Wiping down table

Building a Safer and More Sustainable Food Environment: Key Practices for Food Safety and Restaurant Professionals

By Ainsley Lawrence
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Wiping down table

As consumers become more health-conscious and environmentally aware, restaurants and food producers must adapt quickly to meet these evolving expectations. That means that restaurants need to work hard to reduce contamination, control pesticide use in high-risk foods, implement rigorous surface sanitation protocols, and adopt sustainable practices to create safer, more responsible dining experiences.

Explore key areas for maintaining safe and eco-conscious food environments while learning actionable tips to add to your daily routine as a food safety or restaurant professional. You can create safer, greener practices to benefit your customers and the environment by addressing these areas.

Identifying and Managing Pesticide Risks in High-Exposure Foods

Certain foods are more susceptible to exposure to herbicides and pesticides1 due to their growth patterns and susceptibility to pests. Fruits and vegetables like strawberries, spinach, apples, and peppers often rank high on lists of produce with significant pesticide residues. These foods have thin skins or are consumed whole, making it easier for pesticides to remain on the surface or penetrate the edible parts. Leafy greens and berries also frequently carry higher levels of pesticides due to their delicate structures, which are difficult to clean thoroughly.

To manage these risks effectively, implement rigorous contamination control measures:

  1. Washing: Wash produce with cold water to remove surface residues. A scrub brush for sturdier produce like apples or cucumbers can help dislodge stubborn residues. For softer items like berries, rinsing under running water is often effective. Additionally, consider using a vegetable wash specifically designed to remove pesticides and wax coatings. These washes are typically made with natural ingredients and can be applied directly to the surface of produce before rinsing, providing an extra layer of cleaning for high-risk items.
  2. Peeling: Removing the outer layers of fruits and vegetables, such as apples, carrots, or cucumbers, can eliminate a significant amount of pesticide exposure, though it may also reduce some nutritional content. Doing this also doesn’t guarantee the removal of all pesticide exposure.2
  3. Soaking: Submerging produce in a water-vinegar solution (one part vinegar to four parts water) can help reduce pesticide residues more effectively than water alone. Salt water solutions can also effectively reduce the amount of pesticides on produce.3
  4. Opting for organic: When possible, prioritize organic versions of high-risk foods. Organic produce is grown without synthetic pesticides, reducing exposure to harmful residues. While organic options may come at a higher cost, they are particularly worth considering for items like berries, leafy greens, and other foods frequently consumed raw, where pesticide residues are harder to eliminate.

Food safety professionals should stay informed on updated pesticide regulations. Monitor updates from regulatory bodies such as the Environmental Protection Agency (EPA) and the Food and Drug Administration (FDA). These organizations regularly update tolerances for pesticide residues in food, and new standards or restrictions can significantly impact purchasing and preparation practices.

Ensuring Hygiene with Food-Contact Surface Wipes

Maintaining hygiene and keeping your food-contact surfaces clean helps prevent cross-contamination. Bacteria, viruses, and allergens can linger on cutting boards, countertops, and utensils, creating a risk of contamination if not properly sanitized. Regular cleaning and disinfection of these surfaces protect both consumers and food service operations from potential health hazards.

Food-contact surface wipes4 are an effective and convenient solution to maintain hygiene across food preparation areas. These wipes are designed to safely sanitize surfaces without leaving harmful residues, meeting food industry standards for safety and efficacy. Their pre-saturated formula eliminates the need for mixing cleaning solutions, ensuring consistent application and reducing the risk of improper dilution. They are also quick-drying, making them ideal for high-traffic kitchens where time and efficiency are critical. Incorporate these wipes into daily cleaning schedules and routines to remind professionals to sanitize food-contact surfaces before and after food preparation to maintain consistent hygiene.

