STATE 2021 FROZEN FOOD INDUSTRY - OF - Frozen Food Europe
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ISSUE 2/2021
STATE
THE 2021
OF
FROZEN
FOOD
INDUSTRY
ISSUE 2/2021
STATE
OF
2021
THE
FROZEN
content
FOOD
INDUSTRY
06 FROZEN 22 FROZEN PIZZA
FINGER FOOD Convenience and
Turning a Trend Innovation Drive
into a Bestseller the Market Forward
10 FROZEN POTATO – 24 FREE-FROM
END PRODUCTS FOODS
AND PROCESSES A Global Demand for
Something for Everyone Cleaner Ingredients
14 TECHNOLOGY 28 CONVENIENCE
INNOVATION – NEW PRODUCTS FOR
EQUIPMENT FOR RETAIL AND
THE FOOD INDUSTRY FOODSERVICE
Technology Consumers Look for
in the Spotlight Time-saving Solutions
03
COMMENT
DIVERSITY
IS KEY
BOGDAN ANGHELUTA
editor in chief
A
s we get ready to welcome the cold season, it becomes obvious
that while things have improved, the threat of disruption for the
industry is still high. Regardless of the reasons for which we’re
still in this place, we should expect some of the tendencies seen
in the past year-and-a-half to keep manifesting. While forced to
stay inside, people have experimented with new recipes,
discovered culinary shows, so frozen food manufacturers must be ready to expand
their product ranges with options for all tastes - vegan, exotic, etc. Consumers will still
want to replicate the restaurant experience at home – either with more demanding
dishes, such as seafood (one of the most popular frozen food categories last year, with
an increase in value of 35.3% according to IRI), healthier options like fresh fruit
smoothies which simply aren’t available in the cold season, or snacks to relieve them
of the effort of spending too much time in the
kitchen. Expect more growth, but let’s remember
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Innovation is again that miracles don’t last forever. Things will
paramount here, because eventually return to pre-2020 levels, and when
efforts to develop solutions they do, key to a continuous, steady growth in
that satisfy more needs will the frozen category will be diversification. And
eventually be translated into diversity should be expressed not just in product
higher sales and profit. range, but also in newer, more efficient
technologies. Innovation is again paramount
here, because efforts to develop solutions that
satisfy more needs will eventually be translated into higher sales and profit. We
should keep in mind that is one of the fastest-evolving industries, and demand drives
everything. As such, diversifying all aspects of the business is a great way to keep
ahead. As always, feel free to share your thoughts at
bogdan.angheluta@trade.media. l
04
FROZEN FINGER FOOD
TURNING A
TREND INTO
A BESTSELLER
As we move out of the status-
quo imposed by the events of
the last year-and-a-half, figures
show that some categories have
grown to a degree that guarantees a
stable evolution over the following period.
One of these categories if frozen finger food,
which has been – and continues to be – at high
demand. And looking at the variety offered by
manufacturers, it’s easy to see why.
2/2021
06
T
echnavio projects that the added vegetable, cheese, and potato appetizers to its
frozen snack food market is assortment. It currently supplies to hospitality and
expected to grow by catering customers, wholesalers, quick service chains,
USD11.30bn until 2024, premium brands, and retailers. Although Le Duc has
progressing at a CAGR of always been a specialist in vegetarian snacks
over 6% during the forecast producing for international Business-to-Business
period. Manufacturers are customers, the family business has never really
increasingly launching products in the frozen meat communicated about it’s vegetarian assortment. In
snacks segment, and these have a positive impact on 2019 Le Duc changed her logo into Le Duc Veggie and
the global market. Regionally, APAC will offer several started communicating the brand actively. Following
growth opportunities to market vendors. The the introduction in 2020 of a new range of Veggie
increasing consumer demand for frozen snacks and Burgers, Le Duc will now launch a range of Veggie
the expansion of the distribution capability of vendors Fries in four different varieties at Anuga in Cologne.
will significantly drive the market growth in this region “As more and more people are consciously eating less
over the forecast period. 35% of the market’s growth meat, it is important to offer your guests vegetarian
will originate from APAC, with China and Japan as the food and more vegetables in an attractive way. The
key markets for frozen snack food. Talking about way in which you present your vegetarian food is
Innovate Foods’ recently launched "Now This Is decisive in the success of your sales,” according to
Cheesy!" range, Frédéric Dervieux, CEO of Frostkrone Dick den Hertog, founder of Le Duc. “At the other
Food Group says that the new brand „appeals hand the best way to present vegetarian snacks is
primarily to the young target group that enjoys a huge letting people eat veggie snacks unnoticed more
variety of finger food when gaming together, going to often. A broad group of consumers is prejudged and
small parties or watching an evening’s television. will not choose vegetarian actively. By offering them
Families, too, are really sold on this product range. finger licking tasty Dipping snacks, they will eat this
Especially when time is short, «Now This Is Cheesy!» is snacks unnoticed. During COVID-19 the sales of
the answer, serving up enjoyment and relaxation.” So fingerfood was rising. Consumers have a greater need
far four vegetarian flavours are available. Within the to comfort themselves by snacking at different
coming months, Innovate Foods is planning to extend moments of the day. That’s why we extended our
the range. Regarding the general consumer trends assortment with Veggie Fries. It goes without saying
identified this year by Frostkrone Food Group, that vegetarian snacks should be tasty.
