancePLUS , SIG Combibloc offers its customers a logical next step in classic service benefits: a service agreement that assures the customer of improved filling line performance. Changing market requirements and growing cost pressure call for increasingly lean and efficient production. Every­thing needs to be looked at. Filling costs can only be significantly reduced through high production output and stability in the production process. Stable production processes also increase planning security in respect of operating costs. To assure this, SIG offers the new performancePLUS service agreement. How does performancePLUS work?

performancePLUS is based on a performancerelated payment model. The pricing consists of two components: a basic payment and a performance-related fee, which is linked to the jointly agreed performance target. Together with its customers, SIG will develop a resultsoriented package of technical and organisa-

tional measures that enhances performance in their filling operations. First of all, SIG conducts a preliminary analysis of the conditions on-site. An expert team made up of technical specialists, performance experts, microbiologists, service technicians and analysts from SIG Combibloc will subject the filling machines and related equipment to a thorough examination. This analysis covers all factors affecting the performance of the production process. In order to put together an efficient and effective performancePLUS service package, this analysis focuses on the technical setup, the production processes and hygiene measures, as well as the skills and knowledge of the machine operators and technicians. Based on this analysis, the current per­ formance (OEE – Overall Equipment Effectiveness) is determined and room for improvement in the production process identified. Together with the customer, SIG then defines a performance measurement system on the basis of which the agreed objectives will be measured. In line with this, SIG offers a made-to-measure service package that optimises the production process. The key elements are technical measures and organisational improvements,

performancePLUS : Effectiveness up, costs down • Planning security in respect of available capacity, machine efficiency, storage and line personnel required • Reduction of unplanned machine downtimes • Dependable performance and avoidance of overtime hours • Improved standard processes • Better technical understanding • Reduction of filling costs • Higher output with the same capacity

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performancePLUS Predictability and stability in your production process

Volatile line performance affects output and operating costs

TFC* with traditional service agreements

1,000 units

performancePLUS takes the uncertainty out of the ongoing operation and makes it more plannable

TFC* with performancePLUS

1,000 units

*Total Filling Cost (Filling costs per 1,000 units)

“performancePLUS service products for specific such as optimised routine increases planning customer groups. Our aim processes or extra training security and stability in is to have the right product for the customer’s emthe filling process. And this for every customer by ployees. If these measures means a more efficient the end of 2016. And we are imple­men­ted jointly, production and want to get as positive a SIG assures a specific inreduction of costs.” response as we've had with crease in per­­for­­mance. performancePLUS ”. performancePLUS is of inSebastian Klamke terest for a range of customer groups. From large companies that operate on an increasingly process-oriented basis and that manage production largely via key data, to small businesses that want to increase their production volume using existing filling equipment. Sebastian Klamke, Head of Global Service at For more information on performance PLUS, please contact: SIG Combibloc: “We’ll be developing further [email protected] /// SIG COMBIBLOC MAGAZINE 3/15 

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Interview with Sebastian Klamke, Head of Global Service SIG Combibloc, about the new service agreement performancePLUS .

»We have the impression that customers have just been waiting for an offer like this.«

Mr Klamke, what do you think characterises good customer service? Klamke: When a food manufacturer opts for SIG, then our goal is to enable that customer to make the best possible use of our technology. Our job is to advise, train and support the customer so that he can manufacture smoothly and with maximum effi ciency. Our customers’ success is as important to us as our own. So it’s also our goal, together with our customers, to rise to the current challenges and find suitable solutions. And because our customers’ products, factories and employees are unique, we take a very close look at each individual case. It’s against this background that we created performancePLUS, the latest service offer from SIG Combibloc. What’s so special about performancePLUS compared to other service offers from SIG? Klamke: Previously, we provided our customers with a good technical service and a reliable spare parts supply. There were also 12

service offers available for selected areas such as training or consulting. To keep up with the requirements of today’s market, the increasing cost pressure and increasing consumer demands, we needed new service approaches and offers. A first step in examining and optimising the production processes as a whole was our Operational Excellence Consulting (OEC). And now we’re going a step further: performancePLUS is no ready-made service offer, but a service package individually tailored to the customer, with the aim of increasing effi ciency and reducing TCOs. Following an extensive on-site analysis, we work together with the customer to develop measures for optimising his processes. If these measures are implemented, we assure the customer as part of the performancePLUS service package signifi cantly higher performance of his filling lines – increases of more than 5% are not uncommon. The customer pays for a specifi c level of filling line performance, and not for the carrying

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out of a specifi c service. Another difference from SIG’s existing consulting offer consists in that the customer not only is given suggestions, but will also be given all-round support in implementing any measures. Have you already had feedback on performancePLUS from customers? Klamke: The service package is designed especially for performance-oriented companies that work in a very process-oriented way and manage production largely via key data. We wanted to offer these customers a service package that's attractive for them and holds no risks. The first contracts have already been signed, and others are being negotiated as we speak. We have the impression that customers have just been waiting for an offer like this.

performancePLUS project with a Coca-Cola company Santa Clara, a Coca-Cola company, is one of the first customers who decided to improve the efficiency of their plant with performancePLUS .

