Chelle Hartzer, Orkin
Bug Bytes

Stored Product Insects Are Costly Consumers

By Chelle Hartzer
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Chelle Hartzer, Orkin

How much can pest issues cost? The truth is, it changes based on the pest, the size of the population and the prevalence throughout your food processing facility and products. If you want to protect your bottom line, you need to know which pests are the biggest threat and take steps to prevent them. Let’s focus on one major threat to food processing facilities: Stored product insects.

Believed by some pest control providers to be the costliest pests for food manufacturing and processing businesses, stored product insects can put a huge dent in your profits. What’s worse, these pests can be tough to discover by an untrained eye, and they’re incredibly difficult to control without the help of a pest management professional.

According to the USDA and the University of Wisconsin, “stored product pests can damage, contaminate, or consume as much as 10% of the total food produced in the U.S. alone, while in developing countries that rate has been estimated at 50% or more.”

That’s an astronomical figure for such small insects! Can you imagine the impact on your bottom line if 10% of your product was ruined?

For any business in need of an updated prevention plan, the first step is to review the current integrated pest management (IPM) program to ensure a proactive approach has been implemented to monitor for, and react quickly to, any pest issues around the facility. There’s no one-size-fits-all strategy for an IPM program; each program should be customized to meet the needs of the individual business. Different geography, construction and food products being produced can all create different pest pressures.

According to another study conducted by CEBR on the impact of pests on the global food supply, disruptions caused by pest infestations resulted in $9.6 billion in operating costs in the countries surveyed and 84% of U.S. businesses reported a net impact on revenue due to pest infestation across a five-year period. Diving deeper, 28% of food manufacturers and processors reported pest-related costs associated with contamination of raw materials leading to replacement costs.

In other words, having stored product insects around is expensive. If there were ever any doubts about the value of a proactive IPM program, these statistics prove it. So, let’s take a closer look at how you can work to protect your business against stored product insect—some of the most likely and costly invaders.

Types of Stored Product Insects

The term stored product insect covers a range of insect species that can be broken up into three main subcategories: External feeders, internal developers and secondary feeders. Each category has its own distinct characteristics, which are important to know for detection and proper identification.

External Feeders

This group develops on the outside of products, including damaged grains and processed foods. As they feed, they damage product and leave behind frass (insect droppings) as they make their way through.

Some of the most common external feeders include Indian meal moths and flour beetles.

Adult Indian meal moths are roughly 9 mm long and have a wingspan of 14–20 mm. The front wings on the adults are bicolored, with two main tones: Reddish-brown at the wing tip and silver-grey at the base. If you don’t see the pest itself, you may notice a messy silk webbing spun by the larvae.

Red and confused flour beetles, two of the most common beetle species, are 3–4 mm in length and also have a reddish-brown color. They’re rectangular-shaped beetles and can often be found in grain bins infested with internal developers. This is because flour beetles like to feed on the kernels other stored product insects, like borers, have already broken up. They can also be found in processing lines and finished products.

Internal Feeders

Internal feeders lay eggs inside or outside of kernels of grain but develop entirely inside those kernels. As they develop, they hollow out the kernel, then the adults can go on to damage other kernels.

Some of the most commonly encountered internal developers are lesser grain borers and rice, maize and granary weevils. Weevils measure about 5 mm in length and are usually brown in color with a distinct elongated “snout.” Lesser grain borers, the most common internal feeder across the United States infesting wheat, are a bit smaller and don’t have the snout that weevils do. Both weevils and lesser grain borers have pitted patterns on their bodies, and all can fly except the granary weevil. As the larvae and pupae develop inside grain kernels, damage becomes especially evident when the adult chews out and leaves a distinctive perfectly round hole.

Secondary Feeders

This group typically eats from the outside in and feeds on the mold and fungus that can grow on out-of-condition grain and damp product.

Two of the most common secondary feeders are the foreign grain beetle and sawtoothed grain beetle. Foreign grain beetles love mold, and resemble flour beetles in size and color. To tell them apart, look for two “bumps” on the top corners of the thorax. Eliminating molds and damp conditions that facilitate mold growth is generally enough to help prevent infestations from secondary feeders.

Sawtoothed grain beetles can feed on many types of products and while they can’t physically penetrate packaging, the adults will find holes less than 1 mm in diameter, lay eggs, and the larvae will squeeze through the tiny openings to get to the product. They prefer processed food products like bran, chocolate, oatmeal and even pet foods, but will feed on whatever they can access. Sawtoothed grain beetles are smaller than flour beetles (3 mm) and have distinctive “teeth” on the margins of the thorax.

Prevention, Monitoring & Detection, and Removal

The best way to protect a facility from stored product insects is to employ numerous different tactics. Specifically, it’s important to proactively mitigate pest attractants, monitor for activity in key areas around the facility, and establish thresholds and action plans when pests are detected.

First and foremost, educate all employees about the pests most common around your facility and what to do should they spot one. Your pest sighting log is a great tool, but only if people use it! Have a clear escalation plan for any pest issues spotted. In addition, create a sanitation schedule to ensure all areas and equipment are cleaned to remove food and moisture buildup attractive to pests on a regular basis. While you can’t possibly eliminate all food (you are of course storing and processing food!), the aim is to minimize the amount and the access these insects have to that food source.

Next, make sure all incoming shipments and packages are inspected closely in a sealed off unloading area away from other products. Make sure employees know to check for signs of damage, especially holes caused by boring pests. Taking the time to inspect anything entering your facility in this way will give you a chance to spot pests before they have the chance to spread to your other products. Use the first-in, first-out (FIFO) approach for all goods to ensure older product doesn’t sit. The longer product sits, the more chance it can be infested and it may start deteriorating, and this is especially attractive to stored product insects.

For ongoing monitoring, talk to a pest management professional about deploying pheromone traps strategically around your facility. Pheromone traps are the best tool to monitor for stored product insects, as they will give you an idea of which pests are present, in what numbers, where they are, and they can help you track trends in pest activity over time. If any stored product insects are ever spotted, contact your pest management professional immediately. If there’s a chance of having stored product insects on your product, you absolutely should have pheromone trap monitoring in place.

