FOOD MANUFACTURER ZAMBIA JUNE 2024
Your One-Stop lab testing partner We will find a solution for your food safety testing requirements. Contact us on +27 87 330 3792 Email: [email protected] Testing AssureCloud Vetlab offers a wide range of tests that support you in monitoring the health and environment of your production animals and units. Tests conducted by the microbiological laboratory include (but not limited to): Support your business growth with full testing services from AssureCloud Vetlab – and access Southern Africa’s largest footprint of laboratories and inspection services. PCR testing MS, MG, NCD, IBV, IBD, AI, ILT Serological testing (ELISA) Poultry diseases for AI, AE, CAV, EDS, IB, IBD, MG, MS & NCD – Salmonella Mycotoxin ELISA testing Aflatoxin, Ochratoxin, Zearalenone, Deoxynivalenol (DON) 5/5, Fumonisin, T-2 & HT-2 Bacteriology General bacterial isolation – aerobic and anaerobic, antibiogram; contact & air plates to determine bacterial load in a particular area or environment; products monitoring (total plate count and coliforms enumeration E. coli and S. aureus); Salmonella monitoring programme, Grouping, API; yeast and moulds enumeration; Listeria monocytogenes; Listeria spp Parasitology Blood film examination, oocyst and worm egg counts, Salmonella Water Testing Total bacterial counts, Coliforms and E. coli (Colilert method), Salmonella
Food Manufacturer is a Business to Business (B2B) magazine that targets food and beverage manufacturers, and entire food business across the sector in Zambia. The qualified audience includes buyers and suppliers, packaging specialists, marketers, laboratory technologists, consultants and other purchasing influences. It is positioned to showcase and address key issues in food manufacturing such as value addition and supply chain, quality and standards, security, and more. This magazine has earned a slice of its readers’ time to learn about what’s going on in the industry and reflect their aspirations, needs and plans to run a prosperous business. Covering equipment, ingredients, packaging, software, innovations and solutions and more, giving the latest news and technology for its readers. Our magazine is with you to remind you to take action for a better industry business with a sound scientific and ROI-oriented approach to implementing and managing production protocols and technology throughout their supply chains. This dedication has fuelled growth in our audience engagement that brings together industry professionals, researchers, policymakers, stakeholders and experts from around the country to discuss the latest advancements and challenges in ensuring local quality food manufacturing. As we encourage you to be ready to elevate standards of your products and solutions? We’re excited to help you discover the perfect fit for your business needs. Let’s collaborate and make your success an integral chapter in our ongoing story as a proud nation. Enjoy! Kulani Media Team CONTENTS 4 8 10 12 14 Matrix Software: Africa’s leading Food Processing Software Provider Zambia Sees Boost in Local Fresh Produce Sharing networks, knowledge, platforms, and solutions to help drive efficiency, safety, and sustainability in your supply chain Overcoming Cold Chain Challenges in Meat and Fish How to manage perishable meat products with short shelf life and selling time Zambia Food Processing Industry TechnoServe primary focus on strengthening the food processing sector and improving nutritional outcomes Zambia Bureau of Standards Certification Unlocking Markets for SMEs
Matrix Software’s philosophy is simple: start where the problem is and work from there. They’re a software solutions company specialising in the food processing industry that was started in 2006 from the ground up, because they wanted to be close enough to the problem to gain the specific knowledge and experience needed to solve it. Today, this approach continues to serve them well as they truly understand their clients’ challenges. They meet clients where they’re at and journey with them to develop innovative and fit-for-purpose solutions that elevate their business and truly make a difference. “Our mission is to provide food processors in Africa with innovative software solutions to increase their sustainability and thereby accelerate food security.” Matrix Software is passionately focused on and firmly rooted in Africa – a continent which they believe is rich in untapped potential and many opportunities. “We believe that sustainable success and scalability are built upon a foundation of long-term thinking, and as such we have dedicated ourselves to cultivating strong partnerships and fostering growth as a team and as a business. Agventure’s investment in Matrix Software during 2021 is an example of a partnership that we believe will accelerate our expansions into Africa to unlock the continent’s agrifood potential through technological innovation and entrepreneurship,” says Dewald Carelse, Matrix Software’s CEO. “At Matrix Software, we don’t sell software, we solve problems.” Dewald Carelse, CEO Matrix Software Matrix Software provides affordable, scalable, customisable and user-friendly solutions for the challenges faced by African meat and food producers.Says Carelse, “Relationships build our foundation and people drive our progress. Our clients are at the heart of all we do and through our hands-on