Frédéric Dervieux points out that consumers love
finger food and snacks, and The Frostkrone Food Photo: Frostkrone
Group’s diversity and variety are driving a real food
boom: „Our selection includes small finger food
specialities, trendy snack ideas, tasty potato nibbles,
exquisite cream cheese delicacies and practical pizza
pockets for the oven and microwave. Every year the
range is extended by new product ideas mirroring
current trends.” Free-from goods are hugely popular
with consumers and the Frostkrone Food Group has
launched “Green Date”, a complete snack range. Its six
varieties are bursting with vegetables. The vegan and
gluten-free “Green Date” range has no preservatives,
no flavour enhancers and is not pre-fried. The
production process is especially gentle. Additionally,
The Frostkrone Food Group has brought more
varieties to its “Crunchy Homies” brand and will
showcase these at the Anuga@home. These include
Crunchy Brie Triangles (Brie with a sweet cranberry
dip), Crunchy Emmental Sticks (full-flavoured, nutty
Emmental with a sweet cranberry dip), Crunchy
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Gouda Rings (mild Gouda with a tangy tomato and The new brand „appeals
pepper dip), and Crunchy Tomato and Mozzarella Mini primarily to the young target
Balls (soft mozzarella and dried tomatoes with a hint group that enjoys a huge
of basil, perfected with a fruity tomato dip).
variety of finger food when
MORE OPTIONS FOR VEGETARIANS gaming together, going to small
Producer and supplier of vegetarian snacks and parties or watching an
appetizers Le Duc Food is launching a new, veggie
fingerfood concept: Veggie Fries. The Stellendam-
evening’s television.
based company was the first to manufacture Frédéric Dervieux, CEO of Frostkrone Food Group
American style Onion Rings in Europe in 1998 and
07
plant-based product once in the grocery store. JBT
uses three main mechanical methods of freezing food:
spiral, impingement and IQF (individual quick freezing)
or fluidizing. „Our equipment is always hygienic by
design and help increase the yield and capacity of your
production line without extending the footprint,“
Torbjörn Persson adds. Frigoscandia has developed
the market leading products in spiral freezing, the
Photo: Le Duc GYRoCOMPACT series, with patented advantages
such as self-stacking belts and the industry’s only self-
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contained freezing zone that is a 100% cleanable to
As more and more people are satisfy rigorous hygiene requirements. Apart from
consciously eating less meat, it is bread with living yeast, most food is better preserved
important to offer your guests when quickly frozen. „There is a tremendous
difference between freezing something at -18°C in
vegetarian food and more your kitchen and putting your application in an
vegetables in an attractive way. industry freezer. The hydration, appearance, flavour
Dick den Hertog, founder of Le Duc and texture of the product is always affected to a
certain degree depending on the speed of the process.
Our freezers use impingement technology, a
Growing up between the onion- and potato fields, we revolutionary solution with thousands of high-velocity
respect nature and we realize that we can only make a air jets that blast away the boundary layer of air that
tasty product with the best ingredients from nature.” holds heat around the product. The product is frozen
instantly, with maintained quality,” according to
GETTING TO THE PERFECT Torbjörn Persson. Impingement freezing is best suited
END PRODUCT for products with a high surface to mass ratio, for
As vegan and plant-based become dominant trends in instance thin products like burgers, where the heat
the food industry, it’s also important to see how can quickly be removed from the surface. „Back in the
manufacturers can obtain the materials needed when days when you bought frozen raspberries and peas,
innovating with new recipes. Statistics from the Plant- they came in a big, heavy ice block. Even though you
Based Foods Association show that frozen vegan just wanted a small quantity, you needed to defrost
meat keeps growing at a brisk pace. Not surprising, as the whole package,” Persson points out. „In 1962,
frozen meals bring multiple benefits compared to Frigoscandia made a breakthrough in individual quick
fresh food: higher affordability, better retention of freezing (IQF). Adding true fluidization made it
vitamins and minerals, and extended expiration dates. possible to freeze any fresh fruit and vegetable as a
By freezing the product, we help reducing food waste separate entity. Today, the IQF technology is still one
and make better use of our resources. But freezing of the most cost-effective ways to create a fresh
with good results can be a challenge. JBT’s brand product that preserves its premium quality – months
Frigoscandia is the global leader in the art of freezing after the harvest.” The method benefits the user
food. Torbjörn Persson, global product line director, experience when opening and handling your product.
Freezers at JBT shares some valuable knowledge on Individual quick freezing can also be used for small
how to succeed with freezing your plant-based pieces of vegan meat, e.g., for mince, balls and cubes.
product: „Many manufacturers use nitrogen tunnels JBT’s FLoFREEZE is the world-leading linear freezer
for freezing when setting up a new production line. with IQF technology. Thanks to continuous
Nitrogen can seem to be a suitable freezing medium advancement, it is possible to freeze a much greater
when starting up and for small scale business. range of products – with high capacities, complete
However, from a total investment perspective, cleanability and impressive accessibility. l
nitrogen comes with a high operational cost, why it is
often more reasonable to invest in a mechanical Photo: JBT
freezer.” Mechanical freezing helps reduce production
costs, consequently creating a more affordable
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The hydration, appearance, flavour and
texture of the product is always
affected to a certain degree depending
on the speed of the freezing process.
Torbjörn Persson, global product line director, Freezers at JBT
08
FROZEN POTATO
SOMETHING
FOR EVERYONE
10Western-style cuisine has steadily turned frozen potato
products into a fan-favorite, regardless of the region. This is
adding to the fact that potato is a major staple, ranked fourth in
terms of global production after wheat, rice, and maize. While
french fries clearly dominate the market, demand for other
types of potato products is higher each year.
T
he global frozen potato
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market is projected to Typically a french fry freezer
reach USD79.8bn by
2027, growing at a CAGR
will handle 20 tonnes per hour,
of 4.0% from 2020 to 24 hours a day, 21 days in
2027, a Insight Partners succession before the process
report shows. A surge in
the foodservice market is encouraging the growth
line stands down for
of frozen potato market in the major countries of maintenance and regular
North America, such as Mexico, Canada, and the cleaning. Think about it - that’s
US. Trade figures show a similar image: global
trade volume is up 0.5% compared to 2019 and
approximately 10million, 1kg
prices down 4.7% year-to-date. Segment-wise, bags of french fries destined
when compared to the various frozen potato for supermarkets in one
products such as slices, dices, baked, etc., fries are
likely to emerge as the top-selling frozen potato
production run.
product. By the end of 2022, fries are estimated David Hallifax, head of the EMEA region
to reach nearly USD19bn revenue, according to within the Frozen Food Business Unit at GEA
Fact.MR. On the other hand, wedges are also
likely to experience growth in the global frozen
potato market. Regionally, the US, Canada, and
the European Union are some of the main regions
responsible for production and export of frozen
potato and related products. Conversely, the
evolving countries in terms of production and
export of frozen potatoes include China, India,
Argentina, and others, owing to rapid growth in
business of quick service restaurants. Asia-Pacific
is expected to be the dominant shareholder of the
global market in 2025, due to high growth rate of
population and frozen potato products demand
over there.