The Total Cost of Stored Product Pest Problems

The impact of pest issues caused by stored product insects isn’t limited to the cost of paused operations and replacing contaminated product. These pests are tough to spot, and could be passed along to partners further down the supply chain. Naturally this could hurt the trust between supply chain partners, which is never a good thing!

If your facility gets a reputation of having problems with stored product insects, it’s going to hurt your brand—and that’s going to be another knock to your bottom line. Stored product insects can spread quickly between products placed closely together. So, if pests are mistakenly shipped to a partner’s facility or a store and then on to a customer, now THEY are going to have to deal with stored product insects, too. Being proactive is the best approach, and careful documentation can help you and your supply chain partners track pest issues to the source so they can be resolved quickly and minimize the impact on profits.

It becomes easy to see stored product insects can cause both short-term and long-term effects on the profitability of a business. Don’t let that be your facility and your reputation! Be proactive and partner with a pest management provider to help ensure your facility operations run smoothly and your customers stay happy.

Chris Keith, FlexXray
FST Soapbox

What Should I Do if I Have a Foreign Material Problem?

By Chris Keith
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Chris Keith, FlexXray

Imagine this: While cleaning a slicing machine during a sanitation break, one of your employees discovered a piece of harp wire was missing from the machine. The meat that had been sliced since the cutting machine’s last inspection had already been added to your product, and the product had been packaged. It had already passed through your company’s inline inspection machines without any foreign contaminants being detected.

You enjoy a spotless reputation in the food industry and know that if consumers lose faith in the product, it will suffer significant damage to both its reputation and its bottom line. So what do you do now?

Here’s a look at four different scenarios and how each one can affect a respected food manufacturer.

Option 1: Dispose of the Full Production Run

Disposing of a full production run will give your company complete confidence that the contaminant issue is resolved and will never reach the public. However, you have to take into consideration the full cost and implications of such a move, such as:

Where to dispose of the contaminated product. The FDA has specific rules about disposing of contaminated food products, but those guidelines can be affected by local, state and even federal regulations. Among the disposal options are landfills, rendering or incineration. You must find the proper facility, arrange the safe transportation of the product and procure all the required permits for the disposal.

Food waste. With 40% of the food produced in the United States going to waste, and 50 million Americans not knowing where their next meal will come from, you don’t want to add to the problem.

Product out of stock. Having your product out of stock will be costly. In addition to the lost sales, there’s a chance that consumers will turn to another brand—and not return to buying your product.

Cost of reproduction. To re-run the entire product line, you will essentially double your costs. You will have to pay for the cost of the products used, as well as pay for new packaging and all labor costs.

Option 2: Rework the Product In-House

You can use your own resources and inline equipment to try and troubleshoot the problem. Running the product through the metal detector to look for the harp wire could salvage most of the product, and would give your company the ability to supervise the entire process. That way, if you find the metal, you’d know firsthand that the contaminated product is out of production and won’t reach consumers.

But there are some expensive downsides to this approach. Among the factors that your company must consider are:

Loss of productivity. Both from the standpoint of equipment utilization and the productivity of employees, reworking the product would be costly to the company. You would have to have to slow the production line and manually re-run all the product through the metal detector to look for the missing wire.

Increased labor costs. You would have to pay overtime to your employees and keep your standard production line running while it re-runs the product and looks for the suspected contamination.

Limitations of their inspection equipment. Your results are only as good as the equipment you are using, and there’s always a risk that the metal detector that missed it the first time won’t find it the second time, either.

It seems like a bit of a gamble; if the metal detector catches it the second time around, then it could be worth it. If the product is re-run and no contaminants are found, however, your company is back where it started and must decide how to move forward.

Option 3: Risk It and Ship the Product to Retailers

Since the metal wasn’t detected by the company’s inline inspection system, you cannot be absolutely sure the metal is in the product. You only know that a broken piece of harp wire is missing; it’s unclear whether that wire made it into the food.

The least expensive option—but also the riskiest—is to go ahead and ship the product, hoping that the missing wire didn’t make it into the food and, therefore, never gets discovered by consumers.

There’s a chance that the metal detector was right, the wire isn’t in the food, and things will be fine. However, if the risky gamble doesn’t go in your favor, the consequences could be severe and this becomes the most expensive option of all. Among the risks the company faces are the following.

Costly recall. Food recalls are always expensive. According to a study from the Food Marketing Institute and the Grocery Manufacturers Association, the average recall runs up a $10 million tab in direct costs alone.

This includes the cost of notifying the supply chain and consumers, retrieving the product, storage, disposal and additional labor costs associated with having to perform all of these actions.

Possible litigation. Food recalls often are accompanied by lawsuits, and if the metal wire is eaten by a customer and causes injury, you could be held liable for everything from medical bills to time lost from work due to pain and suffering.

Bad publicity and lost sales. In today’s 24/7 news world and with the power of social networking, news of a food recall can reach consumers at lightning speed. This equates directly to lost sales and can have a negative impact on your brand reputation and market value.

A recent Harris Interactive Poll found that 55% of consumers would switch brands temporarily after a recall, and 15% would never buy the product again. What’s more, 21% said they would avoid buying any other products made by that manufacturer.

Option 4: Use an X-ray Inspection Service

A fourth option can help avoid lawsuits, recalls and bad publicity, while at the same time sidestepping unnecessary waste and the costs associated with disposing of an entire production run or reworking it internally.

You can have your product shipped to an X-ray inspection facility, or use an X-ray inspection rental service.

A contaminant removal service and professional catalog reporting with full traceability could also ensure that the specific contaminant was located and removed, and you would have the confidence that the problem had been resolved as the product reached consumers. There are several other advantages to using a company that offers this type of solution as well, including:

Reduced waste. Because the only product being thrown away would be the product that was contaminated, there would be minimal waste. This is the only option that allows you to recover the rest of the product, with the certainty that it has been inspected and is safe for its customers.