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anta Clara is one of the most important customers of SIG Combibloc in Mexico. The Santa Clara plant is located in Pachuca City, 96 km north of Mexico City. The project started in April 2015 with an audit performed by SIG experts. The audit comprised three filling lines and the objective was to increase the OEE (Overall Equipment Effectiveness) to tap the full potential of the existing equipment. This was achieved by working closer with the customer, having a yearly maintenance plan, customer training program, and daily follow ups to avoid recurring issues. Although the project has not finished yet, the customer already benefits from the results: more output with the same equipment and a smooth production process. Francisco Muñoz, Santa Clara Plant Manager: "Since the start of the performancePLUS concept introduced by our exclusive aseptic equipment supplier SIG Combibloc, we feel both teams work closer together and put more attention to our day by day operation. Finding fast solutions to reoccurring issues over the

past years has been a challenging experience but we are convinced it has been the right decision for us looking at the already achieved and future OEE improvements. Even there are still problems which have to be addressed, the structured way how problems are analyzed and solutions are executed will help us to fulfill the demands in our fast-growing market."

Responsible for the performance PLUS project at Santa Clara (from left): Alfredo Reyes (SIG), Francisco Muñoz (Santa Clara) and Ferdinand Schneller (SIG). /// SIG COMBIBLOC MAGAZINE 3/15 

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Save time and money with FDA master files Filling machines from SIG Combibloc have what are known as ‘FDA master files’ and therefore have validated sterilisation processes. This offers the best conditions for rapid acceptance by the US food and health authorities.

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he USA requires compliance with strict rules and regulations when it comes to food production facilities and methods. In a wide range of food industry areas, the US Food and Drug Administration (FDA) is responsible for checking this compliance. That means before a food manufacturer can start producing a long-life food product in the USA, the manufacturing process and associated production facilities must be registered and tested for compliance. The FDA undertakes this task in the area of foods containing less than 2% dried or 4% fresh meat, and for products that will keep for an extended period without refrigeration and are low-acid, with a pH value of more than 4.6. In addition, the products must have a water activity of 0.85 or greater – that is, they must not be made non-perishable by dehydration (dried products). The production methods for long-life milk and soy beverages, which mostly go on the market in aseptic carton packs, are therefore among the categories that are subject to special mandatory validation of the manufacturing processes. This validation entails considerable time and expense, and involves a degree of uncertainty if the customer buys a filling machine and then has to have it validated on-site and submit the results to the FDA for approval. To save the customer this time and expense, SIG has applied for so-called FDA master files for its entire machine portfolio. For this purpose, complete machine series are pre-validated and the results submitted to the FDA. An FDA master file contains all information relating to the machine functions and the effectiveness of the sterility-related production processes that are used in filling low-acid products in aseptic carton packs. After reviewing the data, the FDA issues a compliance document – known as a ‘letter of non-objection’ – for the machine processes submitted.

Hanno Geissler, Head of Competence Pool Aseptic Processing and responsible for the FDA master files at SIG Combibloc: “By using the FDA master files, we can provide our customers with all the necessary data, information and supporting documents required by the FDA in connection with our filling machines. On the basis of this, food manufacturers can be assured of a safe and rapid start to production on filling machines from SIG Combibloc. Most of our filling machine models have already been presented to the FDA through their master files, and therefore are suitable both for production in the USA and for the production of products for import into the US market. They therefore have validated sterilisation processes, which offer the best conditions for rapid acceptance by the US food and health authorities. The FDA master files save our customers time and money”.

For more information on FDA master files, please contact: [email protected] /// SIG COMBIBLOC MAGAZINE 3/15 

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From glass jars to carton packs: Waitrose opts for combisafe Private label passata range now available in retortable carton packs from SIG Combibloc.

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aitrose is changing the packaging for its own label Passata range, from glass jars to SIG Combibloc’s heat resistant combisafe carton pack. The premium food retailer will now use SIG’s flexible filling technology and the retortable combisafe carton pack for its own label Passata with Basil and Passata with Garlic and Onion products, moving from 680 g glass jar to a 500 ml combisafe. John Vine, Waitrose Category Manager for the initiative, commented: “Switching to combisafe carton pack means we can now offer our discerning customers a lighter long-life alternative, which also guarantees first-class quality and product protection from our stores to kitchen cupboard storage.” The passatas will be filled by La Doria in Italy on food filling machines from SIG Combibloc. Through the use of three modular filling units a hugely diverse range of products can be filled in combisafe – the size and quantity of the chunky product ingredients can vary in virtually any respect and can be measured out precisely. After the products have been filled into the carton pack, which is open at the top, the carton top is sealed ultrasonically. The carton packs are then automatically conveyed into an autoclave. Package and product are sterilised together. In the area of carton packs for long-life food, the use of a rotary autoclave is a world first, delivering optimum temperature distribution inside the carton pack. Due to its rectangular shape, manufacturers and retailers, such as Waitrose, will benefit from maximised transportation and storage efficiency, and use of shelf space in the supply chain. combisafe carton packs fill up the available space on supermarket shelves around 30 per cent better than food metal cans, and also have high visual impact. SIG Combibloc offers a complete perforation opening for combisafe, which means the

