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RESEARCH STRATEGIES FOR DIARY INDUSTRY IndustrY research requirements and future technological trends The activities of the diary focus group Emilia-Romagna Region This publication was realized by ASTER Science Technology Business in collaboration with SIQULIACA and with the support of the EmiliaRomagna Regional Ministry for Productive Activities, Economic Development and Telematic Plan. All information here reported was collected either directly or from previously published sources. Special thanks go to the Enterprises, the Academic Research Groups and to the Laboratories of the Emilia-Romagna High-Tech Network, for their partaking in the activities of the Diary focus group: ACMA S.P.A. CONSORZIO DEL PARMIGIANO REGGIANO GRANAROLO S.P.A. ORLANDINI S.A.S. PARMALAT S.P.A SYMPAC CORAZZA TERMOCONTROL S.R.L. SIQUAL TECAL UNIVERSITÀ DI BOLOGNA Dipartimento Di Biochimica “G. Moruzzi” - Centro Ricerche sulla Nutrizione e Vitaminologia UNIVERSITÀ CATTOLICA DEL SACRO CUORE, PIACENZA Istituto di Microbiologia Published in Bologna – December 2007 – 1st edition Realizzazioni grafiche I MUSICANTI NON DORMONO MAI [email protected] INTRODUCTION - SIQULACA – Regional Centre for Innovation, Safety and Quality in the Dairy Industry, coordinated by the Animal Production Research Centre of Reggio-Emilia (CRPA) - SIQUAL – Regional Laboratory for Food Safety and Quality, coordinated by the University of Parma, with facilities in Parma, Modena, Reggio-Emilia, Bologna and Piacenza - TECAL - Networked Laboratory for the Food Industry Technologies and Systems, coordinated by the University of Parma, with facilities in Parma, Modena and Bologna This document summarizes the main outcomes of a group discussion focused on the Emilia-Romagna dairy sector. A restricted number of regional enterprises, representative of the Emilia-Romagna dairy industry, including both sectors of products processing and dedicated machines manufacturing, have been invited to express their position on the scientific and economic challenges they meet on the way towards innovation and development of new products. Researchers from regional academic institutes and leading actors of the Agro-Food Laboratories of the Emilia-Romagna Hi-tech Network have been also invited to take part to the discussion, in order to draw possible scientific solutions on the basis of their competences. The focus group initiative, recently launched by Aster, consists in a series of guided discussions conceived to explore, in a group setting, what participants think and how they feel about previously decided themes. Participants to the group discussions are regional enterprises and academic research actors, gathered in order to find a common way to overcome the perceived bottlenecks in the development pathway of a specific industrial sector. Three focus groups on the Mechanic, Food and Life Sciences sectors have been already carried out and others will be established in the near future. The working group activity was organized by Aster in cooperation with the Regional Centre for Innovation, Safety and Quality in the Dairy Industry, SIQUILACA. The activities were conducted by meanss of the focus group methodology, with the major goal of improving the dialogue between enterprises and researchers and to speed up future interactions. THE RATIONALE FOR THE DAIRY SECTOR AND THE FOCUS GROUP OBJECTIVES THE CONTEST AND THE “FOCUS GROUP” METHODOLOGY The whole food and drink sector plays a fundamental role in the Emilia-Romagna economy. In the last years, Emilia-Romagna Government’s overall strategy has been strongly intended to support Industrial Research and Technology Transfer, with the main purpose to invest in the knowledge and innovation-based development of the regional production system. ASTER contributes to this policy plan by promoting the co-operation between universities, research centers, enterprises, financial markets and consulting services, so as to establish a regional framework where human resources can be reinforced and knowledge can be spread out and integrated. In particular, the dairy sub-sector occupies a predominant position thanks to the variety of companies present on the territory: from large companies employing a large number of persons, to the several enterprises manufacturing machines for milk and milk products processing, to the numerous micro businesses, cooperatives and related consortium, typically manufacturing Protected Designation of Origin (PDO) products. This dynamic and varied reality pushes the Emilia-Romagna region at the top positions in the Italian dairy market scale, especially with respect to the milk production (see table below). Since 2004 Aster has been coordinating the creation of the EmiliaRomagna High-Tech Network, connecting scientific competences, which share human resources and advanced instrumentation. Since 2005, thanks to the Regional Programme for Industrial Research, Innovation and Technology Transfer (PRRIITT), 4 laboratories and centers focused on the Agro-Food sector have been created. Moreover, one laboratory owing to the HI-MECH District, was created for the study and