Advanced detection capabilities. You can be confident in inspection process using custom technology that enables the detection of foreign particles down to 0.8 mm or smaller. In addition to metal, such systems can also detect product clumps, glass particles, stones, bone, rubber, plastic, wood, gasket materials, container defects and missing components.

This type of solution far exceeds the capabilities of inline inspection machines, and, because it can run a single pallet an hour, instead of the average 10,000 pounds an hour, and thus it spends more time focusing on what is passing through the machine to ensure no contaminants pass through.

Final Thoughts

When it comes to the quality of your product, it’s better not to take any chances. When you put your product line in the hands of a third-party X-ray food inspection company, you know you will get results since food safety is our specialty — and it’s what they do, all day, every day.

Courtney Bosch-Tanguy
Retail Food Safety Forum

Three Reasons your Restaurant Needs to Take Food Safety Seriously

By Courtney Bosch-Tanguy
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Courtney Bosch-Tanguy

Food that is not only fresh and delicious but is also safe to eat is a must for any restaurant. Foodborne illnesses are a real threat to consumers and can permanently mar the reputation of the chain or restaurant who spreads them. If you’re at risk for serving up a chicken breast with a side of Salmonella or a burger crawling with E. coli, it is just a matter of time before someone gets sick. According to the CDC, about one in six Americans will get sick from a foodborne illness each year; more than 125,000 people per year become ill enough to be hospitalized.

Beyond the moral obligation to serve up quality food and to make sure your customers don’t get sick, attention to food safety can also prevent a public relations nightmare for your brand. The very mention of foodborne illness triggers a connection with Chipotle, even though many of the brand’s news-making outbreaks were over three years ago. Keeping customers, your business, and your reputation safe are just three reasons to incorporate food safety best practices into your daily routine.

Promote Customer Safety

You’re in business to serve your community or a specific population, so it is in your and their best interests to ensure the food you are serving up is not only tasty, but safe as well. Proper attention to everything from handwashing, to choosing the right cutting surfaces, to serving and storing food at the proper temperature, and properly labeling prepared foods and ingredients ensures you’re not harming the very customers you are trying to serve.

When you can be confident that your sanitation, storage and labeling process are the best they can be, you can serve every customer with pride, knowing you’ve provided them with the best possible meal or item. Your customers will know they can patronize your establishment with confidence that you take their safety seriously and are consistently dedicated to quality.

Protect Your Reputation

Chipotle, Taco Bell, and other brands found out the hard way: News spreads fast. In this era of smart phones and instant communication, that hair attached to your pasta is horrifying for more than just the patron who ordered it. With social media at the ready, one mistake could be broadcast to an audience of thousands in just seconds.

In 2015, Chipotle made headlines, for all the wrong reasons. The brand had outbreaks in multiple locations, spanning 11 states. Even after a public and thorough store sanitation and cleansing, consumers and media still question the level of food safety in the brand’s locations and how these outbreaks were handled by the company. Chipotle had a more recent incident this summer. The chain committed to retraining all of its restaurant workers nationwide on food safety after nearly 650 customers became ill from eating at one of its Ohio restaurants. Tests showed sickened customers had Clostridium perfringens, which is a foodborne disease that occurs when food is left at an unsafe temperature.

Taco Bell has been under investigation for foodborne illness multiple times in the past few decades, dating back to 1995. From Salmonella to E.coli, the brand continues to struggle with food safety, making it a frequent target of both the news media and comedians cracking jokes at the brand’s expense.

Protect Your Business

Chipotle suffered in more ways than one during that series of publicized outbreaks. The company’s stocks and profits plummeted, even after the outbreak appeared to be over. Jack in the Box never fully recovered after a tragic case of E. coli outbreak that resulted in the deaths of four children almost two decades ago.

Consumers have long memories, and there is no such thing as an isolated incident anymore. Focusing on food safety in this digital, social-media-powered era is more important than ever before. Simple steps, from properly training your employees about food safety, to implementing the right tools and technology to manage a food safety program, to properly labeling and testing food before you serve it, can help your brand maintain its sterling reputation and keep your customers safe.

Every step you take towards implementing proper food safety protocol is a step in the right direction for your customers, your business, and your reputation.

Tim Lozier, EtQ, Inc.
FST Soapbox

How to Mitigate Risks and Issues in Your Supply Chain

By Timothy Lozier
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Tim Lozier, EtQ, Inc.

As business becomes more global, effective and efficient, supply chain management is more vital than ever. Even if you’ve optimized your supply chain, uncertainty can cause issues when sourcing raw materials, goods and services, which could ultimately impact on your business, customers, revenue and reputation.

Fortunately, forward-looking risk management can help you understand potential problems in the supply chain and allow you to create contingency plans or take mitigating actions. Supplier risk management will let you ensure quality at every stage, help you prepare for potential issues, and deliver goods and services to the quality and deadlines your customers expect.

An Overview of the Supply Chain

The supply chain is the process through which you source raw materials, goods, services and other key functions from your suppliers. It has multiple facets:

  • Identify the right suppliers and vendors.
  • Negotiate prices, terms and conditions.
  • Place orders with suppliers.
  • Arrange for transport of goods and services to your business or to other manufacturers.
  • Make payments to suppliers.
  • Receive products and services into your business for onward provision to end customers.

If you want to avoid problems and maximize quality throughout the supply chain, you will need to explore each of these areas.

Key Risks to Effective Supply Chain Management

Here are the main risks on the supplier side, and how to manage potential issues.

Poor Quality Supplier Challenges

Risks with poor quality suppliers include:

  • Goods, services and raw materials that do not meet your requirements.
  • Delays in sending out your orders.
  • Unreasonable demands made to your business.
  • Hidden, detrimental terms and conditions.
  • Damaged vendor relationships.

You can mitigate these risks through:

  • Getting recommendations from other organizations that are sourcing similar items or services.
  • Insisting on samples of the items you are planning to purchase.
  • Reading reviews of suppliers and feedback from other customers.
  • Ensuring you have robust contracts in place that clearly define the relationship.
  • Employing a vendor manager who can ensure that relationships and negotiations run smoothly.