Waitrose is changing the packaging for its own label Passata range, from glass jars to combisafe.

top of the carton pack can simply and safely be torn off by consumers, without the use of scissors. This allows easy pouring and even spooning to remove all contents from the carton pack, hence reducing food waste. John Vine: “The carton pack’s impact on the environment will also be an important factor both to Waitrose and our environmentally aware customers. The low weight of the carton pack, due to resource-efficient use of raw materials, plus the excellent environmental performance of the unprocessed cardboard, are major factors in why combisafe has the best environmental performance”.

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Deepanjan Roy, Managing Director at CHI Limited

Nigerian food manufacturer CHI Ltd. launched Hollandia-brand ‘Malt & Milk’ malt drink. 18

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Picture credit: monkeybusinessimages/iStock/Thinkstock

‘Hollandia Malt & Milk Drink’ combines the positive health associations of both milk and malt and is positioned as ‘The Great Naija Shake’. However, the Great Naija Shake is not just about Hollandia Malt & Milk as a product, but also about the active and adventurous lifestyle of the average young at heart Nigerian who is constantly looking for new things to explore. The Great Naija Shake nudges you to break out of routine and enjoy life in new ways. In other words, it’s premised on the view that magic happens when you shake up & find new ways of doing or expressing the seemingly ordinary things in life.

Energy without caffeine: Malt beverages Beverage concepts with malt are gaining in popularity: They promise plenty of potential because their are in line with two trends: they have less sugar and are based on natural ingredients.

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n the soft drink and milk drink sector, there are currently two trends that food manufacturers simply cannot ignore: as far as possible, beverages should be made 100 per cent from natural ingredients, and they should contain no added sugar. Against this background, malt beverages promise plenty of potential, because the products are in line with both trends. Especially in the Middle East, Africa and Southeast Asia, malt beverages are very popular. Malt can be used creatively in a huge variety of product formulations. So malt beverages can be positioned very widely. Kalayanee Poon-asawasombat, Ph.D., Head of Cluster Marketing Asia-Pacific South at SIG Combibloc: “In the beverage industry, manufacturers can give innovative extra value to products in a wide range of different segments using malt as an ingredient. Combinations of milk and malt are possible, as are formulations using fruit and malt, or yoghurt and malt. And malt extracts are also ideally suited for crossing with various natural flavours. Chocolate or coffee flavours are a perfect complement to malt, and it also combines well with fruit. There are all kinds of possibilities for healthy and delicious beverage creations, and right now they promise good prospects of success”. Malt is produced by germinating and drying cereal grains such as barley, wheat, rye or spelt in a malting process. For the subsequent processing into foods, the grains are crushed or ground. In food applications, malt is best-known world-wide for its use in making alcoholic beverages – primarily in /// SIG COMBIBLOC MAGAZINE 3/15

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“Manufacturers can give innovative extra value to products in a wide range of different segments using malt as an ingredient.” Kalayanee Poon-asawasombat

brewing beer. Malt is used in the production of whiskey as well. And it is also used as an ingredient in bread and pastries, sweets, and alcohol-free malt beer or so-called ‘Nährbier’ (nourishing beer). Another classic is the use of malt in breakfast drinks. The caffeine-free, sweet alternatives to coffee products are drunk not only by adults but by children as well. Brand names such as ‘Ovaltine’ (Ovomaltine in some European countries) and Horlicks are well-known players in the sector that have made a name for themselves in various parts of the world over many decades, with instant powder for malt drinks; but these branded beverages are also available as ready-to-drink products. In Vietnam, for instance, FrieslandCampina markets ‘Ovaltine‘-beverages in aseptic carton packs. High-quality protein

Malt beverages were originally strengthening, restorative products for growing children, as well as for sick people and the elderly. But 20