CONTINUOUS PRODUCTION IS KEY
There is a range of machinery that suits very
different applications, but the key is continuous
production so the lines never stop other than for
cleaning and maintenance - every hour not in
production is a wasted resource, according to
David Hallifax, head of the EMEA region within
the Frozen Food Business Unit at GEA. “Typically
a french fry freezer will handle 20 tonnes per
hour, 24 hours a day, 21 days in succession before
the process line stands down for maintenance and
regular cleaning. Think about it - that’s
approximately 10million, 1kg bags of french fries
destined for supermarkets in one production run.
The scale and size of this type of freezer is quite a Photo: GEA
11rupture in the cell wall. When the
common food defrosts after packing and
sight around storage, these cells thaw and the rupture
the world in the results in moisture loss, commonly referred to as
temperate potato growing and processing zone,” weight loss. And not the dieting kind!” In terms of
he points out. “Look for a supply partner offering energy management, food can be frozen very
a range of freezing systems that can freeze any quickly or slowly, depending on how fast the heat
type of food as diverse as chicken nuggets to (or energy) can be extracted from the food, he
french fries to croissants, pain au chocolat and goes on to say. This is dependent upon the
other niche pastries. When we consider freezing temperature difference between the cooling
joints of pork, beef or poultry or other bulk foods medium – usually refrigerated air and the velocity
such as ice cream or cheese, a very different of the air passed over the product. The velocity is
freezing regime and freezer design is required. used to help break down the boundary layer
Understanding how food freezes and how it surrounding the food, in order to allow efficient
should be handled correctly allows us to offer the heat extraction. This freezing time costs energy, in
correct energy efficient solution that delivers a other words, money. Thus, energy management is
high quality frozen product, with maximum just as important in freezing food as it is for the
product yield.” David Hallifax argues that when rest of the production line. “To put the energy
considering freezing food, if you over freeze or demand in context, a 20,000kg/hr french fry
take the temperature below your target level it‘s freezer for instance extracts around 3,400kW of
generally not detrimental to the food – not like heat every hour. That said, our refrigeration
with chilling food. “However, it will be to your colleagues are specialists in manufacturing heat
energy bill; hence, we promote the use of pumps, which are able to convert this heat into
Callifreeze to avoid wasting energy. When we another useful form – hot water, which can then
chill a product, we will be given a specific be re-used. By this method we help with
temperature range to achieve, in order to deliver a sustainability and reduce energy demand, which
q 79.8
high quality product. is good for the planet and also the french fry
Consequently, we have producer, by means of a lower energy bill.” As
to closely manage the air the world recovers from the pandemic and more
temperature and air nations develop economically, there will be an
velocity in the chiller. increasing demand for frozen food because it
The key here is that we offers convenience, reduces waste and the
bn USD is the really don’t want to take range of foods caters to everyone’s needs
projected size of the product surface whether it’s vegan, vegetarian, dairy, meat,
temperature below its bakery, fruits and vegetables or prepared foods.
the global frozen freezing point because “So, the frozen food market will continue to
the water in the cells of grow in parallel with the world’s emerging
potato marke the food can freeze and economies, and I for one can‘t wait to see where
in 2027. potentially cause a it goes next!,” Hallifax concludes. l
12TECHNOLOGY INNOVATION
TECHNOLOGY IN
THE SPOTLIGHT
2/2021
14Creating a state-of-the-art machine isn’t always easy, and the work
that goes into researching and developing every aspect is sometimes
enormous. But the demands of manufacturers keep growing, and as
such, technology providers need to innovate day-in and day-out,
turning what was once a selling point into an absolute requirement.
W
hen determining the best potatoes may be similar to the processing of
Urschel cutter for the job, certain root vegetables, according to Jacko. „There
each cutting application is are very few machines and manufacturers out
unique. Feeding method there that can truly cut foodstuffs when fully
and effective delivery of frozen. Customers cut products in a fresh, cooked,
the product into the or frozen-tempered state. Decreasing
cutting area should be temperature tends to stiffen or create a frozen
considered, Mike Jacko, vice president of crust on a chicken breast, harden a strawberry or
Applications & New Product Innovation at
Urschel explains. While one machine may be able
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to process meats, poultry, vegetables (including Details matter in the set-up of
potatoes), fruits, and other products, the machine
set-up and required feeding method need to be
the machine. Power and gearing
taken into consideration. Machines may overlap in options also need to be clearly
types and size of cut available. Product defined. Some products require
characteristics and best delivery method to the
cutting area is a strong consideration when
more power or higher gearing
choosing the right Urschel machine for the job. versus others.
„There are many factors in the machine set-up Mike Jacko, vice president of Applications
depending on types of components available for & New Product Innovation at Urschel
the machine. Specific to cutting, some machines
operate using a 3-dimensional cut incorporating
different styles of spindles, feeding discs, and a
slicing knife area. Depending on the targeted style
of cut, not all of the 3 designated cutting stations
may be equipped with knives. After determining
the cutting station set-up, concentrating on the
particular knives on each related station is
another important step. Knife edges and types
should be paired with specific products to deliver
optimum results. Details matter in the set-up of
the machine. Power and gearing options also need
to be clearly defined. Some products require more
power or higher gearing versus others.” Jacko
shows that while every cutting application is
unique, there may be correlations between
products that share characteristics, especially
when creating a similar end-product. „It comes
down to taking into account such items as
density, rigidity, size, shape, temperature, and a
number of other factors when identifying the
product entering the dicer or slicer. Depending on
the product characteristics, products may require
preconditioning or additional steps prior to
feeding into the dicer.” Like vegetables, broccoli
and cauliflower for example, share similar traits,
and a line making riced cut vegetables of these
could be combined. Leafy vegetables with
similarities may also be effectively reduced in a
parallel manner. Characteristics and end-product
targets are major factors. Similarly, slicing of
various root vegetables to create chips. Reducing Photo: Urschel
15soft cheese, so that slicer/dicer with sharp knives vegetables and fruit industry puts great
can cut without damaging the knives or other importance in equipment performance and
parts. The products may then get fully frozen. reliability.” FAM has a range of innovative cutting
Tempering requires the customer to have good solutions dedicated for the frozen vegetables and
systems for controlled freezing, warming-up fruit industry. Its cutting solutions are designed
slowly to specific temperatures maybe as accurate for even the most demanding production
as +/- 1° C on some products. All machine models environments with the highest level of efficiency
are designed to run efficiently to promote at peak production volumes, with minimal
uninterrupted production. Each cutting downtime and the lowest TCO in mind. “Seeing
application should be paired one of the Urschel the importance of cutting equipment in a
machines suitable to meet or exceed line processing line, we at FAM, are committed to
expectations. Processors benefit from less waste drive innovation in the field of food cutting. We
and increased usable, in-spec product. Machines work closely with our customers to feel their
offer time-saving and labor-saving benefits. pulse on new trends, needs and requirements.