Unexpected Prices or Supply Challenges

Risks with pricing and supply include:

• Volatile pricing and potential overcharging.
• Suppliers not being able to source and provide what you have ordered.

You can mitigate these risks through:

  • Locking in guaranteed pricing for specific areas and predefined lengths of time.
  • Auditing of invoicing and costs versus agreements and contracts.
  • Getting backup suppliers in place if your original supplier has a supply issue.
  • Guaranteeing with the supplier that they will hold a certain amount of inventory for your specific needs.
  • Insisting on regular reports of stock levels that you can draw down from.

Cultural, Environmental and Economic Challenges

Risks with culture, environment and the economy include:

  • Language and cultural barriers with suppliers leading to misunderstanding.
  • Local laws that impact on a supplier’s ability to meet your needs.
  • Environmental factors like natural disasters
  • Unstable political movements.
  • Societal unrest and conflict.

You can mitigate these risks through:

  • Getting backup suppliers in place if your original supplier has a supply issue.
  • Using local expertise to understand and deal with any potential legal or political issues.
  • Creating a contingency plan in the event of a natural disaster or economic issues.
  • Using a relationship manager who can understand and deal with differences in language and culture.

Transportation and Distribution Challenges

Risks with transportation and distribution include:

  • Inefficient logistics and distribution, leading to delays or loss.
  • Unexpected costs of transportation, import and export, including tariffs and customs.

You can mitigate these risks through:

  • Getting backup distributors in place if your original distributor has an issue.
  • Reading reviews of distributors and feedback from other customers.
  • Ensuring you have robust contracts in place that clearly define the relationship.
  • Understanding potential costs throughout the supply chain.
  • Creating a contingency plan in the event of supplier issues.

Examples of Supply Chain Risks and Issues in the Food Industry

Let’s dig into some potential risks to food supply chains, and how you might mitigate them.

Unusual Weather Patterns Lead to Smaller Harvests and Lower Yields
Food manufacturers rely on a steady supply of raw materials to make the products consumers eat every day. However, weather and climate can be anything other than predictable, and have several associated risks. Potential mitigation plans include:

  • Identifying early climate trends that could impact a region and seeking out alternative sources.
  • Having backup contracts with other suppliers if the crops from one region fail to meet appropriate yields.
  • Developing alternative products that use fewer of a particular type of raw material or ingredient.
  • Stockpiling vital ingredients in secure, long-term storage.

Tariffs Impact Import and Export Prices
Political uncertainty can result in increased customs tariffs to trade in certain goods. Potential mitigation plans include:

  • Importing or exporting a surplus of goods before the tariffs come into effect.
  • Seeking out alternative routes for food supply chains that do not go through impacted countries.
  • Diversifying into food production that’s not impacted by specific tariffs.
  • Moving part of manufacturing to regions not affected by tariffs.

Unexpected Production Issues Impact Food Safety
Food safety is critical to consumer confidence and a food manufacturer’s reputation. Despite stringent quality in the ingredient and manufacturing process, the global food supply chain can sometimes introduce contamination or other risks. Potential mitigation plans include:

  • Clear, objective, verified, regular testing of all raw ingredients, independent of origin, type or destination.
  • Labeling, batch numbers and other identifiers so all goods can be tracked through the supply chain to allow for easy identification of contaminant sources.
  • st recall process so any products that are in stores can be easily removed and returned for testing.
  • Exceeding FDA regulations and guidelines for safe food manufacturing.

When you’re managing risk in the supply chain, it is vital to capture all potential issues and prioritize them in terms of likelihood, impact and any other variables that are critical to your business. You can then get risk mitigation plans in place, and ensure your stakeholders and cross-functional teams have the resources they need to resolve your supply chain risks.

Stephanie Pollard, ClearLabs
In the Food Lab

The Power of Advanced NGS Technology in Routine Pathogen Testing

By Stephanie Pollard
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Stephanie Pollard, ClearLabs

The food industry is beginning to transition into an era of big data and analytics unlike anything the industry has ever experienced. However, while the evolution of big data brings excitement and the buzz of new possibilities, it also comes coupled with an element of confusion due to the lack of tools for interpretation and lack of practical applications of the newly available information.

As we step into this new era and begin to embrace these changes, we need to invest time to educate ourselves on the possibilities before us, then make informed and action-oriented decisions on how to best use big data to move food safety and quality into the next generation.

Stephanie Pollard will be presenting “The Power of Advanced NGS Technology in Routine Pathogen Testing” at the 2018 Food Safety Consortium | November 13–15One of the big questions for big data and analytics in the food safety industry is the exact origins of this new data. Next Generation Sequencing (NGS) is one new and disruptive technology that will contribute significantly to a data explosion in our industry.

NGS-based platforms offer the ability to see what was previously impossible with PCR and other technologies. These technologies generate millions of sequences simultaneously, enabling greater resolution into the microbial ecology of food and environmental surfaces.

This represents a seismic shift in the food safety world. It changes the age-old food microbiology question from: “Is this specific microbe in my sample?” to “what is the microbial makeup of my sample?”

Traditionally, microbiologists have relied on culture-based technologies to measure the microbial composition of foods and inform risk management decisions. While these techniques have been well studied and are standard practices in food safety and quality measures, they only address a small piece of a much bigger microbial puzzle. NGS-based systems allow more complete visibility into this puzzle, enabling more informed risk management decisions.

With these advances, one practical application of NGS in existing food safety management systems is in routine pathogen testing. Routine pathogen testing is a form of risk assessment that typically gives a binary presence/absence result for a target pathogen.

NGS-based platforms can enhance this output by generating more than the standard binary result through a tunable resolution approach. NGS-based platforms can be designed to be as broad, or as specific, as desired to best fit the needs of the end user.