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athletes soon discovered the products as well. Malt beverages are a good energy source, because malt is packed full of vitamins, minerals, starch, protein and trace elements. The nutrients in malt beverages are quickly absorbed and processed by the body. Malt beverages, which naturally have a nutty-sweet, slightly buttery taste, are therefore an ideal source of energy for mental and physical activity. Due to the high-quality proteins, malt beverages can also alleviate stress. They are healthy and great-tasting alternatives to sweet and thus high-calorie soft drinks. Modern malt beverages in particular have the potential to sell well. They are best-sellers in countries where malt beverages have been popular for a long time, such as parts of Asia. But they are currently also fi nding their way into countries where malt is largely a newcomer – for example in the Middle East and Africa. In Nigeria, for instance, malt beverages are establishing themselves as popular thirstquenchers. Many people in the Middle East and Africa abstain from alcohol for religious reasons, but like the aromatic beer taste. The malt flavour is therefore extremely popular in these regions. New in Nigeria: ‘Hollandia Malt & Milk Drink’

The product concepts and innovations can often be customised to cater the taste preferences in the respective regions and the intended target group. For instance, with its ‘Hollandia Malt & Milk Drink’, Nigeria’s largest producer of Juice, Nectar, Still Drink & Liquid Dairy products, CHI Ltd., has its sights on dynamic consumers who are looking for natural, tasty and wholesome beverages to quickly and effectively top up the body’s own energy reserves between meals. ‘Hollandia Malt & Milk Drink’ is a ready to drink, premixed malt & milk combination that combines the energy of malt and the goodness of milk in one sip. Before now, consumers

mixed malt drinks with milk to get this rejuvenating combination. ‘Hollandia Malt & Milk Drink’ caters to this need gap in being the convenient premixed combination of malt and milk. The market launch of the new product in aseptic carton packs combiblocMini 200 ml is supported by TV clips. ‘MILO’: product classic in Asia

Sales of RTD malt beverages are continuing to see positive growth in Asia as well. In Indonesia and some other Asian countries, Nestlé has a best-selling chocolate-flavoured power beverage with barley malt on the market under the brand name ‘MILO’. Barley is particularly rich in fibre and Vitamin B. The product is aimed mainly at teenagers who need a healthy energy boost between meals. ‘MILO’ comes in carton packs with 125 and 200 ml volumes. Kalayanee Poon-asawasombat, Ph.D., from SIG Combibloc Asia-Pacific South: ‘MILO’ in carton packs has become a product classic. For many Asians, malt beverages are closely associated with positive childhood memories. And they want to pass that on to their own children. So now the next generation is also enjoying the delicious and nutritious drinks. ‘MILO’ also sells extremely well as an RTD product. They now fill the products on a CFA 124 fi lling machine from SIG – this machine can fi ll up to 24,000 carton packs per hour”. Natural power drink

Nestlé Indonesia offers ‘MILO’ - a special malt beverage for active children which is also the topic of an advertisement campaign.

And Vietnam too is emerging as a strong market for malt beverage sales. Kalayanee Poon-asawasombat, Ph.D.,: “Kantar Worldpanel has rated Tonic Food Drinks, to which malt beverages originally belong, as currently a ‘Hot Category’ in the cities of Vietnam. Since the second quarter 2014, there’s been significant volume growth in the double-digit percentage range, compared to the previous year – a volume plus of 38 per cent, for /// SIG COMBIBLOC MAGAZINE 3/15

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Picture credit: Jupiterimages/Stockbyte/Thinkstock; NutiFood

years old. With this target group in its sights, instance, for the 3rd quarter. In addition the carton decor is designed so that it to ‘MILO’ from Nestlé and ‘Ovaltine’ from FrieslandCampina, other customappeals to children and at the same ers have now launched malt time highlights the positive qualities of the product. beverages which will benefit The carton designs show from this positive market “Kantar Worldpanel active children playing development”. has rated Tonic Food popular sports such as NutiFood, for exdrinks – to which malt football, basketball and ample, has brought drinks originally belong – badminton, and name ‘NuVi’, a new RTD as currently a Hot the contents calcium, malt beverage for chilCategory in Vietnam.” Vitamin D, phosphorus dren, onto Vietnam’s and zinc for healthy supermarket shelves. Kalayanee Poon-asawasombat growth, as well as malt The product is available and Vitamin B for general in combiblocMini 125 and strengthening – at school, 200 ml. ‘NuVi’ is a natural and in your free time. The power drink that combines the market launch of the products is healthy nutrients from milk and accompanied by an array of marketing activicereal grains, making it ideal for growing ties such as online clips and advertising in children in particular. Core target group for super markets. the ‘NuVi’ beverages is children from 4 to 12

Ideal for growing and active children: ‘NuVi’ malt beverage from NutiFood, Vietnam. 22

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Picture credit: Super Corbis/F1online

‘Super SuSu’ from Vinamilk is positioned as "energy for the brain" and targeted at children between 4 and 12 years old.