Longrunning parts are simple to changeover.” Our in-house engineering, design and
manufacturing of precision blades, cutting tools
and machinery, combined with a highly qualified
DESIGNED FOR THE MOST team of application experts has allowed us to
DEMANDING ENVIRONMENT launch a multitude of innovations that have set
Cutting machines are at the core of every several new standards in industrial food cutting.”
vegetable and fruit processing line, turning Harvesting seasons are short and as with fresh-
produce into ready to use value-add food frozen vegetables and fruit it is paramount to
products. They offer a unique opportunity for keep the time between harvesting and freezing to
processors to meet constantly evolving consumer an absolute minimum to maintain all the
needs and expectations and helps them to be nutritional value and quality of the produce,
more competitive by creating unique end optimizing production time at minimal operating
products that stand out in the market. According costs is critical for processors. “That’s why FAM’s
to Karel Van Velthoven, product marketing cutting solutions are designed to be extremely
manager at FAM, using state-of-the-art cutting reliable, without compromising on cut quality and
equipment also helps processors optimize their capacity and with minimal downtime,” Karel Van
efficiency and yield. “Innovating food cutting Velthoven says. “As different products have
equipment sits deeply embedded in our DNA and different textures, it is important for processors to
is definitely a never-ending process. We are have the highest level of flexibility in selecting the
striving to offer our customers always better and right cutting solution for the right product.
ever more efficient cutting
solutions by focusing on
continuous improvements
and innovations related to
cut quality, cut
consistency, machine
reliability, total cost of
ownership, sanitation,
operator safety and user-
friendliness. With typical
mid- to high-capacity,
continuous production
environments, the frozen
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With typical mid- to
high-capacity, continuous
production environments,
the frozen vegetables and
fruit industry puts great
importance in equipment
performance and reliability.
Karel Van Velthoven,
product marketing manager at FAM
Photo: FAM
16Photo: Bühler
of updates specifically catered towards the most
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SortControl demanding vegetables and fruit processing
applications and offering an even higher level of
integrates our reliability and user-friendliness. Next to that, FAM
customers' SORTEX always looks to enhance its machine and cutting
machines into their tools portfolio to best meet their customers’ needs.
Adaptations and enhancements are continuously
local automation made in close collaboration with its customers to
system. It also allows help them lead new food cutting trends and
central data achieve the highest production efficiencies and
yield, Karel Van Velthoven concludes.
collection, enabling
agile working, DIGITALIZATION IS THE BACKBONE
operability, and OF DEVELOPMENT
flexibility. Bühler Insights - Bühler's central platform for
connected products and services - feeds into a
Janine Wegmann, bigger concept of digitalization. Digitalization as a
product manager at Bühler whole can optimize efficiency for manufacturers
in many ways, such as through live monitoring,
Our machines are user-friendly and designed for self-optimization, and remote reporting, Krishna
quick and safe changeover between different Kumar, Digital Development manager at Bühler
products. Our team of application specialists have explains. “For example, historical data analysis
an in-depth knowledge about the parameters that allows manufacturers to detect trends and take
affect the cutting, such as shape, temperature, action on specific parameters that may not have
size, texture, and the condition of the product. been visible before. Digitalization can also
This knowledge helps us select the best cutting eliminate various variables and unknowns that
solution, delivering the greatest value and highest would otherwise impact quality by providing
yield for the customer. Our cutting machines for operators with analyzed and visualized data in
the frozen vegetables and fruit industry offer real-time and alarms with the SORTEX Monitoring
sturdy, reliable technology, allowing processors to System. It liberates operators from monotonous
combine high capacity and flexibility with minimal monitoring tasks so they can take action quicker
downtime and low TCO.” In 2020, FAM launched for personal efficiency. There is also process
Volantis™, a V-belt slicer designed for the efficiency to onboard different machines.” When
precision transverse slicing of a wide variety of it comes to innovation, Bühler works on its
elongated and oblong products such as green machines so they are up-to-date in terms of latest
beans, carrots, zucchini etc. More recently, the technological developments. For example, ProSort
company has introduced the Tridis240 HD, a X 4.0 is an Industry 4.0 ready operating
heavy duty version of its renowned Tridis drum environment complete with TrueColor™ frame
dicer family. This HD version comes with a series capture and EasySim™ sensitivity adjustment.