To optimize the use of food-contact-safe wipes, begin by removing visible debris or food particles from surfaces before sanitizing to ensure the wipes’ cleaning agents work effectively. Pay special attention to high-touch areas such as cutting boards, prep tables, handles, and storage containers, as these are hotspots for cross-contamination. Always adhere to the manufacturer’s guidelines regarding contact time to allow the sanitizing agents to fully eliminate bacteria and viruses.

Incorporating Sustainable Practices in Food Service

Sustainable practices in restaurants play a pivotal role in reducing waste and conserving resources, making the food industry more environmentally responsible. Fortunately, sustainable practices are becoming more widespread in restaurants, with 47% of restaurants tracking food waste and 22% donating leftover food.5

By adopting eco-friendly strategies, restaurants and food service businesses can minimize their environmental impact while meeting consumer demand for greener dining options. These efforts benefit the planet, improve operational efficiency, and appeal to eco-conscious customers.

To reduce waste, restaurants can implement strategies such as composting food scraps, donating surplus food to local charities, and improving inventory management to avoid spoilage. Encouraging the use of reusable or biodegradable packaging materials further minimizes waste, addressing one of the largest contributors to landfill pollution in the food industry. Implementing portion control and offering flexible menu options can reduce food waste by aligning servings more closely with customer demand.

Energy-efficient operations are another key component of sustainability. Investing in energy-saving appliances, such as Energy Star-certified refrigerators and ovens, can significantly reduce utility bills while lowering the carbon footprint. Simple measures like switching to LED lighting, maintaining HVAC systems regularly, and using programmable thermostats can also make operations more energy-efficient.

Water conservation is equally important. Consider installing low-flow faucets, recycling gray water where permitted, and training staff on efficient water usage to help reduce consumption.

Also, staff should be educated on sustainable practices so that they can consistently apply these efforts. Hosting regular training sessions and establishing clear sustainability goals encourage employees to embrace eco-friendly habits.

Implementing these practices enhances environmental responsibility and caters to the growing demand for sustainable practices in restaurants. Diners are increasingly seeking establishments that prioritize sustainability, and adopting these initiatives can improve brand loyalty and market competitiveness. Diners may even be willing to pay more to eat at a restaurant focusing on sustainability.6

Conclusion

Food safety is more of a commitment for modern restaurants than a checklist. Tackling pesticide exposure, keeping food surfaces spotless, and embracing sustainability are more than best practices; they’re how responsible businesses protect public health and the planet. By carefully managing pesticide use and focusing on high-risk foods, restaurants can dramatically reduce contamination risks.

Also, keep in mind that sustainability isn’t a buzzword. Restaurants that reduce waste, conserve energy, and make environmentally conscious choices save resources and respond to a growing consumer demand for responsible dining. When food service professionals invest in safety and sustainability, they build trust, demonstrate integrity, and show that great food can also mean great responsibility.

The future of dining is clean, safe, and green. And it starts with the choices we make today.

Woman shopping

5 Thirst-Quenching Benefits of Adding Smart Packaging to Beverages

By Emily Newton
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Woman shopping

Smart beverage packaging can create innovative customer experiences, reduce waste, improve safety and more. Today’s packaging technologies can transform how customers and retailers interact with beverage products. What benefits can manufacturers gain from integrating smart packaging into their products?

1. Improved Customer Convenience

Smart beverage packaging can drastically improve customer convenience. Simple text labels are the typical information available to customers on a beverage bottle. They are mainly looking at the expiration date and the ingredients, but more information could be available. Smart packaging can offer more details and indicate the qualities of a beverage more efficiently.

For example, intelligent freshness sensors can go inside or outside the beverage container. Chemical sensors can automatically respond to changes in the beverage’s condition, such as chemical indicators that the beverage is expired. When the sensor detects those indicators, it changes color.

So, regardless of the estimated expiration date, a customer can quickly see when a beverage goes bad. A color-coded responsive chemical sensor on the beverage packaging is also easier to understand for those with vision difficulties or children who have not learned to read yet.