Imagine using an NGS-based platform for your routine pathogen testing needs, but instead of limiting the information you gather to yes/no answers for a target pathogen, you also obtain additional pertinent information, including: Serotype and/or strain identification, resident/transient designation, predictive shelf-life analysis, microbiome analysis, or predictive risk assessment.

By integrating an NGS-based platform into routine pathogen testing, one can begin to build a microbial database of the production facility, which can be used to distinguish resident pathogens and/or spoilage microbes from transient ones. This information can be used to monitor and improve existing or new sanitation practices as well as provide valuable information on ingredient quality and safety.

This data can also feed directly into supplier quality assurance programs and enable more informed decisions regarding building partnerships with suppliers who offer superior products.

Similarly, by analyzing the microbiome of a food matrix, food producers can identify the presence of food spoilage microbes to inform more accurate shelf-life predictions as well as evaluate the efficacy of interventions designed to reduce those microbes from proliferating in your product (e.g. modified packaging strategies, storage conditions, or processing parameters).

Envision a technology that enables all of the aforementioned possibilities while requiring minimal disruption to integrate into existing food safety management systems. NGS-based platforms offer answers to traditional pathogen testing needs for presence/absence information, all the while providing a vast amount of additional information. Envision a future in which we step outside of our age-old approach of assessing the safety of the food that we eat via testing for the presence of a specific pathogen. Envision a future in which we raise our standards for safety and focus on finding whatever is there, without having to know in advance what to look for.

Every year we learn of new advancements that challenge the previously limited view on the different pathogens that survive and proliferate on certain food products and have been overlooked (e.g., Listeria in melons). Advanced NGS technologies allow us to break free of those associations and focus more on truly assessing the safety and quality of our products by providing a deeper understanding of the molecular makeup of our food.

Megan Nichols
FST Soapbox

Sustainability Strategies for the Food Industry

By Megan Ray Nichols
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Megan Nichols

Sustainability is a word that you’ll hear a lot these days, especially as industries try to become more eco-friendly. The food industry has been lagging behind in the world of sustainability, and in order to keep up with national and international food demands, it is difficult to implement the kind of change that is necessary to make the world a little greener. However, that doesn’t mean that food companies shouldn’t try. The following are some sustainability strategies that might be easier to implement in the food industry.

Water Conservation

field irrigation
Field irrigation (Wikipedia commons image)

While the majority of the Earth’s surface is covered in water, only about 3% of that water is drinkable—and 2 of that 3% is frozen in the planet’s glaciers and ice caps. This is why water conservation is so important. According to the United States Geological Survey (USGS), roughly 39% of fresh water used in the United States is used to irrigate crops.

Switching from flood irrigation with sprinklers to drip irrigation can reduce water usage.

Wastewater reuse is also a new technique that is gaining traction in the food industry. While it isn‘t practical in all situations due to the technology needed to remove chemicals and impurities from the wastewater, it can help reduce water waste and water use in the food industry. Simply reviewing water usage and switching to procedures that are less water-intensive can save a company money and reduce its overall water usage.

Natural Pest Control

Pesticides and fertilizers are among some of the most dangerous chemicals in the food industry. For largescale operations, however, they are necessary to ensure a large and healthy harvest. Some companies, such as Kemin Industries, are shunning these typical processes in favor of more sustainable options.

“Our mission at Kemin is to improve the quality of life for more than half the world’s population, and we believe sustainability plays an important role in our work,” said Dr. Chris Nelson, president and CEO of Kemin Industries. “Our FORTIUM line of rosemary-extract-based ingredients uses Kemin-grown rosemary for maximum effectiveness against color and flavor degradation. Kemin is the only rosemary supplier that is certified SCS Sustainably Grown, and we’re one of the world’s largest growers of vertically integrated rosemary.”

Vertical integration doesn’t have anything to do with how the rosemary is grown. In the agriculture industry, it means Kemin owns the entire supply chain for its rosemary, from field to processing to distribution.

“We use botanicals—spearmint, oregano, marigold and potato, in addition to rosemary—in our other products as well,” continued Nelson. “As an ingredient manufacturer, we understand the value of good suppliers. When the planet is supplying us with the ingredients we use in our products, it’s important to us that we are responsible in our growing practices.”

Sustainable Distribution

Distribution is one of the biggest problems when it comes to creating eco-friendly and sustainable supply chains. Upwards of 70% of the products in the United States are transported by truck, and each of those trucks generates CO2 and greenhouse gases.

There are two plans of attack for sustainability in food distribution: Reducing the distance food needs to travel, and upgrading trucks to use greener fuel options like biodiesel or electricity, such as the ones Tesla is offering.

Reducing the emissions created by tractor-trailers could help make the entire process a bit more sustainable, although it would require a large investment to upgrade the distribution process.

Back to Their Roots

It’s only in recent decades that agriculture has started being sustainable in an effort to keep up with the demands of the consumer. By going back to our roots and focusing on farming techniques that promote things like soil health—by rotating crops instead of using artificial fertilizers—and lowering water use and pollution, agriculture can become sustainable once again.

Farming, sustainability
Creative Commons image

Modern agricultural techniques are detrimental, both to the environment and to the people who work there. These methods ensure we have enough food to supply consumers, but they lead to soil depletion and groundwater contamination. In addition to this, it can also lead to the degradation of rural communities that would normally be centered on farm work. That’s because corporate farms focus on quotas and large harvests without the community angle.

These commercial farms also cost more to run, and many have poor conditions for farmworkers because of the harsh chemicals used to kill pests and fertilize depleted topsoil.

Farm numbers have dropped since the end of World War II, with corporate farms taking the place of smaller family farms. While the number of farms has dropped, the remaining farms have increased in size. The average farm in 1875 was roughly 150 acres, and there were more than 4 million of them. Today, less than half that number remains, but the average size of the farms has increased to more than 450 acres.

Sustainability is a popular buzzword right now, but it’s a lot more important than most people believe. Switching to sustainable practices, whether that means changing production, distribution or anything in between, will help ensure the food industry can keep fresh, healthy food on our table for decades to come without damaging the environment. Sustainability is something that should be adopted by every industry, especially agriculture.