approach, we have developed a wide range of solutions to meet their evolving needs. With our team’s technical support and consulting expertise, we engineer success by dismantling obstacles and nurture the successful operations of our own business and that of our clients.” “Our work speaks for itself - we are the architects of exceptional user experiences, crafting software that solves the challenges of stock control, yield management, traceability, plant productivity Matrix Software: Africa’s Leading Food Processing Software Provider and tracking cost margins,” states Carelse. “Our clients’ interests steer our every move, and our success starts with them.” The complexities inherent in the food processing industry demand robust solutions that go beyond standard off-the-shelf software. Matrix Software’s solution, powered by Microsoft’s SQL Server and running on standard Microsoft Windows machines, offers our clients a cost-effective and scalable option tailored to their needs. Their proven track record shows that they have the knowledge and know-how to meet the requirements of the meat processing industry – one of the toughest perishable sectors – and their system can be easily adapted to other perishable processing industries. Many clients in the seafood, dairy and fresh produce industries have tangibly benefited from their solutions to increase profitability. A tailor-made system consisting of a wide variety of configurations ensure that clients have accurate job costing, complete stock control, fit for purpose quality control, and complete process traceability, equip food manufacturers with the tools necessary to navigate the industry’s nuances effectively. Furthermore, the Matrix Software system integrates the latest technology, including Android-based mobile scanners, integrated RFID solutions, automated weighers and easy-to-use label designers. The software is developed in South Africa specifically for the South African and African markets, so it’s designed to be cost-effective and easy to support. The systems are leased on a month-to-month basis, which makes it simpler for businesses to get started without a large capital investment. As a team, they’re proud of their African heritage and they work hard to provide excellent service and ensure reasonable transactions for their clients. Says Carelse, “Looking ahead, we remain committed to growing our business and continuing our relentless focus on solving the difficult issues within our industries. Our structures, processes and billing models are designed to ensure a win-win outcome for both our clients and our business, and we look forward to continuing providing the high level of service that our clients have come to expect from us.” Find out why more than 200 clients trust Matrix Software as their software solution provider of choice by visiting their website at www.matrixsoftware.co.za or email [email protected]. PAGE 04 FOOD MANUFACTURER MAGAZINE ZAMBIA | 2024
“At Matrix Software, we don’t sell software, we solve problems.” Dewald Carelse, CEO Matrix Software Matrix Software provides affordable, scalable, customisable and user-friendly solutions for the challenges faced by African meat and food producers. Says Carelse, “Relationships build our foundation and people drive our progress. Our clients are at the heart of all we do and through our hands-on approach, we have developed a wide range of solutions to meet their evolving needs. With our team’s technical support and consulting expertise, we engineer success by dismantling obstacles and nurture the successful operations of our own business and that of our clients.” “Our work speaks for itself - we are the architects of exceptional user experiences, crafting software that solves the challenges of stock control, yield management, traceability, plant productivity and tracking cost margins,” states Carelse. “Our clients’ interests steer our every move, and our success starts with them.” The complexities inherent in the food processing industry demand robust solutions that go beyond standard off-the-shelf software. Matrix Software’s solution, powered by Microsoft’s SQL Server and running on standard Microsoft Windows machines, offers our clients a cost-effective and scalable option tailored to their needs. Their proven track record shows that they have the knowledge and know-how to meet the requirements of the meat processing industry – one of the toughest perishable sectors – and their system can be easily adapted to other perishable processing industries. Many clients in the seafood, dairy and fresh produce industries have tangibly benefited from their solutions to increase profitability. A tailor-made system consisting of a wide variety of configurations ensure that clients have accurate job costing, complete stock control, fit for purpose quality control, and complete process traceability, equip food manufacturers with the tools necessary to navigate the industry’s nuances effectively. Furthermore, the Matrix Software system integrates the latest technology, including Android-based mobile scanners, integrated RFID solutions, automated weighers and easy-to-use label designers. The software is developed in South Africa specifically for the South African and African markets, so it’s designed to be cost-effective and easy to support. The systems are leased on a month-to- month basis, which makes