Energy for your brain

Another new malt drink on the Vietnamese market is ‘Super SuSu’ from Vinamilk. Under the slogan ‘Super SuSu – Energy for your brain’, the chocolatey malt drink from Vinamilk is intended primarily for children between 4 and 12 years old who need an energy boost when learning. These beverages come in volume sizes of 125 and 200 ml in combiblocMini. The cartoon characters on the carton packs show sporty, smart active boys and girls, and express the idea that learning is fun with the right portion of energy. The market launch of ‘Super SuSu’ is also accompanied by TV commercials and promotional activities at the point-of-sale. Kalayanee Poon-asawasombat, Ph.D.: “Trying to make sure the foods you eat are as healthy and natural as possible is one of the major consumer trends that can be seen not just in Asia, but globally. Malt drinks are a healthy alter­

native to caffeinated and calorie-laden energy drinks. We expect that in the future a wealth of further malt beverages will appear on the market which explicitly contain potent substances from nature”.

Here you can find several examples of TV commercials: CHI/Nigeria: http://kurz.link/38X http://kurz.link/397 NuVi/Vietnam: http://kurz.link/398 SuperSuSU/Vietnam: http://kurz.link/399 /// SIG COMBIBLOC MAGAZINE 3/15 

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Dos Pinos becomes SIG’s first customer in Costa Rica

Picture credit: Dos Pinos

Central America’s largest cooperative opts for SIG Combibloc filling technology.

Production plant of Dos Pinos in Alajuela.

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roducts from Dos Pinos are the fi rst choice for consumers in Costa Rica, as the 2015 “Brand Footprint” annual report published by Kantar Worldpanel confi rms: 99.7% of survey participants said they had purchased products from Dos Pinos during the previous year. This successful cooperative – Central America’s and the Caribbean’s largest dairy company – has now become SIG's fi rst customer in Costa Rica. Costa Rica is a nation of milk drinkers, with an average annual per-capita consumption of 200 litres, putting the country third in 24

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Central and South America, close behind Argentina and Uruguay. This market environment, the product quality and consistent innovation make Dos Pinos one of the most important and well known dairy companies of Central America and the Caribbean. Dos Pinos was established in Costa Rica in 1947, when 25 dairy farmers combined to market their milk together to ensure fairer and more stable prices. The cooperative now counts 1,400 milk suppliers among its members. In Costa Rica alone it has 3,900 employees, with a further 600 in the surrounding countries.

It focuses on manufacturing high-quality Reliable partner dairy products such as milk, cheese, yoghourt, Gonzalo Chaves, CEO of Dos Pinos commented: “We strive to offer high-quality food, ice cream and butter. The umbrella brand “Dos which means we have to use the best quality Pinos” covers more than 600 different prodingredients and operate at the highest ucts. Dos Pinos has a presence in a totechnological level. We are confital of 10 countries in Central and Costa Rica dent that SIG Combibloc will South America, as well as the is a nation of milk be a partner that we can USA and the Caribbean. drinkers, with rely on in this context.” Its three production faThe first stage will cilities today process more an average annual involve installing a filling than 1.4 million litres of per-capita consumption machine CFA 712 at milk every day. The comof 200 litres, putting the the Alajuela location to pany’s portfolio now also fill combiblocSmall and includes non carbonated country third in Central combifitSmall carton packs. soft drinks in addition to and South America. At the beginning, they will milk products. Besides Costa fi ll 16 milk products in Rica itself, Dos Pinos markets combiblocSmall 250 and 330 ml, its products in Nicaragua, Honduas well as in combifitSmall 250 ml with ras, San Andrés, the Dominican screw cap combiSmart. In a subsequent stage, Republic, El Salvador, Mexico, Guatemala, Dos Pinos juices will also be fi lled in carton Panama and the USA, among others. Although packs from SIG. other private-label products are on the rise in For more information on Dos Pinos, visit these regions, consumers remain very loyal to www.dospinos.com. the Dos Pinos brand, recognizing it as the most loved and respected brand in Costa Rica in 2014 according to Saatchi & Saatchi. Dos Pinos’ corporate social responsibility strategy is supported by three pillars: Nutrition, support for socially vulnerable populations and sustainable environmental management. Dos Pinos has a raft of programmes Facts & Figures: Dos Pinos and projects in place to help its environmental balance – including extensive measures to cut emissions and adopt environmentally milk suppliers friendly means of processing waste water. Environmental management systems help to record and evaluate production processes, in Costa Rica and 600 in surrounding countries and then introduce measures to ensure the company’s environmental balance continues of milk can be processed every day in the three to improve. These efforts as well as projects production plants. in the other pillars place Dos Pinos as a top company regarding corporate social responsibility in different studies run by research are available under the Dos Pinos umbrella brand. agencies.

1,400

3,900 employees > 1.4 Mio litres > 600 products

/// SIG COMBIBLOC MAGAZINE 3/15

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Perfectly equipped for processing innovative products: the new Sterideal ST5T-SPEC UHT heat exchanger unit.