Jessia Burke, Allergen Control Group
Allergen Alley

Allergen Detection & Control: Challenges & Strategies

By Jessica Burke
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Jessia Burke, Allergen Control Group

While global market demand for “free-from” food products is increasing, undeclared and mislabelled allergens, sulphites and gluten, throughout the supply chain, continue to be the number one cause of consumer product recalls. This is of major concern since the number of individuals affected by life-threatening allergies is on the rise, especially in children. Unfortunately, there is no cure for a food allergy; avoidance of allergenic food(s) is the only way to prevent an allergic reaction.

It is clear that allergen recalls negatively affect the consumer, however, they also result in huge financial implications and loss of brand credibility to all organizations involved. Businesses and brands may take a significant hit to their reputation since consumer perception plays a key role in the success of a business. With the increased use of the internet and social media, it is even more important to stay out of the spotlight and avoid recalls.

Among the reasons allergens hold the #1 position for product recalls may be lack of knowledge, insufficient supplier and raw material information, packaging errors, and accidental cross-contact. Cross-contact may be the result of poor cleaning practices, inadequate handling and storage procedures, employee traffic, and improper identification and assessments of risks. In addition, from a regulatory perspective, priority allergen lists and ingredient labeling laws vary from country to country, causing confusion for both manufacturers and consumers.

The good news is, implementing a strong allergen control plan can help to prevent recalls, protecting consumers and your business.

It starts with conducting a thorough risk assessment of each step in your process to determine where procedures and controls need to be implemented. A process flow diagram is very useful in understanding where allergenic ingredients and foods exist in the plant and where they are introduced into the process.

Control measures must be implemented even before raw materials enter the facility. The importance of understanding the incoming ingredients, inputs and suppliers cannot be overstated. The allergen status of every raw material handled or present in a food business needs to be identified and effective risk assessment tools applied. This involves identifying and documenting the food allergens present in each raw material, including non-food items like maintenance and cleaning chemicals. It’s imperative to recognize suppliers and backup suppliers’ vulnerabilities to ensure the success of the program. This should include identifying all allergens handled in the facility, as this might not be obvious based on ingredient declarations or product specification documents. Ensure supplier ingredient specification documents are current and routinely reviewed so accurate assessments can be made about the level of allergen risk.

Ensure there is segregation of allergenic foods or ingredients at every step of the process, from receiving raw materials through to shipping finished product. It is important to review labels at receiving to confirm the allergen status of raw materials. This serves as verification that ingredients have not been modified and the allergen status is still accurate. It also provides the basis upon which to determine storage and handling requirements. Visual tools are great for displaying the allergen status of each raw material. This can be done through applying color coded stickers or tape, unique tags or some other method, and should be done immediately at receiving. To avoid the potential for cross contamination from one ingredient to another, each allergen and/or group of allergens should have its own designated storage area or space. In addition, never store allergenic ingredients above ingredients that do not contain the same allergen.

Ensure there is segregation of allergenic foods or ingredients at every step of the process, from receiving raw materials through to shipping finished product. (Shutterstock image)

Controlling allergen risk throughout processing can be a major challenge since there are so many opportunities for cross contact. Ideally, physically segregate production of foods containing allergens from the production of non-allergenic foods. When physical segregation is not possible, dedicated production lines and equipment is best practice. Barring this, scheduling production runs appropriately can reduce the risk of cross contact and minimize sanitation and changeover activities. Where possible, schedule non-allergenic production before processing allergen-containing products. In addition, dedicate and identify tools and utensils for allergenic ingredients and products. Providing a visual aide can help ensure appropriate practices, and one way to do this is through color coding. Similarly, use dedicated employees on non-allergenic production lines and/or allergenic production lines. Make the employees easy to identify by implementing colored uniforms, hairnets or smocks. Identify allergenic materials by labelling or color coding throughout the manufacturing process. This should include rework, which should only be added to work in progress containing the same allergens.

Control of allergens does not stop at processing; the Maintenance department also plays a big role. Sanitary design needs to be considered when purchasing any piece of equipment. The equipment must be easily and fully washable to ensure proper sanitation. Positioning of equipment is also important in terms of cleanability and the potential of cross contact from an allergenic production line to a non-allergenic production line. Airflow and the potential for contamination of air borne allergenic dust to non-allergenic ingredients, products and equipment also should to be considered. Lastly, maintenance procedures must be put in place to prevent cross contact. This includes processes for repairing or maintaining equipment, cleaning tools and changing work apparel between repairs, as appropriate.

Consumers rely heavily on ingredient declarations and allergen statements on packaging to make purchasing decisions. “For those living with the medical condition of food allergy, the simple act of eating is complicated; avoiding their allergen is the only tool they have to manage the risk of a potential allergic reaction. These consumers require accurate labeling information to help them stay safe while still having sufficient food choices,” states Jennifer Gerdts, executive director at Food Allergy Canada. As such, it is imperative that the information on finished product labels and packaging is accurate. A solid allergen control program includes processes for reviewing labels for new and modified products to ensure they are reflective of the ingredients in the product. Labels and packaging should also be verified for accuracy prior to receipt, and at the beginning of a production run or at changeover. Outdated labels and packaging should be discarded immediately to prevent the chance of accidental usage. Inventory control procedures and label/packaging reconciliation is imperative to ensure the correct labels/packaging have been applied to the appropriate finished product.

It is crucial to develop and implement robust procedures for effectively cleaning equipment, utensils, food contact surfaces and non-food contact surfaces. This must include cleaning between batches of allergenic and non-allergenic production and responding to allergen spills. Carefully consider the tools and cleaning chemicals used for each the task, as this can make a significant difference in the success of the sanitation program. Verification and validation of cleaning practices must be undertaken to confirm that cleaning activities are effective in removing the allergens in the facility. This can be done through visual inspections, swabbing after sanitation and trending results.