18MAXIMUM EFFICIENCY, MINIMUM
FALSE REJECTION
VIRTO GROUP, the largest frozen vegetable
company in Spain, has updated its deep-frozen
vegetable sorting plant with eleven TOMRA
Nimbus BSI+ sorters. They join the 22 TOMRA
optical sorters already installed in different group
factories, which include Helius, Genius, Blizzard,
and Sentinel II models. The Nimbus BSI+ sorter,
featuring Biometric Signature Identification
technology (BSI), stands out for its high
performance, the easy configuration when adding
new programs, and its minimal false rejection rate
(less than 1%). „We did a lot of internal tests, and
we saw that this technology worked very well
with deep-frozen vegetables, so we agreed with
VIRTO to conduct an on-site validation,” said
Alejandro Palacios, area sales manager at TOMRA
Food for Spain and Portugal. "At the beginning of
2020, we gave them a Nimbus BSI+, and they
tested it for a month. We were able to confirm
that this equipment did everything we thought it
Photo: TOMRA
would and that it worked really well. It was an
effective technology for detecting foreign bodies
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We did a lot of internal tests, and foreign plant matter (even dangerous plants
and we saw that this like jimsonweed). Also, there was minimal false
rejection. TOMRA's BSI+ technology brings added
technology worked very well value to the frozen vegetable sector, as it achieves
with deep-frozen vegetables, what other machines cannot. As for the potential
so we agreed with VIRTO to of the BSI+ technology, when we were validating
the machine, we were surprised by the fact that
conduct an on-site validation. the Nimbus was delivering very similar results
Alejandro Palacios, area sales manager when working with a single product and with
at TOMRA Food for Spain and Portugal ingredient blends. While the machine's behavior is
already good, I am convinced that the results in
the next few months will be even better. Without
“Our drive for our innovation comes from solving a doubt, this technology gives us a competitive
problems for our customers. Our recently edge." The Nimbus BSI+ works by detecting
developed cameras improve reject efficiency to objects' biometric characteristics and is capable of
give our customers greater yields. Bühler Insights removing a large number of foreign bodies and
allows thorough performance data analysis, and unwanted plant matter. In VIRTO GROUP’s case,
our latest curved chute has been designed to the difficulty lies in the enormous variety and
reduce spillage,” Janine Wegmann, product quantity of products that it has. „Each product has
manager at Bühler points out. SORTEX its specific characteristics and its unique origin:
Monitoring System is a dashboard with crucial plant, animal, marine. The fact that we are not
sorter KPI's such as yield, throughput, defects working with a single product means that we have
(ejections) to give an overview of the machine's to make changes in the programming continually.
performance. “SortControl integrates our That's why the ease with which the Nimbus BSI+
customers' SORTEX machines into their local can be configured is an advantage for us. Fine-
automation system. It also allows central data tuning all the programs will take a while, but we're
collection, enabling agile working, operability, and already getting better results, especially with
flexibility.” Bühler's PolarVision technology products that contain the more complex
combines four sorting technologies fitted in a ingredient blends," according to Francisco Casas,
unique platform, spanning the visible and non- in charge of sorting at VIRTO GROUP. In addition
visible optical spectrum for superior foreign to the advantages of the Nimbus BSI+, it is worth
material (FM) removal. “As consumers are noting the further added value of TOMRA Insight.
becoming more and more health-conscious, This cloud-based data platform unlocks valuable
PolarVision has proven to be the most efficient and innovative opportunities for users of TOMRA
and trusted solution to satiate any concerns sorting machines. It turns the sorting process into
regarding the safety and quality of the frozen fruit a strategic management tool that allows users to
and vegetables that we eat,” Wegmann adds. make decisions based on real data collected from
20TOMRA units at every step of the value and technology, a revolutionary solution with
production chain. With TOMRA Insight, the thousands of high-velocity air jets that blast away
machine generates data throughout the process, the boundary layer of air that holds heat around
which is stored in the cloud. "It is one of the the product. The product is frozen instantly, with
greatest added values of BSI+ technology. maintained quality. Impingement freezing is best
Knowing what the machine is doing will be very suited for products with a high surface to mass
important when optimizing performance. It ratio, for instance thin products like burgers,
enables us to make informed decisions, such as where the heat can quickly be removed from the
tracing the types of foreign materials that are surface." Not least, one of most commonly used
being discarded and determining good and bad technologies is individual quick freezing. Back in
farming areas, whether we should expand in one the days when you bought frozen raspberries and
or the other, etc. It is a very powerful tool for real- peas, they came in a big, heavy ice block, Petrie
time monitoring and decision-making to improve says. "Even though you just wanted a small
the business," José Antonio Baldero, technical quantity, you needed to defrost the whole
manager at VIRTO GROUP adds. package. In 1962, Frigoscandia made a
breakthrough in individual quick freezing (IQF).
CHOOSING THE RIGHT Adding true fluidization made it possible to freeze
METHOD OF FREEZING any fresh fruit and vegetable as a separate entity.
Spiral freezing is ideal for large or thick products Today, the IQF technology is still one of the most
and heavy belt loads, such as prepared meals, cost-effective ways to create a fresh product that
warm goods, nuggets and burgers. With its preserves its premium quality - months after the
compact, streamlined design, the spiral freezer harvest. The method benefits the user experience
can help you minimize the refrigeration footprint when opening and handling your product." l
in your facility, according to Bob Petrie, president
of JBT Protein EMEA. Furthermore, it helps you
save energy and increase the efficiency of the
production line. Frigoscandia has developed the
market leading products in spiral freezing, the
GYRoCOMPACT series, with patented advantages
such as self-stacking belts and the industry’s only
self-contained freezing zone that is a 100%
cleanable to satisfy rigorous hygiene
requirements. "With the right equipment and
process, you can freeze almost any product with
excellent results," Petrie points out. As such, he
says, many manufacturers use nitrogen tunnels
for freezing when setting up a new production
line. Nitrogen can seem to be a suitable freezing
medium when starting up and for small scale
business. However, from a total investment
perspective, nitrogen comes with a high
operational cost, why it is often more reasonable
to invest in a mechanical freezer. "Mechanical
freezing helps reduce production costs,
consequently creating a more affordable plant-
based product once in the grocery store. We use
three main mechanical methods of freezing food:
spiral, impingement and IQF (individual quick
freezing) or fluidizing. Our equipment is always Photo: JBT
hygienic by design and help increase the yield and
capacity of your production line without
N
extending the footprint." Bob Petrie also mentions Today, the IQF technology is
impingement technology: "Apart from bread with
living yeast, most food is better preserved when
still one of the most cost-
quickly frozen. There is a tremendous difference effective ways to create a fresh
between freezing something at -18°C in your product that preserves its
kitchen and putting your application in an industry
freezer. The hydration, appearance, flavour and
premium quality - months after
texture of the product is always affected to a the harvest.
certain degree depending on the speed of the Bob Petrie, president of JBT Protein EMEA
process. Our freezers use impingement
21FROZEN PIZZA
CONVENIENCE AND
INNOVATION DRIVE
THE MARKET
FORWARD
22Frozen pizzas are simple to prepare and time efficient, and their
convenience is provides a good explanation for the increasing
sales among different types of consumers. Innovation is also a
lucrative area in this category, with manufacturers constantly
introducing plant-based or free-from options.