it simpler for businesses to get started without a large capital investment. As a team, they’re proud of their African heritage and they work hard to provide excellent service and ensure reasonable transactions for their clients. Says Carelse, “Looking ahead, we remain committed to growing our business and continuing our relentless focus on solving the difficult issues within our industries. Our structures, processes and billing models are designed to ensure a win-win outcome for both our clients and our business, and we look forward to continuing providing the high level of service that our clients have come to expect from us.” Find out why more than 200 clients trust Matrix Software as their software solution provider of choice by visiting their website at www. matrixsoftware.co.za or email info@matrixsoftware. co.za PAGE 06 FOOD MANUFACTURER MAGAZINE ZAMBIA | 2024
Overcoming cold chain challenges in trading meat and fish. Meat is a perishable product with a short shelf life and therefore short selling times. The preservation of meat, both red and poultry, at sufficiently cold temperatures holds utmost importance for both local trade and export purposes, be it in chilled or frozen form. Raw materials, ingredients, intermediate products and finished products that are likely to support the growth of pathogenic microorganisms and spoilage bacteria, are to be kept at temperatures that do not result in health risks. For this reason, the cold chain should not be interrupted throughout the entire meat distribution process, spanning from the slaughterhouse to wholesale, and from retail display to the end consumer. The growth of urbanisation and the middle class has brought along new consumer habits and increasing demand for chilled and frozen foods. The convenience of pre-slaughtered and frozen meats is becoming the preferred way of purchasing meats by many African consumers, as to ensure the quality and good health conditions and treatment of meats. This consumer trend underscores the significance of investing in the cold chain at every step of the journey. In this article, we explore four indispensable tips to overcome the cold chain challenges in trading meat, to ensure it remains pristine throughout its journey. 1. Proper packaging Efficient packaging plays a crucial role in overcoming cold chain challenges when trading meat. Various factors, including economic, technical, and legal considerations, influence the selection of packaging, with its main purpose being to safeguard the product from external contaminants and ensure it remains undamaged during transportation from the producer to the consumer. Meat and poultry are packaged chilled or frozen and often in humid environments, so packaging needs to act as a protective barrier, shielding the food from gases, light, and water vapour. These elements can lead to colour deterioration, lipid and unsaturated fat oxidation, protein denaturation, and a loss of sensory qualities. Additionally, an effective barrier prevents the loss of moisture from the food to the surrounding environment, thereby averting dehydration and weight reduction. In addition to these protective functions, packaging should also exhibit physical and chemical stability across a range of temperatures, such as freezer conditions. By ensuring that the animal protein products are packaged in appropriate materials, you provide insulation and protect against potential temperature fluctuations. Vacuum-sealed or specialised temperature-controlled packaging is ideal for preserving the meat quality and shelf life by restricting the amount of bacteria growth, especially convenient for local retail distribution. For export, meat is treated under deep frozen and packaged with solid paper-based board boxes, which freezes much faster than other packaging. 2. Cold rooms, slaughterhouses and freezers Preservation of red and poultry meat for trade and export purposes, in either chilled or frozen form at sufficiently cold temperatures is essential for successful national and international trade. A fresh piece of meat can only be kept fresh for a few days, while frozen can be kept for several months. Usually, pork, beef, lamb and poultry carcasses are chilled immediately after post-mortem inspection at the slaughter line or chilling rooms. Most often, after 24 to 96 hours of chilling, the carcasses are usually moved to a processing room where they are further cut into primary cuts. These cuts can be typically stored for up to 6 weeks in vacuum packs under anaerobic conditions. PAGE 08 FOOD MANUFACTURER MAGAZINE ZAMBIA | 2024