One of the most important tools for ensuring the success of any allergen control program is educated employees. All foods handlers, regardless of their position, should undertake training in food allergens. Employees are the eyes and ears of the plant floor, the more knowledgeable they are, the more likely proper procedures will be followed, and potential risks identified.

Complete regular reviews of the allergen management program to ensure that it remains current, effective, and continues to assist in the production of a safe and legal food product. The program should be reviewed, at a minimum, whenever a customer complaint is received regarding allergic reactions, there is a change to raw materials or suppliers, there is a change in manufacturing processes, there has been an introduction of new machinery, or there is a change to cleaning practices and procedures.

An important aspect of an allergen control program is allergen testing. Testing can be used to confirm the allergen status of raw materials at receipt, to verify cleaning processes, and to evaluate finished products. An array of test methods exist for this purpose, including but not limited to, immunochemical methods such as ELISA or lateral flow devices, DNA-based methods, such as Polymerase Chain Reaction (PCR), Mass spectrometry (MS), and other non-specific methods such as Protein tests, ATP and visual inspection to verify cleaning. The choice of test method is very important and depends on the purpose of the test, the type of sample, food matrix, processing effects, desired turn-around time, availability of equipment, skill level of person doing the analysis and cost. ELISA and lateral flow devices are often used on-site at the production facility because results can be obtained quickly, costs are relatively low, and personnel can be easily trained to use these tests. In some circumstances of highly processed samples, PCR may be a better choice. However, PCR testing requires specialized equipment and skilled technicians so is usually performed in a third-party testing lab. Mass spectrometry is yet another option but can be costly and like PCR, this method requires specialized equipment and skilled personnel to perform the analysis.

As you can see, there are many factors to consider when developing an effective allergen control program. While it may seem daunting, it is critical understand how to identify and assess all allergen risks and develop a plan to control, verify and validate each one. The upfront work may be challenging, however once implemented, an effective allergen control program will protect allergenic consumers from the potentially life-threatening effects of inadvertently consuming and allergenic product, and will protect your business from financial loss and a tainted brand reputation.

Karen Everstine, Decernis
Food Fraud Quick Bites

A Look at Fraudulent Labeling Practices

By Karen Everstine, Ph.D.
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Karen Everstine, Decernis

Food fraud happens in many ways, and it can be challenging to categorize the various methods of fraud. Dilution and/or substitution involves the intentional addition of an alternate product with the intent to replace weight or volume (olive oil, juices and fish are prone to this type of fraud). Artificial enhancement is the addition of a substance that is not intended to replace weight or volume, but to have a functional effect (such as the use of industrial dyes in spices). Certain forms of food fraud, such as theft/resale, counterfeit packaging, or overruns may not involve the addition of alternate ingredients. However, as customers and consumers, we would be taking a risk to trust the safety of any foods that are intentionally misrepresented.

Food Fraud
Categories of methods by which food fraud happens (as defined in the Food Fraud Database1). Graphic courtesy of Decernis

While all forms of fraud can be considered “mislabeling” in one way or another, we consider fraudulent labeling claims to be defined as misrepresentation of a label attribute that implies a particular production technique. Examples include representing non-organic products as organically produced, the sale of foods as halal that do not meet the appropriate standards, changing poultry expiration dates, and labeling products such as eggs and Iberian ham as “free range.” In 2017, a company in Canada was fined for selling falsely labeled kosher cheese. More recently, in Malaysia, millions of products were seized based on the use of fraudulent halal labels.

We have compiled more than 300 records of food fraud involving the use of fraudulent labeling claims. The most common fraudulent claims identified in our records are shown in the chart below.

Fraudulent labeling claims
Fraudulent labeling claims based on records reported in the Food Fraud Database.1

Consumer interest in organic foods is increasing and NSF cites “added value claims” such as organic and free range as one of the important factors driving food fraud risk.2 There continues to be a need for robust analytical tools for the authentication of organic foods. However, recent research has indicated it may be unlikely that authentication of these food products can be can be achieved by a single analytical method or the measurement of a single marker.3,4 Given the technical complexity and cost of ensuring the authenticity of organic label claims through analytical testing, preventing this type of food fraud also requires strong supply chain management and trustworthy supplier relationships along with effective auditing programs.

References

  1. The Decernis Food Fraud Database is a continuously updated collection of food fraud records curated specifically to support vulnerability assessments. Information is gathered from the scientific literature, regulatory reports, media publications, judicial records, and trade associations from around the world and is searchable by ingredient, adulterant, country, and hazard classification.
  2. NSF, “Risk Modelling Of Food Fraud Motivation – ‘NSF Fraud Protection Model’ Intelligent Risk Model Scoping Project FS 246004.” (2014). Retrieved from https://www.food.gov.uk/sites/default/files/media/document/NSF%20Final%20report.pdf.
  3. Inacio, CT and Chalk, PM. (January 2017) Principles and limitations of stable isotopes in differentiating organic and conventional foodstuffs: 2. Animal products. Crit Rev Food Sci Nutr.. Retrieved from https://www.ncbi.nlm.nih.gov/pubmed/25849871
  4. Capuano, E., et al. (September 11, 2012). Analytical authentication of organic products: an overview of markers. Journal of the Science of Food and Agriculture. (Vol. 93) No. 1. https://doi.org/10.1002/jsfa.5914
Laura Bush, Mike Taylor
Food Safety Culture Club

Is FSMA Driving Food Safety Culture?

By Lauren Bush, Michael Taylor
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Laura Bush, Mike Taylor

We were asked if we think FSMA is driving strong food safety cultures. Our answer is: Yes, but there’s more to the story.

For the dozens of impacted families that advocated for years on behalf of the thousands of individuals who are sickened and die each year from foodborne illness, FSMA marked a sea change in accountability for preventing foodborne illness. And it demonstrated that the consumer voice can impact a Washington legislative process often perceived as impenetrable to the everyday citizen. It’s also true, however, that even before FSMA, leading companies had been implementing modern preventive measures in response to unacceptable illness outbreaks and consumer demands. And food safety thought leaders were writing about food safety culture and working to drive it. We thus see FSMA reinforcing the movement to strengthen food safety cultures rather than being the primary driver.