A q 63.3%
recent report by Technavio
suggests that the global
frozen pizza market will
register an annual growth
of 4.61% and an
incremental growth of was the market share of thin
USD4.17bn until 2025.
For 2021, the category growth is estimated by
crust pizza in 2021.
Technavio at just under 4% - 3.9%, to be more
precise, which is still a decent result taking into used. As far as innovation goes, Cappello’s recently
account the fact that the market size spiked last showcased the very first line of Keto Certified
year when people spend more at home. Region- pizzas, low net carb pizzas that combine authentic
wise, a different study conducted by Future Market pizza taste and texture with easy cook times and
Insights revealed that the US is a leader in the intentional nutrition such as healthy fats and high
frozen pizza market, accounting for 80.9% of the fiber. Cappello’s has also just revealed the latest
North America market in 2021, supported by addition to their almond flour ravioli line, Butternut
favourable consumer purchase patterns. Italy holds Squash Ravioli, a dairy-free option for fans of
the lead in the Europe market with a share of stuffed pastas. Another free-from novelty comes
nearly 16%, owing to growing consumption as a from Feel Good Foods, who introduced its first
staple food. Brazil accounts for over 32% of the gluten-free Detroit-style pizza to the frozen aisle.
Latin America market in 2021, aided by favorable Available in Margherita, Truffle Mushroom, and
changes in consumer cuisine preferences. Thin Four Cheese, the thick crust and square shape is
crust pizza accounts for a market share of 63.3% in what sets these pizzas apart from all the other
2021, owing to the preference for low-calorie gluten-free frozen pizzas, which all are round with
products. Meat toppings are anticipated to witness thin crust. All in all, it’s likely that interest towards
lucrative growth with a CAGR of 6.8%, supported new, innovative varieties of frozen pizza will rise,
by a relatively large meat-eating consumer base. and this will help force manufacturers to adapt –
The study also highlights that consumers look for which should have an impact on other frozen
food items that are easier to transport while having categories just as well. l
a longer shelf life, and fast-paced lifestyles have
influenced consumers to seek ready-to-eat foods.
Consumers are willing to pay a premium price for
products obtained from organic and authentic
sources. Producers of frozen pizza are
consequently pushed to provide detailed
information through labels. Consumers are hesitant
to buy frozen products owing to concerns over
processed ingredients, but, by providing accurate
information about the additives used,
manufacturers can gain consumer confidence and
long-term brand loyalty.
q 16%
INNOVATION IS KEY
The most important trend in frozen pizza
manufacturing is plant-based, as consumer demand
in this category is changing the landscape. It's a
change experienced by many categories in recent
years, so it should come as no surprise that using was Italy’s market share of the
plant-based ingredients is turning into something
quite usual. Still, the mainstreaming of plant-based
European frozen pizza market
pizza is taking different forms, usually in topics in 2021.
23FREE-FROM FOODS
A GLOBAL
DEMAND
FOR CLEANER
INGREDIENTS
24There’s little doubt consumers are looking for free-from foods.
It’s a trend that has become more and more evident in the last
ten years, whether we’re looking at vegan, gluten-free, palm
oil-free, GMO-free or lactose-free. In general, we’re witnessing
a global demand for more natural ingredients. In this context,
what can manufacturers do to respond?
F
ree-from, which does not with ingredients they just consider to be “clean.”
yet have a generally Of the American consumers who choose foods
accepted definition, and beverages with clean ingredients, a quarter
seems to refer to the said their top motivation for doing so was seeking
preference for products out health benefits from foods and beverages
that do not use unnatural with clean ingredients, while 21% are looking to
preservatives or do not avoid the possible harmful effects of chemical-
contain allergens. Due to the changing market, the sounding ingredients, 18% who most want to
food industry faces a huge challenge to create avoid the possible harmful effects of unfamiliar
free-from that offer the same texture, sensation ingredients, 18% who want to be familiar with
and taste that known products offer. This aspect is what goes into the foods and beverages they
extremely important, as the final consumer isn’t choose and 17% who think foods and beverages
ready to sacrifice either the taste or texture. with clean ingredients are more nutritious.
Therefore, the introduction of successful
alternatives can be difficult, with some ingredients AWARENESS IS HIGHER
being harder to replace. A successful example The product package is still the first place
comes from the dairy market – here, there are consumers look for information about the
many alternatives, such as soy or rice milk. ingredients: 62% consult the ingredients list and
It should be mentioned that while there plenty of 52% look at front-of-package information,
alternatives and efforts to develop them in case according to the IFIC survey. Other sources of
they are missing, not all ingredients can currently information trail far behind, including the websites
be replaced. As such, clean labels become or social media accounts of
extremely important for consumers, as they can brands/companies(20%), family or friends(16%)
show what has been used and where those raw and QR codes on packages(8%). But the figures
materials come from. According to changes somewhat when Americans seek more
the International Food Information Council's (IFIC)
“From ‘Chemical-Sounding’ to ‘Clean’: Consumer
Perspectives on Food Ingredients” report, nearly 2
in 3 American respondents (64%) say they try to
choose foods made with clean ingredients. When
q 64%
these consumers were asked how they define
clean ingredients, “not artificial or synthetic” was
the top choice of 22%, while 16% chose “organic,”
15% chose “fresh,” 14% cited “something they
know is nutritious” and another 14% selected
“natural.” At the bottom of the list, 6% cited the of US consumers say
following options as their top choice: something
with a familiar or recognizable name, something they try to choose
that doesn’t have a chemical-sounding name and
something with a name they can pronounce.
foods made with
Similarly, consumers were asked about clean clean ingredients.