development of advanced mechanics for food processing. Among these, there is one centre that is specifically focused on the dairy sector and two laboratories whose research activities are strictly connected to this sector: Emilia-Romagna (tons) % Emilia-Romagna with respect to Italy Milk Butter Cheese 599.533 38.903 158.780 20,8 32,5 13,8 Table 1. Industrial production of milk, butter and cheese in Emilia-Romagna (tonns). Source: ISTAT 2006. III between package manufacturing enterprises and end utilizers, leading to a major consciousness about potentially toxic breakdown chemicals migrating from packages into food matrix. Shelf-life is becoming increasingly significant in response to changes in current consumer demand and as a consequence of the modern wholesale distribution requirements. The dairy industry in Emilia-Romagna is markedly subdivided into two different realities: on the one hand, the Parmigiano-Reggiano district, encompassing small-micro enterprises spread over the provinces of Parma, Reggio-Emilia, Modena and Bologna on the left side of the Reno river; on the other hand, milk and other dairy products supply-chain, dominated by few large companies, such as Granarolo and the internationally oriented group of Parmalat . This trend forces enterprises to direct their interests towards intelligent packaging technologies and smart package devices aimed at maximising product shelf-lives, including antimicrobial active packaging, altered atmosphere, innovative technologies and more accurate and less expensive analytical systems for microbial assessment. Keeping this in mind, the main objectives of the dairy focus group are: 1. to identify challenges facing the dairy sector, that can be appropriately highlighted through the voice of a group of companies, representative of the Emilia Romagna area; 2. to evaluate some of the current barriers and constraints to the dairy industry development and innovation and to draw possible solutions; 3. to raise awareness of the results achieved, producing a document which can be used as a driver for future regional policy. Finally, waste prevention by changing the design or choosing biodegradable materials, leading to the reduction of the amount and toxicity of the waste eventually generated, is also a point of emerging interest in the contest of constantly increasing sensitivity to environmental impact of solid waste generated by human activities. THE DISCUSSION THEMES AND RELATED INDUSTRY REQUIREMENTS Dairy products as functional foods “Functional Foods” are foods or dietary components that may provide a health benefit beyond basic nutrition. Milk and deriving products, such as yogurt and cheese , constitute one of the most important types of functional food. Key dairy ingredients for functional benefits cover calcium and phosphorus minerals, probiotic micro-organisms, prebiotic oligosaccharides and bioactive peptides. Four technical themes have been identified and discussed: 1. Packaging of dairy products 2. Dairy products as functional foods 3. Raw milk, derived products and processing procedures safety assessment 4. Cheese protelysis Packaging of dairy products The Parmigiano-Reggiano, to the production of which is directed almost the 80% of the entire milk production in Emilia-Romagna, is a suitable example of a dairy functional food. Indeed, the high calcium bioavailability, the presence of bioactive peptides and the possibility to regulate production processes in order to reduce sodium and saturated fatty-acids concentrations, make this famous “typical” product a perfect candidate for the nomination to natural functional food. Packaging technology must balance food protection with other issues, including energy and material costs, heightened social and environmental consciousness, and strict regulations on contaminants. As a consequence, several aspects should be taken into account when considering this theme. First of all, sanitary and safety impositions drive industry investments towards emerging automated sanitizer technologies for industrial machines, in order to guarantee an increased end product quality and to reduce costs afforded by enterprises. Small enterprises of the regional Parmigiano-Reggiano district should work in close connection with researchers and universities in order to acquire major consciousness of these healthy aspects and to be able to adequately promote the nutritional properties of their product. On the other hand, food manufacturers developing new dairy products, free from the specifications for Protected Designation of Origin (PDO) products, have wider boundaries for the creation of new products with healthy properties. Secondly, great interest has been arising from the study of new materials and accessory devices, with the aim of minimizing food contamination, of extending food shelf-life and of improving nutritional and organoleptic properties. Food safety should be supported by a more active cooperation IV - adaptation of innovative technologies, already employed in other contests of the agro-food sector, to the dairy industry; personnel training with special regard to good practises, and safety policies. Nonetheless, the