In slaughterhouses, the meat cold chain starts with two main steps. (a) Primary chilling Where the meat carcasses are rapidly cooled after slaughter, so that the warmest point of the carcass is at a temperature of between +3°C to +7°C, depending on the cut and type of meat. (b) Secondary chilling Where the meat temperature is maintained below +7°C for red meat and below +4°C for poultry meat at all times, during chill storage, cutting, deboning, mincing, and before transportation. For frozen products, the shorter the freezing time is, the lesser the damage to the cellular structure of the protein, which will result in a better quality after defrosting, with a longer shelf life. Considering the shorter time required for freezing, many are opting for “blast freezing”, also called “shock freezing”. which means, freezing the product into the core in a short time. The faster you freeze an animal protein into the core, the less you will dehydrate it. Considering that meat is sold by weight, progressive dehydration means losing money. Therefore, faster freezing time will result in more output and more kilogrammes to sell. modular slaughterhouses for meat with cold rooms and freezers Considering the processing of meats, and animal proteins in general, requires very strict and precise cooling protocols, it is important to invest in high-quality cooling technology and cold storage facilities at production sites, ports, and distribution centres, with reliable refrigeration systems capable of maintaining the required temperature for the specific animal protein products. InspiraFarms Cooling provides modular and prefabricated slaughterhouses for the meat and poultry industries, offering the necessary temperature ranges and cooling features to efficiently cool and store meats. Our modular slaughterhouses offer a comprehensive solution for an animal protein treatment, encompassing various components such as slaughtering spaces, air-conditioned production areas, cold rooms for deboning, cuttingpacking, and dispatching halls, chilling and holding rooms for smaller meat cuts, blast freezing tunnels, freezers for further processing, and freezing rooms for carcasses Do you have questions or interested in starting a project? Get a quote today. 3. Temperature Monitoring Temperature is the main post-processing parameter in the determination of shelf-life in a cold chain of chilled and frozen food products. Therefore, it is critical to have a set of sensors to collect temperature data. At slaughterhouses, traders can adopt the InspiraFarms remote monitoring system which is integrated with our data cloud system. The system comes with a userfriendly online platform that works on any mobile or desktop device, allowing the instant sharing of detailed data and reports on temperature, humidity, door openings, and energy consumption, among others. The system consists of IoT-enabled sensors, including intelligent sensors, loggers, and electronics that work together to generate the key data needed to optimise cooling performance and track your energy consumption. This set of data solutions is available for both InspiraFarms cold rooms and as retrofitting for cold rooms delivered by others. By employing such efficient temperature sensors or data loggers throughout various stages of transportation— loading, unloading, and storage—meat traders can promptly detect any deviations from the necessary temperature range. This enables them to take immediate corrective measures, ensuring timely intervention. 4. Cold chain in meat transport and distribution Refrigerated trucks have different characteristics and performances. In brief, its size, initial temperature of incoming meat, the targeted temperature during transportation, mechanical characteristics (e.g., power of compressors, ventilation and insulation), as well as cost matters are issues of priority when considering the reefer. In general, the vehicle must be provided with a good refrigeration system capable of maintaining the required temperature of the meat at all times during distribution. It is therefore critical to collaborate with reliable transportation providers experienced in handling animal proteins, to ensure that the vehicles used for transportation are equipped with proper refrigeration units and can maintain the desired temperature throughout the journey. 5. Documentation and traceability for meat trading Maintaining meticulous and comprehensive records of temperature monitoring, handling procedures, and transportation conditions is of utmost importance. These records serve as crucial evidence of adherence to quality and safety standards, offering reassurance to all stakeholders involved in the trade. Further, in the unfortunate event of a product recall due to quality or safety concerns linked to the cold chain, proper documentation and a well-established traceability system becomes indispensable. Traders can quickly determine which products are affected, trace their distribution routes, and retrieve them from the market. In turn, this helps in risk management, regarding cold chain challenges, such as temperature fluctuations or improper handling, which can lead to spoilage, contamination, and increased health risks. Moreover, traceability proves instrumental in managing risks associated with cold chain challenges. With issues like temperature fluctuations or improper handling leading to spoilage, contamination, and heightened health hazards, a reliable traceability system allows traders to pinpoint the source of these challenges and take immediate corrective measures. For instance, if a problem arises in a specific batch of meat, the documentation allows traders to identify precisely where the issue occurred, preventing its spread to other batches. PAGE 09 FOOD MANUFACTURER MAGAZINE ZAMBIA | 2024