New UHT unit expands the testing possibilities in the combiLab A new heat exchanger unit supplied by JBT Corporation’s Stork Food & Dairy Systems business unit, has been added to the equipment in the filling machine pilot plant at SIG's combiLab. The state-of-the-art system is ideal for processing a wide range of innovative products before the beverages are then aseptically filled in carton packs from SIG Combibloc. 26 

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Picture credit: René Schiffer

I

n the combiLab, product developments such as new drinks­plus concepts, and developments relating to filling technology, are tested under real conditions. This service helps turn product ideas into success stories.

High degree of automation

The new Sterideal ST5T-SPEC UHT heat exchanger unit, supplied by JBT Corporation’s Stork Food & Dairy Systems business unit, adds to the facilities in the combiLab and complements the existing possibilities. Rudolf Flörke, Head of Aseptic Technology at SIG Combibloc: “The new Stork UHT in our combiLab is a higher performance model than our previous UHT system, and allows for the flexible requirements with regard to the heat treatment of a wide range of products. In addition, it has a much higher degree of automation. Customers who use our services in the combiLab will also benefit from these advantages, when they work /// SIG COMBIBLOC MAGAZINE 3/15 

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Picture credit: René Schiffer

Experts from all beverage sectors came together at the ‘BevTech Europe’ conference of the International Society of Beverage Technologists (ISBT).

“Customers who use

and are seeing very positive with us to develop and our services in the manufacture innovative combiLab will also benefit development. All kinds of new combinations are posproduct concepts under from the advantages of sible, and with our technolreal conditions, and test the the new UHT unit.” ogy they’re feasible as well”. process technology”. With Rudolf Flörke the new Stork UHT and its possibilities with regards to Close network of experts the aseptic fi lling of innovative The new Stork UHT has just been beverages with particulate content, showcased at the International Society the course for the future has been set. of Beverage Technologists (ISBT) ‘BevTech Dr Sven Fischer, Global Technology Director Europe’ conference, which was jointly sponat SIG Combibloc, adds: “Especially in the field sored by Stork and SIG Combibloc and was of beverages containing perceptible product held at SIG in Linnich (Germany). particulates – known as ‘inclusions’ – we The ISBT was founded in 1952 as a platform should expect quite a few things in the future. for information exchange and knowledge Beverages that you don’t just drink, but can transfer in the field of beverage technology. also in a sense chew, have now found their The association, set up in Washington, D.C., way from Asia into various parts of the world, now has more than 1,000 members. It is the 28

SIG COMBIBLOC MAGAZINE 3/15 ///

sectors of the beverage industry, and we’re only organisation in the world dedicated to the proud to offer our customers real added value scientific and technical aspects of the developwith a close network of noted experts”. ment, processing and filling technology, packIn the filling machine pilot plant of aging and distribution of non-alcoholSIG Combibloc's combiLab, the ic beverages. Its members include focus is on new product develbeverage technologists, scienopments and reworkings and tists and beverage manufac“We’re proud to further enhancements relatturers, as well as suppliers offer our customers ing to the aseptic filling systo the beverage industry real added value with tem, with testing under real engaged in technical and a close network of conditions. The aim is to scientific positions. noted experts.” quickly and flexibly test Dr Sven Fischer: “HostDr Sven Fischer proto­types of packaging ing this year’s BevTech materials, filling machines, Europe conference gave SIG carton packs and new product Combibloc the opportunity to concepts, perform targeted test series present our combiLab portfolio to a top-class professional audience, and closely and carry out test fillings, and provide autho­ linked to that we also showcased our experiritative information on the entire packaging ence and our current projects relating to the system and the filling process, for internal drinksplus technology. Using this technology, projects and for customers of SIG. The beverages containing up to ten per cent combiLab is extensively equipped for these natural particulates can be processed and purposes – with equipment for product proaseptically filled in carton packs using our cessing and aseptic filling machines for beverstandard filling machines for liquid dairy ages and food. Applicators for closures and products and non-carbonated soft drinks. In downstream equipment are also part of the the wide-ranging group of experts, we had range. brought together the right specialists from all Dr Sven Fischer: “We’re pleased to have been able to welcome many members of the ISBT, along with guests from our customer base. There was a lot of positive feedback for the mix of presentations, exchanges of expeAbout JBT Corporation's rience and insights into actual practice that we Stork Food & Dairy Systems were able to offer in our combiLab”. Main activities of Stork Food & Dairy Systems are the development, production and supply of integrated processing and filling lines for the dairy, juice, food processing and pharmaceutical (neutraceutical) industries. Stork Food & Dairy Systems are continuously expanding their experience and expertise in the areas of (aseptic) filling, (UHT) processing, plastic bottle making and packaging technology of liquid food products. www.sfds.eu

For more information on the services of combiLab, please contact Katja Saragazki, Global Marketing: [email protected] /// SIG COMBIBLOC MAGAZINE 3/15 

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From the tree, back to the tree: maple water in carton packs Maple water needs a packaging solution that is every bit its equal when it comes to naturalness – and so US company ‘Drink Maple’ launched maple water from Vermont in combifitMidi 1,000 ml.