institution of the European Food Safety Authority (EFSA), with the major role to assess the risk regarding food and feed safety, and the recent changes in the European food laws affecting label and product claims, together with a general rising awareness of the relationship between diet and health, has increased the industry demand for scientific and clinical studies. Both small enterprises and large companies expressed the urgent need for improving relationships among all the actors of the supplychain, with the aim of providing a more effective production and reaching higher standards of final product quality. Integrating technological competences with biologic, nutritional and medical aspects is not only an imposition of the new European directives in matter of food labelling, but it also becomes a marketing strategy to better respond to the increasing consumer interest in attaining wellness through diet. Cheese proteolysis Proteolysis during cheese ripening has the important role of forming the texture, body and flavour of all matured cheese. The process involves a number of biochemical reactions which are determined by enzymatic systems present in the milk and in the rennet, by the milk natural microflora and by whey starter bacteria. Raw milk, derived products and processing procedures safety assessment Milk and dairy products are among the most controlled foods in the agro-food sector. The process involve all levels of the supply chain: from controls conducted in the feed-stuff factories, through the monitoring of raw materials, to the regulations for processing and distribution. The innovation opportunities for the dairy industry are indissolubly linked to the nutritional and sanitary quality of the raw milk used as feedstock for processing operations and to the safety of the environmental conditions in which it is produced and processed. Proteolysis may result in positive or negative modifications of initial substrate, deeply modifying nutritional and organoleptic properties of the final product. Among non-desirable modifications can be cited rheological faults, unpalatable organoleptic attributes, the formation of toxic breakdown molecules. Among desirable effects, the formation of bioactive peptides which increase the cheese nutritional value thanks to the reported influence of these molecules on human health. Technical approaches at the base of control analyses include physicochemical and microbiological analyses, contaminants detection, processing parameters registration, tools for rapid and accurate tracing of food through the production and distribution chain, analyses for nutritional value assessment and “on farm” quality controls. The study of enzymatic modifications generated by the proteolytic process and the comprehension of the relationship existing between the expression of these modifications and the quality of the end-products, are a wide field of investigation toward which enterprises must direct their interest in order to optimize dairy production. Industry investments in this sector are principally directed towards the development of new technologies in order to quickly, easily and effectively support the quality assessment support. Special interests include biosensors for mycotoxins or environmental persistent pollutants detection, which nowadays are still provided by means of complicated and expansive methodologies and the employment of robots for the monitoring of production procedures. With regard to the Parmigiano-Reggiano production, controls on raw milk are typically commissioned to private laboratories and to the Parmigiano-Reggiano Consortium. Enhanced nutritional and organoleptic properties resulting from cheese proteolysis are strictly dependent on the possibility to adequately control the action and interaction of factors influencing the specific enzymatic activities, such as the moisture content of cheese, pH values, salt content, temperature, etc. The possibility to drive the proteolytic process toward desired modifications by minimizing undesired effects, must pass through the investment in innovative technologies. Two are the crucial aspects on which dairy farmers can operate: 1. quality and quantity of proteolytic agents; 2. environmental conditions both before and during ripening. Scientific interests in this contest are principally linked to: - development of innovative, self-cleaning, cost-effective automated machines; Big companies, whose ripening-stores are usually equipped with automatic machines, are looking at the acquirement of new V - dedicated softwares for the on-line monitoring of environmental parameters. In smaller enterprises the human work is still the decisive factor influencing the ripening results. In this contest, industry interests need to be addressed toward cost-effective technologies for an automated management of the process and consequent adequate personnel training. Development of new survey tools and support services and update of existing ones such as a new methodology for milk payment proportionate to quality expressed by presence and quantity of bacteria and new tools for production process control. Coordinated