eating. Nearly half (46%) consider themselves to
be clean eaters—with 21% ranking “eating foods
that aren’t highly processed” as their top
definition of the term (nearly half, 49%, ranked
this in their top three). Another 14% of self-
described clean eaters defined it as eating foods
found in the fresh produce section, 13% as eating
organic foods, 11% as eating foods with simple
ingredients lists and 9% defined it as eating foods
25general information about food ingredients, with account for a significant proportion of the global
20% saying family and friends are their top free-from foods market size. Increasing
source, followed by websites or social media investments of companies towards making their
accounts of brands/companies(19%). All in all, portfolio plant-based and organic ingredients
63% of adults say the ingredients in a food or have been supplementing the growth of GMO-
beverage have at least a moderate influence on free foods. Experimental diets of consumers, such
what they buy; 42% of respondents agree that as paleo and vegan, have led to increasing in
adding preservatives to foods is a way to help demand for GMO-free foods. GMO-free foods
reduce food waste and 39% agree that adding an are expected to show significant growth of 1.7X
ingredient to a food would be positive if it during the forecast period. Geographically, North
extended shelf life. Still, the most important figure America is a mature free-from foods market, and
might be this: 62% of respondents saying they are accounts for one-third demand in this space. This
paying more attention to ingredient lists now than area is expected to experience slow growth
they did five years ago. during the forecast though, while demand from
South Asia & Oceania is expected to be
STEADY RISE EXPECTED significantly high. Players trying to increase their
Overall, the free-from foods market is estimated penetration in the market and increase the
to expand at a CAGR of nearly 6% up until 2030, awareness of consumers regarding the benefits of
according to a report by research company allergen-free food are expected to drive the
Fact.MR. In terms of products, GMO-free foods growth of the South Asia & Oceania free-from
q 42%
foods market. In an industry dominated by trends
related to health and well-being, it is almost
obvious that free-from will give a clear direction in
terms of products. Given that the new
generations are much more aware of the impact
of the food industry on themselves and even the
of US consumers agree that environment in general, it is hard to believe that
adding preservatives is a way to there will be a 360-degree change in consumer
demand. And producers will make sure, as they
help reduce food waste. have always done, that these demands
do not go unanswered. l
26CONVENIENCE PRODUCTS
CONSUMERS
LOOK FOR
TIME-SAVING
SOLUTIONS
28Consumers today live in a fast-paced world, so it comes as no
surprise that they are constantly seeking convenient products
and solutions. The large number of convenience formats
presented in retail and foodservice serve as evidence to that.
A
ccording to the Global frequently. A good quarter of respondents (26%)
Opportunity Analysis and turned to delivery services more often. How
Industry Forecast, the consumers handle frozen food products has also
frozen food market changed for the better: 19% of respondents said
amassed worldwide sales that they had been cooking for themselves using
of USD291.8bn in 2019 frozen ingredients more frequently. The
and is estimated to reach popularity of cooking frozen meals increased
USD404.8bn by 2027, which means a CAGR of considerably among 14% of consumers. Also in
4.2% between 2020 and 2027. Meanwhile, the Germany, total volume sales of frozen food
European frozen food market is forecast to reach declined by 4.5% in 2020 to 3.66 million. The
USD124.1bn by 2027. And convenience product total value of frozen food sales fell by 1.8% to
make up a significant part of that. In its latest EUR15bn (vs. EUR 15.3bn in 2019), according to
research for the global convenience market, IGD figures from the German Frozen Food Institute
revealed that 70% of the top 10 global (dti). Increased demand for frozen products and
convenience retailers for sales per square metre high acceptance among consumers resulted in
are based in Europe. The forecasted growth of extremely good performance in the in-store and
the seven retailers is set to add EUR3.5bn in sales home delivery segments, but this could not
by 2026, which represents a compound annual compensate for the collapse of the out of home
growth rate of 3%. In the UK alone, convenience (OOH) market. In the in-store and home delivery
sales are forecast to grow by 12.5% (+GBP5.5bn) segments, frozen food recorded a growth of
by 2026, driven by a continued focus on 12.1% in volume in 2020. Frozen food sales in the
neighbourhood locations, underpinned by higher in-store and home delivery segments rose by
levels of working from home and suburban living, 13.4% to EUR9.4bn, passing the nine-billion mark
the IGD report shows. From a global perspective, for the first time. Due to the crisis in the
the convenience market is continuing to grow at foodservice industry, per capita consumption of
pace driven by the US, China and Russia, with 7- frozen food decreased by 2.1 kilograms in 2020 to
Eleven maintaining a significant lead globally. The 44.8 kilograms (2019: 46.9 kg).
q 404.8bn
top 10 players will add USD43.1bn in sales by
2026, a CAGR of 3.7%.
POST-PANDEMIC COOKING &
PURCHASING PATTERNS
Cooking and food behaviour in Germany has USD is the projected value of
changed considerably during the COVID-19
pandemic, as shown by the TK- global frozen food sales in 2027.
TRENDBAROMETER, a representative consumer
survey conducted by the market research institute
INNOFACT AG on behalf of the dti. From
consumers’ perspective, the three most important
aspects in relation to food are the freshness of
products (92%), a healthy diet (81%) and natural
ingredients (81%). During the COVID-19
pandemic, the importance of a healthy diet and
the freshness of products increased for at least
one-quarter of respondents. The trends for
vegetarian (22%) and vegan (15%) food are much
less significant than previously thought, with
respondents rating these criteria as significantly
less important. During the COVID-19 pandemic,
people have been cooking for themselves with
fresh ingredients more often, as 41% of
respondents confirmed. Nearly one-third of
respondents (31%) ordered takeaway food more
29GROWTH IN ALL SEGMENTS with ready meals might affect market growth.