After all, a genuine food safety culture is as much about people and motivation as regulation. The people in food companies driving strong cultures are motivated at a personal level by knowing the severe harm deadly pathogens in food can inflict on illness victims and their families. And they are motivated at a business level by the realization that the success of a food company hinges on continuously meeting high consumer expectations for food safety. These personal and business motivations are the original and continuing drivers of strong food safety cultures.

The 2011 enactment of FSMA was made possible by the coming together of consumers, food safety experts, and industry leaders who agreed that application of the best available science to prevent problems is the responsibility of everyone. This agreement and the enactment of FSMA powerfully demonstrated how far our food safety culture had come since the uphill battles of 25 years ago over accountability for keeping E. coli O157H:7 out of ground beef and mandating HACCP for meat, poultry and seafood. There is now consensus that adoption of modern preventive controls is a basic responsibility of everyone producing food.

Food safety culture is about much more, however, than simply doing the basics of preventive controls. It’s about staying on top of change in the hazards that occur in our food system and in the means available to minimize them, and being committed to continuous improvement in response to these changes. FSMA took the breakthrough step of making continuous improvement a regulatory requirement by tying the definition of preventive controls to current expert knowledge about how to control hazards and requiring controls to be updated regularly as new knowledge emerges. In this way, FSMA reinforces the movement to strengthen food safety culture and makes it everyone’s responsibility.

But it all still comes back to motivation. Stop Foodborne Illness has long contributed to that motivation by sharing the stories of individuals and families who have experienced devastating loss and lasting harm from foodborne illness. Companies seeking to strengthen their cultures invite Stop constituents to tell their stories in employee training sessions and meetings with senior executives. In this new era of food safety, we see great opportunity to expand collaboration with food companies to help drive the widest possible implementation of best practices, continuous improvement and strong food safety cultures. In this effort, FSMA is our important ally.

Bush and Taylor co-chair the Board of Directors of Stop Foodborne Illness, a non-profit consumer organization that represents victim of foodborne illness and their families.

Leonard Steed, AIB International
FST Soapbox

Unannounced Audits: Are You Ready?

By Leonard Steed
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Leonard Steed, AIB International

Many industries are moving toward unannounced third-party certification audits and the food industry is no different. If regulatory audits are unannounced, why is the food industry reluctant to adopt unannounced third-party audits? There are a number of benefits to unannounced audits—most importantly is their positive impact on a company’s food safety culture and how they prepare facilities to face FDA inspections.

Unannounced audits for food are required for many third-party certification audits. Typically, regulatory audits are always unannounced. Unannounced audits help demonstrate compliance and provide confidence to all stakeholders that your manufacturing sites are operating on the same GMP level, day to day, shift to shift, for every day your organization is manufacturing and distributing food products. With announced audits, companies tend to prepare for them before they occur. However, if there is a significant amount of difference between your sanitary operations prior to and during an announced audit versus normal operating conditions, you are sending your employees the wrong message.

Although there are differences between certification schemes, the GFSI third-party unannounced audits usually have a 40- to 60-day window in which the audit must be completed to allow the certification body to complete technical reviews and review corrective actions so that the certificate does not lapse. If it is a surveillance audit, then the audit is more likely to be truly unannounced, but a company still has the option of using blackout dates and the auditor will verify that the request was necessary. The bottom line is most companies have a certain timeframe when they know unannounced audits will occur.

Leonard Steed will present “Unannounced Audits: Are You Ready?” on November 14 at the 2018 Food Safety ConsortiumThe biggest impact on third-party audits is when the audit score is directly related to financial incentives for employees. This situation motivates employees to pursue activities to achieve the maximum score, not directly related to food safety. Activities may include significant audit preparation to eliminate or reduce GMP deficiencies, reduce or control the auditor’s access to records or areas of known plant deficiencies, “auditor shopping”, and to appeal any audit finding that lowers the score. Switching auditors or appealing findings can be legitimate tools to correct a system when auditors make errors in judgement or behavior. The activities to achieve the highest score should be reasonably governed because they could take away from the primary goal to operate in a food safe mode.

The goal of an internal audit program is to be compliant with regulatory inspections and third-party certification requirements and should therefore be risk-based. Determine what factors present the most risk to an organization and then align internal audits with those risks. At this point in time, being able to perform well on a regulatory audit should be a primary concern. Since the FDA and state regulatory agencies usually perform unannounced inspections, it would seem necessary to have your food safety plan, prerequisite programs and operations in a constant state of readiness to mitigate the risk of potentially unsafe food in commerce resulting in a recall.

One way to evaluate your food safety culture is to anonymously survey employees at all levels of the organization to gather information on attitudes and opinions about food safety and institute changes to improve your position. Another way is to initiate change by instituting unannounced audits on all manufacturing shifts and require participation by all departments in the audit function to move away from “QA-centric” food safety verification systems. The significant change is that all departments would be involved as an auditor and responsible for maintaining regulatory compliance. For some companies, the inclusion of all plant departments in the audit function has moved the needle in the goal to improve their food safety culture. To further define food safety culture in other terms, it could mean adhering to GMPs all the time, the importance of accurately completing and verifying food safety records, and fostering consensus between departments on the severity of food safety nonconformances requiring prompt corrective action.

Maintaining GFSI certification is an excellent way to achieve food safety requirements for compliance with FDA inspections. Although not specifically required by GFSI, another application of your internal audit program is to review your regulatory policy by performing a mock FDA inspection to identify any gaps in hazard analysis, identify preventive controls including the supply chain controls, accurately complete food safety records, and provide examples of corrective actions when preventive controls were not completed properly, and environmental corrective actions. If you decide to perform a mock FDA inspection of your facility, do not forget to include the FDA Guidance document criteria, as it is important to understand what the FDA expects to see when they are evaluating your implementation. Your internal audit program is a proactive program to note nonconformances before they become full blown problems, so don’t be afraid to use it to its fullest extent.