by: CRPA spa, Animal Production Research Centre CONCLUSIONS The focus group allowed the industrial actors to interact directly with researchers, giving insights on some of the actual challenges faced by regional dairy industry. In turn, the presence of university researchers provided quick and tailored answers and clarifications to the issues raised by enterprises. For more information: http://www.aster.it/siquilaca.html DAIRY ENTERPRISES PARMIGIANO-REGGIANO CONSORTIUM In 1928, based on the proposal made by the Association of Entrepreneurs and the Provincial Council for Corporate Economics (Chamber of Commerce) of Reggio-Emilia, the voluntary Consortium for the protection of the Grana Reggiano (Reggiano Hard Cheese) was established. After receiving the official legal approvals, the Consortium, whose denomination is now "Consorzio del Formaggio Parmigiano-Reggiano", was joined by all manufacturers and carried on with renovated vigour its protection activity that still characterises it today. Moreover, the concurrent presence of big industries and of the Parmigiano-Reggiano Consortium in representation of the numerous micro-enterprises dedicated to its production, allowed the highlighting of both divergences and possible convergences in the industrial perspectives and technological needs of the two different realities. In this context, the role of integrating structures like ASTER and SIQUILACA for the promotion of specific initiatives, addressed to facilitate the dialogue between academy and industry, resulted of crucial importance. The Consortium's tasks were (and are): the defence and protection of the Designation of Origin, the facilitation of trade and consumption by promoting every initiative aimed at safeguarding the typicality and unique features of the product. The focus group experience is only a starting point for future synergies and co-operations aimed at enhancing the competitiveness of the regional dairy productive context. The results here reported are not intended to be exhaustive. Rather, they represent the initial stage of a more structured process to be improved in the next future and hopefully supported by local, national and European policy actions. One of the most important measures adopted by the Consortium with the aim of protecting the product sales was that of introducing in 1964 the mark of origin of the dotted inscription "ParmigianoReggiano" encircling the wheels, thereby conferring to the cheese its current external appearance. THE FOCUS GROUP ACTORS The consortium groups the Parmigiano-Reggiano production small and micro enterprises (445 in 2007) dislocated in the province of Parma, Reggio-Emilia, Modena, Mantova at the right side of the Po river and Bologna at the left side of the Reno river. THE COORDINATOR SIQILACA - Centre for Innovation, Safety and Quality in the Dairy Industry Activities focus on creating innovative tools and services with the objective of guaranteeing the production of high quality and hygienically safe Parmigiano-Reggiano cheese. Specific actions in support of the introduction of new methods include: - Provision of information related to the use of newly developed techniques for the direct identification of bacteria occurring in milk; For more information: www.parmigiano-reggiano.it GRANAROLO S.P.A. Granarolo counts 10 productive sites wide distributed on the national territory, with around 1.900 employees and a turnover of more than 950 million of euros. Besides preserving and reinforcing the leadership in the fresh milk VI and biological products market, with the acquisition of Yomo, Granarolo is also the most important Italian producer of yogurt. Moreover, the company is the principal follower in the markets of the UHT milk, of the fresh or for-cooking use diary products and of the ready- meals. Parmalat is a company with a strong innovative tradition: the group has been able to develop leading-edge technologies in the driving sectors of the food market, particularly in UHT milk, ESL (extended shelf life) milk, functional milks, fresh fruit juice-based drinks, functional fruit drinks and cream-based white sauces. The company was born in 1957 from a small cooperative situated in the close proximity of Bologna, under the control of Granlatte, the agricultural cooperative, together with which it constitutes the most important Italian dairy supply-chain, directly participated by associated producers. For more information: www.parmalat.com INDUSTRIAL MACHINES MANUFACTURE ENTERPRISES ACMA SPA Acma SpA is a company known throughout the world and can boast an experience of 80 years of design, production and trading of machines for packaging foodstuffs, confectionery products, detergents, cosmetics and liquids all told. Since the early ‘90’ s, the Group has being structured into two separate but converging realities: a cooperative of milk-producers (Granlatte) - that work in the agricultural sector and collect the raw milk - and a joint stock company (Granarolo S.p.a.), dipped into the dynamics of the wholesale distribution and dedicated to the product processing and marketing activities. The Mantua Liquid Division - specialised in the production