Most of you dear readers may already have some basic knowledge about ZABS however, it is important that we reintroduce ourselves before we delve into the subject of certification. Before 2018, ZABS was known for its role in regulating all products that fall under the compulsory standards in addi- tion to other functions such as the development of standards, testing of products and pro- vision of training and certifi- cation services. Well, this has since changed. The mandate of ZABS was redefined in 2018, from being a regulator to “A friend of industry” making our role more focused on helping industry to improve the quality and safety of products, ser- vices and systems. We enable the development of standards and encourage their use while providing conformity assessment services such as testing, training and certification. These services are voluntary and are available to help Industry produce quality products that meet the expec- tation of the consumers and complies to the various specifi- cations or regulations that may be in place. Certification: Unlocking Markets for SMEs The food industry is one sector that we are passionate to see grow and have local products take their pride of place in the market. We are all eager to see local manufacturers and producers rise to the occasion however, many of them particularly SMEs face challenges in meeting the requirements laid out by their customers in the high value markets. These challenges relate to limited knowledge of how to improve processes, product quali- ty, and product packaging among others. As ZABS, we have devoted attention to assisting players in the food industry align themselves towards implementing quality sys- tems that will help them succeed in today’s business environment. This is through the Certified Local Supplier Scheme (CLSS) which is a product certification scheme specifically for SMEs in the food industry. Product certification denotes the process through which a product is subjected to, in order to veri- fy that it has passed quality and performance tests. It is a process whereby a third party, such as ZABS, provides CERTIFICATION Unlocking Markets for SMEs PAGE 10 FOOD MANUFACTURER MAGAZINE ZAMBIA | 2024
We are your top-tier meat-processing company in Zambia. We offer you a variety of product made from lamb, goat, beef, and pork. We are situated in a cuttingedge process- ing facility in Makeni. This facility includes two abattoirs, which are our pork and halal abattoirs. Our success is driven by our people, our focus on results and our strict quality control. We Meat Standard Quality. As a company, we are able to deliver you the highest quality meat that is “fresh from the farm. “ For example, consider the delivery of fresh meat to your business. We use a cold chain management system to supply fresh meat to you. This requires the use of cold rooms, refrigerated transportation, and monitoring of temperature profiles. This is just one of the numerous factors that make our meat so high grade. The Meat The World Owes You. If you’re looking for premium meat, first-rate packaging, free delivery, special cuts, and a broad variety of meat selections that all fit your requirements, search no further. Contact us for all enquiries and we’ll get you what you deserve Factory Plot 288 h Makeni Konga | +260 969 412 597 / +260 969 412 407 [email protected] www.kachema.com
2852 (JUNE 22 POINTED CIRCLE) www.chep.com A Brambles Company Contact us today. +260 960 994281 | [email protected] Plot 10936, Off Mukatasha Road, Chinika Industrial Area, Lusaka, Zambia 8015 POOLING PALLET Zambia has made great strides in import substitution in vegetables with an increased number of local products in multinational chain stores. Among some of the vegetables the country has stopped importing is sweet corn, red cabbage, cocktail tomatoes, groundnuts, English cucumber, garlic, ginger, pineapples, okra, and celery. A survey conducted in Lusaka recently found most shelves stocked with local produce. There is an increased participation of local farmers in the agribusiness supply chain and Zambian farmers are cultivating most of the vegetables that were being imported from South Africa. “But if growers cannot get their produce to market or to retailers on time, food insecurity in Zambia will be compounded” says Muchie Sarari, CHEP Zambia Business Manager. CHEP’s pallets, crates and containers form the invisible backbone of the global supply chain. From producers to food manufacturers, distributors, and retailers, CHEP’s support of vital food supply chains fan across Zambia via its service centre in Lusaka. It provides a managed pallet pooling program that is more economical and more environmentally sustainable than single use, white wood pallets and other delivery platforms. Its reusable packaging is specifically designed for multiple trips over an extended life, offering a rapid return on investment and a lower cost-per-trip than single trip packaging products. Here’s why some of the Zambian companies are finding the CHEP offering so appealing - + Cost effective - Pooled distribution platforms offer all the benefits of ownership without major capital outlay and also helps to maintain a positive cash flow. Budgeting is simplified with a daily hire fee per product, which includes rental, wash, repair, and management. + Better product protection - Returnable packaging, such as CHEP’s Reusable Plastic Crates (RPCs), is manufactured and designed to be more robust and durable than single use cardboard, helping to reduce the risk of product damage during transit. + Reduces transport and handling needs - Returnable packaging is designed to be stacked and are often collapsible, thus reducing storage and transport space and the