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aple water, the lifeblood of juicy maple trees from the US state Vermont, needs a packaging solution that is every bit its equal when it comes to naturalness, believes ‘Drink Maple’. So this ambitious company from Massachusetts has now launched the new US trend beverage in carton packs from SIG Combibloc. The syrup boiled from the sap of the maple tree is popular all over the world. The fact that the original form, the pure maple water, is also a uniquely tasty, hydrating and revitalising source of nutrients is currently spreading like an insider tip among consumers with their finger on the pulse. Maple water has a high content of minerals, trace elements, antioxidants, polyphenols and electrolytes. Refreshing maple water is revitalising and nutritious. It has a strengthening effect on a range of organs and bodily functions, and is believed to make the skin radiant. The low-calorie natural tree water with a slightly sweet taste is now available in combifitMidi 1,000 ml and will appeal to health- and beauty-conscious consumers. 30 

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Kate Weiler and Jeff Rose, founders of ‘Drink Maple’: “Basically, maple water is the un-trendiest beverage you can imagine. Native Americans and teams of explorers who came to North America started tapping water from maple trees hundreds of years ago. These nature experts are the real discoverers of the many health-promoting benefits of maple water. It’s lactose- and gluten-free, has very few calories and contains 46 naturally occurring nutrients – for instance, it’s got more of the trace element manganese than a cup of kale. Manganese activates numerous enzymes in the body, strengthens the bones, and supports healthy thyroid function and blood sugar balance”. From one tree to another

In spring, the maple water starts to run in the trees. The nutrients that the tree has drawn from the ground and collected during the winter flow through the tree to the furthest tips of the branches. Kate Weiler: “That’s the moment when the liquid maple water is collected straight from the trees – in a

traditional and completely natural way, without harming the trees. Maple water and carton packs go together naturally in the truest sense of the word. It’s a harmonious overall concept for people who take their responsibility for their health and the environment seriously”. This is why carton packs are the perfect packaging for maple water. They are manufactured up to around 75 per cent from wood, a renew­able and sustainable resource. This reduces the consumption of fossil raw materials such as oil. And because trees absorb CO2 and release oxygen while they are growing, sustainably managed forests also help to protect the climate. More about Drink Maple at www.drinkmaple.com

/// SIG COMBIBLOC MAGAZINE 3/15 

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CO2-bonus for product and packaging: Lupin drinks in carton packs Protein from sweet lupins as a GMO-free alternative to soybeans.

Picture credit: Prolupin/Ansgar Pudenz

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The Sweet Blue Lupin (Lupinus angustifolius) is cultivated in MecklenburgWestern Pomerania – regionally and without genetic engineering. 32

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ith their white-flowering umbels, not only are Sweet Blue Lupins pretty to look at, but right now they are also attracting the interest of the food industry. Researchers from the Fraunhofer Institute for Process Engineering and Packaging (IVV) in Freising, Germany, and Prolupin have found a way to produce the unique, purely herbal lupin protein isolate (LPI), which is similar to animal proteins, from lupin seeds. The researchers received the Deutsche Zukunftspreis 2014 (the Federal President’s award for technology and innovation) for this innovative process. On the European market, the high protein content of lupins could make the plant a climate-friendly and GMO-free alternative to soy beans imported from Asia and South America. In Germany, the fi rst lupin drinks are now available in aseptic carton packs from SIG, under the umbrella brand MADE WITH LUVE (LUVE is an abbreviation for LUpins and VEgan). In ancient Egypt, Greece and South America, lupin seeds were considered a high-value staple food. However, because of the bitter compounds they contain, people lost interest in them. Through careful breeding, in the early 20th century the Sweet Blue Lupin with much lower alkaloid content was developed. With between 36 and 48 per cent protein content, lupin seeds are extremely high in protein, and in material composition they are similar to soybeans. Lupin seeds contain all the essential amino acids – including lysine. That makes lupin protein particularly high-quality. The fat content of lupins is four to seven per cent – so sweet lupins are

much lower in fat and have less allergy potential than soybeans. In addition, lupins are free from starch, cholesterol and gluten, and they are a good source of minerals and trace elements. Malte Stampe, managing director of Prolupin GmbH: “The seeds of the native Sweet Blue Lupin are the raw material for the protein, which we extract using a patented and very gentle process developed by the Fraunhofer IVV. In foods, milk, meat and egg can be replaced with the protein – making lupins of interest for vegetarians, vegans and anyone else who wants to eat a healthy, varied diet that is also climate-friendly. Lupins flourish particularly well in sandy soils such as those found in northern and central Europe – they can therefore be grown on the soils here, and also harvested and processed here. Lupins thus have a CO2 bonus compared to soybeans. We don’t need to fly the lupins halfway round the world, thus avoiding the CO2 emissions generated by long transport routes. And lupins are even good for the soil, enriching it with nitrogen”.