of net weight fillers, automatic capping machines, monoblocs and labeling technology - caters for the liquids sector seen as a whole (beverages, dairy products, personal care, chemical products etc.). Nowadays, the Group is a solid point of reference for agricultural and zootechnical enterprises in Italy and represent one of the most important national alimentary group. Acma possesses the experience and the resources needed to offer a complete engineering service for providing turnkey bottling and packaging systems. Per informazioni: www.granarolo.it PARMALAT S.P.A In the case of food products, ACMA cover milk; dairy products; beverage; edible oil and sauces. Parmalat S.p.A. is a new company, established on October the 1st, 2005 and lead by the CEO Enrico Bondi. Parmalat Group is one of the major players worldwide in the production and distribution of milk, mainstream dairy products (yogurt, cream-based white sauces, desserts, cheeses) and fruit-based drinks, with 2006 revenues of over 3.8 bln. For more information: www.acmagd.com SYMPAC CORAZZA Application sectors covered by Sympac Corazza include dairy industry (in particular for processed, cream and fresh cheese production, butter and margarine), soup cubes and yeast The group is present in twelve core countries, across five regions (Europe, North America, Central and South America, Australia and South Africa). On December 31st, 2006, the total number of employees, including only integrally consolidated companies, was 15,475. Products and services include: - Dosing and wrapping machines for triangular and square processed cheese portions in a range from 10 to 500 gr. and further packaging into round boxes or cartons of different shapes - Complete line for dairy industry, including processing equipment supplied by our German sister company - Complete lines for dosing and packaging paste soup cubes - Machines for dosing and packaging butter portions up to 250 gr.Line Engineering e assistance for overhauling and optimizing complete lines for dairy industry applications Parmalat ranks among the leading players worldwide in the UHT milk market and in the functional milk segment and has attained a significant competitive position in the expanding market of fruitbased beverages. The group enjoys a strong brand awareness. The company’s brands portfolio includes, as a global brands, Parmalat and Santàl, as international brands Zymil, Fibresse, Physical, Jeunesse, Omega3, First Growth, Smart Growth, Ice Break/Rush as well as strong local brands. For more informations: www.corazza.it VII ORLANDINI S.A.S. well as to provide reliable information for the consumers. Orlandini s.a.s is based in Reggio-Emilia: the firm designs and produces complete systems for dairies with the latest technology and certified production cycles. It specialises in the installation of milk processing machinery, the production and maintenance of heating systems for dairies, the production and maintenance of milk floatation and transportation systems and the design and construction of salting systems. It handles the sale, installation and repairing of double-bottomed vats, steam generators, cream skimmers, mixers, floatation and salting tanks, trolleys and consumables for dairies. Orlandini also specialises in the maintenance and repairing of systems and apparatus; it is experienced in the modernisation of existing systems as well as the supply of new equipment. Moreover, Orlandini specialises in the SALTING of Parmigiano-Reggiano: its modern dipping system handles the filtration, circulation and refrigeration of the brine, ensuring perfect and effective salting of the cheese. Orlandini S.a.s: handles the distribution, installation and servicing of its entire product range. For more information: www.orlandinisas.it TERMOCONTROL S.R.L. In particular, the Regional Laboratory is developing methodologies at high technological levels, exploiting new achievements obtained in chemistry, molecular biology, genomics, proteomics, nanotechnologies, microbiology, etc. The research is currently organised in four main projects: - Development of innovative screening methods for the detection of pesticides, mycotoxins, pollutants and phyto- and zooresidues such as biosensors and micro-arrays, chromatographic techniques and mass spectrometry; - Detection of new and emerging pathogenic micro-organisms in food products, with particular regard to the emerging phenomenon of antibiotic-resistance; - Study of the functional properties of foods, modification of the nutritional value and development of xenobiotics during the industrial processing and domestic storage. Particular attention is paid to the identification of allergens in food products with the aim of complying with the new EU-labelling regulations and of developing ipo-allergenic technological processes; - Molecular characterization of traditional products, authenticity, identification and preservation of autoctonous microorganisms in typical products, detection of GMOs, sensorial properties and consumer science. Termocontrol is located in S.Giovanni in Persiceto (Bologna). Coordinated by: University of Parma, Department of Organic and Industrial