The global ready meals market size is expected to Moreover, rising cases of obesity and other
grow at a CAGR of 5.5% from 2020 to 2027, lifestyle diseases are anticipated to hinder the
according to a study by Grand View Research. market growth. Thus, manufacturers are focusing
Shifting consumers’ food preferences towards on introducing nutritious and healthier products
ready-to-eat food products owing to the busy to retain their market share. Frozen and chilled
lifestyle of working individuals as well as hectic meals held the largest revenue share of more than
work schedules of college grads and students is 50.0% in 2019 and are expected to maintain their
expected to be a key factor for the market lead over the forecast period owing to a wide
growth, similar to the increasing demand for range of products with high shelf life. Frozen pizza
minimally processed and additive-free food is the most popular frozen ready meal, thereby
products with an extended shelf life. Precooked or significantly contributing to global revenue.
ready meals are highly convenient and they help Canned meals are anticipated to expand at the
save time and effort required for meal fastest CAGR of 6.1% from 2020 to 2027 owing
preparation. This has led to a higher demand for to rising popularity among young consumers
ready meals, especially among the working across the globe. The dried product segment,
population and students across the globe. Ready which includes foods such as instant pasta and
meals are a cost-effective alternative as they are noodles, is also likely to witness significant growth
precooked. Moreover, easy availability of ready in the future. l
meals throughout the year will have a positive
impact on their demand. In addition, print and
media advertisement has played a key role in
creating awareness about ready meals, thereby
augmenting the overall market growth. Rise in the
per capita income is another factor driving the net
sales of ready meals in most parts of the world.
However, increasing safety concerns associated
q 124.1bn
USD is the projected value of the
European frozen food market in 2027.
30Ad closing 31.01 Ad closing 25.03
JANUARY/FEBRUARY MARCH/APRIL
EDITORIAL PLAN 2022 1
Frozen Pasta for Catering and Foodservice
product innovation, manufacturers, suppliers
Bakery and Pastry
key market players, producers, suppliers
Publishing 09.02
2 PLMA, ANUGA FOODTEC SPECIAL EDITION
Appetizers, Snacks and Pies
Publishing 11.04
high convenience, filo pastry products, pizza, ready meals
Frozen Vegetables, Fruit, Mushrooms, Green Herbs
trends and market overview
Frozen Desserts Technology Innovation for Frozen Vegetables & Fruit
market dynamics, new product development cutting, slicing, peeling, dicing
Bio and Organic Products for the Food Industry BeNeLux Market Review
clean label and energy saving products major players and new products
Frozen Potato Market
Cooked & Pre-Cooked IQF products for the Food Industry
innovative products and European overview
rice, pasta, sauces, cereals, noodles, vegetables
Frozen Potato Technology
cutting, slicing, peeling, dicing Technology and Equipment
Technology & Logistics industrial freezing, proofers, ovens, coolers, freezers
conveyor belts, spiral ovens, IQF freezers & chillers Meat Alternative Products
Packaging Technology plant based substitutes
state-of-the-art equipment and solutions Thermal Equipment & Chillers
Smart Industrial Kitchens technological flexibility in professional kitchens
trends and digital solutions Private Label Food
Ice Cream Market in Europe innovation, new products, producers, retailers
evolution and estimates Frozen Fish & Seafood
Nutrition & Ingredients sustainable practices, market overview, major processors
for frozen bakery and potato products Nutrition & Ingredients
Frozen Food in Germany vegetables, fruit and herbs
recent developments, review, estimates Frozen Food in the UK
market overview
Trade fairs: Biofach, Gulfood, Internorga, FoodEx JAPAN, CFIA Rennes,
M.A.D.E., Alimentaria Trade fairs: PLMA, Anuga FoodTec, IFFA Frankfurt,
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market overview for retail and foodservice
4 SIAL SPECIAL EDITION 1
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Frozen Pasta & Sauces Market Coated/Breaded/Batter Foods
trends, new product development, producers, suppliers new products, market evolution
Frozen Pizza Market Ethnic Foods - Greek, Mexican, Italian, German, French & Asian Food
product trends, producers, markets overview
major producers, suppliers, country breakdown
Potato Market Update
Technology and Innovation for Frozen Pizza
frozen fries market overview in retail & foodservice
processing machines, toppings, portioning and forming
Potato Technology Innovation
Ingredients for the Food Industry new equipment for frying, cooking and seasoning
for pasta, pizza, ready meals (herbs, rice, vegetables, Vegetarian and Vegan Food
mushrooms, processed meat) product trends, innovations
Frozen Finger Food, Fried or Baked Mix Balls Technology & Logistics
trends and successful products trends in cold storage and warehousing
Frozen Burgers Frozen Food in Spain and Portugal
new products, producers and suppliers latest market developments
Frozen Snacks and Pastry Technology & Logistics
innovative products for retail and foodservice industrial freezing equipment
Optical Sorting Technology Dishwashing Machines for Professional Kitchens
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Deep Freezing Technologies, Proofing, Baking, Cooling Nutrition & Ingredients
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Frozen Food in the US
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Ready to bake & Pre-Baked Foods
market innovation, producers, new products
Key Exhibitors Road Map and Event Agenda
SIAL Trends Convenience Food for Retail & Foodservice
special report European market evolution, category breakdown
Bakery & Pastry Frozen Products for Catering & Foodservice
new product innovation, suppliers, producers suppliers, producers, processors
Frozen Vegetables, Fruit, Mushrooms, Green Herbs Meat and Veggie Burgers
solutions for retail and foodservice innovation and trends
Technology Innovation for Frozen Vegetables and Fruit Technology & Logistics
cutting, slicing, peeling, dicing freezing and chilling equipment
Technology & Logistics Quick Service Restaurants & Bar and Snack Channel
trends and solutions in packaging equipment market evolution, leading operators in Europe
Technology Automation & Artificial Intelligence Front Cooking Devices, Bakery Stations and Take-Away-Counters
applications in professional kitchens equipment innovation & hygienic requirements
Meat and Poultry Products
market overview in EU vs USA Nutrition & Ingredients
Frozen Food in France ethnic food innovation
key players, product innovation, suppliers Frozen Food in Scandinavia
Global Retail Market producers, suppliers, consumer trends
consumer behavior, new products, processors, suppliers European Retail Market
Nutrition & Ingredients suppliers, major retail categories, food trends
for pre-baked and ready to bake foods
Trade fairs: Sirha 2023, Marca Bologna 2023, Fruit Logistica 2023,
Trade fairs: SIAL, südback Stuttgart, INTERPOM Kortrijk Gulfood 2023You can also read