associated costs. + Improved hygiene and guaranteed loadbearing - On return to our service centre, RPCs are washed to in-country hygiene specifications and pallets are repaired to ensure that it delivers the load bearing value it is specified to. + Flexibility - Distribution platforms are available in any volume you need, for the period you specify, and therefore provide the maximum flexibility to cater for seasonal peaks and troughs. You no longer need to hold on to high levels of stock during seasonal lows and pay the price for it. We’re excited to connect with you to find new ways to collaborate, innovate and build smarter and more sustainable supply chains - creating more value and using fewer resources, together. Zambia sees boost in local fresh produce It’s better for business. It’s better for our planet. Sharing networks, knowledge, platforms, and solutions to help drive efficiency, safety, and sustainability in your supply chain. 8004 RPC STRINGER PALLET 8071 BULK BIN
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Zambia’s Food Processing Industry F ood processors make up 60% of Zambia’s manufacturing output, and 90% of processing focuses on foods (vs beverages). Major value chains include grains (maize and wheat for cereal blends), edible oils from sunflowers and other seeds, soy, and dairy. Within the region, Zambia’s ample maize production and the border with eight countries provide opportunities for regional trade and increased foreign exchange earnings. Combined with Zambia’s advantages with regard to food production (contains 40% of Southern and Central Africa’s water supply; only 20% of the 75 million ha of arable is currently in production), Zambia is in a favourable position to become more of a regional hub for food production and food security. STRATEGIC APPROACH In line with our programme objectives and through the proposed intervention areas, our support to SME food processors will result in improved business skills, and food quality and safety standards. SMEs will also see increased market system integration, voice, experience a sense of validation, belonging and support. We will measure the results of our support by tracking (1) reduced gaps in performance between men and women-led or owned food processing SMEs, as well as (2) increased confidence and positivity about opportunities. Improving mindset, practices through our support will lead to increased sales of marketable volumes, increased revenues, and jobs created. The overall effect of our interventions will be amore inclusive SME food processing sector, in Zambia, resulting in increased resilience and economic and nutritional benefits for the BOP, particularly women and youth. The project will implement three key activities 1. Sector-wide trainings a critical tool for knowledge transfer at scale, stimulating industry dialogue and creating a community of practice within the processing sector. 2. Customized technical assistance FED programme’s team of Food Technologists and Business Advisors will support 100 SMEs with CTA – working with five groups of 20 over a three to six- month period. 3. Support SME access to finance This activity is designed to address SME food processors’ limited access to finance – one of their biggest barriers to competitiveness and growth. the technical team will support SME finance in two ways: 1) launch a small in-kind grants fund, through which the programme will procure goods and services, such as capital equipment or paying directly for safety certifications, on behalf of the grantee and 2) facilitate linkages between SMEs and third-party finance providers (either projects or FIs) Since 2008, TechnoServe has operated in the Zambia with a primary focus on strengthening the food processing sector and improving nutritional outcomes. TechnoServe has worked with over 1,500 food processors like Java Foods across Africa, which has led to $14 million in increased investment, more than 1,100 new jobs created and strengthened markets for approximately two million small holder farmers (SHF). As a result, TechnoServe improved the standards, quality and access of staples and therapeutic and supplementary foods for the most vulnerable. A key part of this work has been in Zambia. Tillage Village Pintos Beverages PAGE 14 FOOD MANUFACTURER MAGAZINE ZAMBIA | 2024
We offer nutrition support with: NUTRITION SERVICES @eatsmartdietetics Check out our shop and grab a Zambian weight loss plan or diabetic guide. The choices are endless. Meal plans, ebooks & more If you want the best chance for success this is the option for you. Research confirms that ongoing support and a personalized meal plan are key to achieving your nutrition goals. Unlock consultations, resources, and unwavering support between sessions. Invest in your employees' well-being for enhanced productivity and engagement. Health and well-being programs not only increase staff happiness but also boost productivity. Weight Loss Diabetes High Blood Pressure High Cholesterol Gastritis IBS Allergies & Intolerances Kidney Disease Pregnancy & Lactation Sports Nutrition Cancer & so much more! One on One coaching Corporate Wellness Programs OUR SERVICES & PRODUCTS CONTACT US: Teaching you how to eat healthy with affordable and accessible cultural food. +260763580766 @cultural_dietitian @cultural_dietitian FOLLOW US : [email protected] www.eatsmartdietetics.com