Chemistry Termocontrol produces monitoring and detection systems for dairy industries, mainly directed to cooked cheeses, as ParmigianoReggiano. For more information: http://www.aster.it/siqual.html Termocontrol commercializes the first licensed, easy and reliable automated system for the production method control and for the traceability of industrial processes. For more informations: www.termocontrol.com EMILIA-ROMAGNA HI-TECH NETWORK LABORATORIES SIQUAL - Regional Laboratory for Food Safety and Quality The Regional Laboratory is aimed at performing research on the most relevant topics related to food quality and safety. Its mission is to represent a reference point for industries and control institutions involved in the production and distribution of food, as TECAL - Networked Laboratory for the Food Industry Technologies and Systems The laboratory was created with the two-fold objective of coordinating technological research relative to food production processes and plants, and of becoming a technical-scientific centre of excellence promoting the competitive development of the food engineering industry in Emilia-Romagna. Research focuses on: 1. The development of highly innovative food processing technologies such as optimisation of aseptic systems to improve food safety, high-pressure treatments, ultrasound sterilisation processes, extrusion process modelling, food product conditioning and packaging, and VIII - derive from Brassicaceae and Lamiaceae edible plants; - evaluation of the effects of phytosterols on cholesterol biosynthesis; - effects of n-3 polyunsaturated fatty acids on cholesterol biosynthesis; - n-3 polyunsaturated fatty acids in cardiovascular prevention: - regulatory effects on blood pressure; - antioxidant and molecular effects of green tea; - nutritional evaluation of the modification occurring in food after treatment with innovative, non-thermal processing. thermal process optimisation The development of cost-effective traceability methodologies for the procurement of raw materials and the distribution of finished products The laboratory researchers are currently working on three main projects: - Optimisation of food industry aseptic processes Innovation and improvement of alternative food processing technologies including the use of high pressure in the treatment of liquid foods and optimisation of thermal processes - New technologies and processes for the automation of food traceability along food supply chains through re-engineering of traceability logistic processes, UHF radio-identification systems for traceability of certified products (e.g. PDO products such as Parma ham) and development of electronic and optical sensors For more information: www.foodsci.unibo.it UNIVERSITÀ CATTOLICA DEL SACRO CUORE OF PIACENZA Microbiology Institute Microbiology Institute at UCSC has been active in dairy microbiology research since the last 50 years.A special efforts, since the beginning of the ‘80s, has been paid by the Istituto, to the assessment of functional properties of dairy foods. This pioneering work has been supported by EU funding to several European projects in which the Istituto was involved. Coordinated by: University of Parma, Department of Industrial Engineering For more information: http://www.aster.it/tecal.html EMILIA-ROMAGNA UNIVERSITY DEPARTMENTS UNIVERSITY OF BOLOGNA Dip. di Biochimica “G. Moruzzi”: Centro Ricerche sulla Nutrizione e Vitaminologia Microbial ecology of the gut, taxonomy of lactis acid bacteria, the presence of genes encoding for drug resistance in non pathogenic, food related bacteria are among the main issues of research recently addressed by the Istituto. Current activities include: - assessement of the presence and transferability of genes encoding for drug resistance in lactic acid bacteria; - characterisation of new species of lactic acid bacteria; - assessment of the impact of intestinal microbiota on the immune system by meanss of nutrigenomic approach. Research activity is based on the determination of the biological activity of food components or food themselves, utilising ex vivo (cultured cells) or in vivo (animals, humans) experimental models. To verify the biological effectiveness of food and/or food components is an essential step since in vitro activity is often not accomplished to activity in biological systems. The Institute provides antibiotic resistance profiling of lactic acid bacteria; characterisation and assessment of probiotic and prebiotic foods in order to fulfil criteria of the EU Reg. CE 1924/2006. Different researches are not only focused on the determination of the biological activity in respect to specific end points, but also on the clarification of the cellular and molecular mechanism of action of food components. Once verified, the effectiveness of the food components is rationalised considering food consumption as part of a correct human diet and bioavailability. For more information: www.unicatt.it Current activities include: - evaluation of antioxidant activity and effectiveness in the counteraction of oxidative stress of extracts/essential oils IX ASTER and the Emilia-Romagna High Technology Network