Picture credit: Prolupin/Angelika Heim

Lupin seeds With between 36 and 48 per cent protein content, lupin seeds are extremely high in protein. They contain all the essential amino acids and are a good source of minerals and trace elements. With a fat content of four to seven per cent, sweet lupins are much lower in fat and have less allergy potential than soybeans. Lupins are free from starch, cholesterol and gluten.

With the ‘MADE WITH LUVE’ product range, Prolupin is targeting not just vegans, but all health-conscious consumers.

CO2 bonus for product and packaging

With the ‘MADE WITH LUVE’ product range Prolupin is targeting not just vegans, but all health-conscious consumers. The product range includes lupin drinks, ice cream, desserts, yoghurt alternatives, pasta, spreads and mayonnaise. Malte Stampe: “We decided to bring out our lupin drinks in carton packs. The carton packs from SIG Combibloc safeguard the quality of the beverages, and are gentle on the environment – just like our lupin products. Carton packs are composed on average up to 75 per cent of wood, a renewable resource. That means they use much less fossil resources such as oil, than products like PET bottles. In addition, while they’re growing, trees absorb CO2 and give off oxygen. So sustainably managed forests help protect the climate. For this reason, we think lupin drinks and carton packs fit together very well, and consumers fi nd them easier to handle than competing products”. /// SIG COMBIBLOC MAGAZINE 3/15

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NEWS Coffee Mate in carton packs successful in Mexico Nestlé Mexico has once again expanded its best-selling range of popular coffee creamers in the aseptic carton pack from SIG – a true success story. What started in summer 2013 with three varieties of the popular Coffee Mate products in combifitMidi 500 ml now includes 10 different flavours, which are offered in 500 and 750 ml volumes. More flavours are in the pipeline. All varieties are free from lactose and cholesterol, and are therefore very well-tolerated.

Sunkist’ smoothies with bits of fruit Korean producer Haitai Beverage has now launched two ‘Sunkist’ brand premium smoothies in the aseptic carton pack combiblocMini 200 ml. Part of the ‘My Real Smoothie’ range, the drinks are available in Apple/Mango with apple bits, and Strawberry with peach bits. The pieces of fruit give the smoothies a very special texture and authenticity, and offer an unusual drinking experience. With the market launch of these smoothies, Haitai Beverage is introducing Korea to another premium product in the new product category of drinksplus products with perceptible added value.

USA: Cocktail Mixers in convenient carton packs Powell & Mahoney Cocktail Mixers – in collaboration with Leahy-IFP Co. – introduces a new line of foodservice packaging. Powell & Mahoney Cocktail Mixers are now available in combiblocMaxi 1420 ml, making it affordable, quick and easy for bartenders to create consistently enjoyable cocktails anytime, anywhere. The products are available in Margarita, Peach Bellini and Bloody Mary flavours – and more are set to follow.

www.youtube.com/user/CappyEgypt

Huiyuan exhibits combidome at EXPO in Milan Chinese Huiyuan Group is participated at EXPO 2015 in Milan, Italy. From May 1st up to October 31st the company also showcased a breakfast juice in combidome.

Picture credit: Huiyuan

Egypt: Coca-Cola opts for the carton pack Since August 2015, Coca-Cola Egypt has offered its Cappy-brand juice drinks and nectars in carton packs from SIG Combibloc. The beverages are available in the small-size combiblocMini carton pack and in the 1-litre format combifitPremium. This is the first time Coca-Cola Egypt has opted for carton packs. Previously, the products were sold in Egypt only in PET bottles. The market success that other Egyptian beverage manufacturers have enjoyed with their products in carton packs prompted Coca-Cola to include the aseptic carton pack in its own packaging portfolio. The launch of the Cappy products in the carton pack was accompanied by a wide-ranging marketing campaign.

Given the international center for economy, culture, and fashion, Huiyuan believes Milan Expo is the best platform for the Group to present its brand and products to the World. Over a six-month period, Milan Expo 2015 was a global showcase. More than 140 participating countries show the best of their technology. In addition to the exhibitor nations, the Expo also involves international organizations, and expects to welcome over 20 million visitors to its 1.1 million square meters of exhibition area.

Bangladesh: PRAN expands production capacity PRAN, the leading beverage manufacturer in Bangladesh, is now expanding its production capacity with another filling machine from SIG. PRAN has been a customer of SIG Combibloc since 2010. The first two CFA 112-32 filling machines started production in 2011. The company uses them to fill non-carbonated soft drinks and milk drinks in the combiblocMini carton pack. At the beginning of 2015, a further CFA 112-32 filling machine was installed at PRAN. The company aims to use the flexible filling machine technology and the support provided by SIG to bring out further innovative products and to grow locally and globally. In Bangladesh, PRAN wants to grow in particular in the milk-mix beverage category.

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