2. Less Beverage Waste

The USDA estimates that 30 to 40% of America’s food supply goes to waste annually, creating billions of dollars of lost revenue. This deprives thousands of people of food and beverages that could have fed families in need. Preventing food waste is a complex problem for food and beverage manufacturers since waste often happens in grocery stores.

Smart packaging could help reduce food waste by making it easier for retail employees to identify beverages nearing expiration dates. Additionally, some types of smart packaging devices could improve logistics for retailers so cases of older drinks aren’t lost or misplaced before they expire.

For example, beverage manufacturers can ship their units in cases with smart RFID or QR tags that retailers can easily track. The tags could be scanned or entered in an inventory management database where retail employees could view expiration date notifications and inventory items from oldest to newest.

Similarly, smart packaging features like color-coded chemical freshness indicators could be helpful for employees as well as customers. Colors are much easier to identify at a glance than numerical expiration dates. As a result, it is more likely that employees would notice a unit that is older than others and know to get it on shelves while it is still fresh.

3. Safety Verification and Recalls

Traditional product recalls use purchase dates or batch numbers to identify at-risk units. Sometimes all recently-purchased units need to be recalled. Customers may even guess whether a unit is risky based on the expiration date. These methods require careful inspection of the text on the packaging or the receipt, which many customers don’t keep.

Smart packaging technologies like QR codes or chemical sensors can relieve some confusion surrounding individual unit safety. Efficient, accessible and effective packaging technologies for verifying unit safety can allow beverage manufacturers to pursue a broader range of products safely.

For example, recycling water can help reduce water waste and minimize strain on natural water sources, particularly in areas with scarce clean water sources. In fact, the average American household wastes 95% of the 400 gallons of water they consume each day. With the right filtering and cleaning processes, manufacturers could recycle this water.

Beverage manufacturers could safely use recycled water by integrating smart sensors into their packaging. This precautionary design element would allow customers to quickly verify that their recycled water product is safe to drink. A growing number of customers are prioritizing sustainability today as long as they can do so safely. This type of design feature could open new doors in the sustainable beverage market.

If a product needs recall, customers and retailers can scan a QR code on each unit’s packaging to see if it is part of the affected batch.

4. Easy Tracking of Beverage Shipments

Logistics is becoming increasingly complicated today as businesses face high competition, rising freight costs and a need for more truck drivers. So, it’s more important than ever to have effective ways to track beverage shipments. Smart packaging can increase logistics visibility and reduce the risk of lost or damaged goods.

RFID asset tracking allows businesses to use RFID tags to monitor objects remotely. Beverage manufacturers could integrate these tags into shipping crates or cases. The tags help logistics personnel organize their freight while allowing the manufacturer to have GPS tracking on their shipment.

Additionally, climate monitoring tags can quickly reveal if goods were damaged during transit. Smart sensor tags are available today that respond chemically to environmental changes, such as temperature or moisture. So, if the conditions inside a crate of beverages shift outside of a safe threshold, the sensor will show the change.

5. Innovative Consumer Experiences

Smart packaging can create fresh, unique interactive experiences with customers that build engagement and foster brand loyalty. There are a growing variety of technologies for doing this, such as QR codes and NFC tags. Both utilize customers’ smartphones to generate individualized experiences for them.

For example, a beverage company could put a QR code on their bottles that links to a video showing customers how to make a smoothie with their beverage. Businesses can also use QR codes for gamification, such as rewarding points toward coupons or a raffle. All of these engagement opportunities can build connections between customers and brands.

Beverage companies can even use QR codes and NFC to increase environmental transparency. Sustainable packaging is a big deal to many customers today. Surveys show almost 70% of consumers would pay more for sustainable packaging options.

Beverage companies can create digital interactive maps of their products’ supply chain to illustrate sustainability efforts. A QR code or NFC tag on the packaging can connect customers with this interactive digital experience. Creating such an experience to explain the environmental impact of a product can be a great way to foster loyalty with sustainability-minded customers.

The Future of Beverage Packaging

Smart packaging can be revolutionary for beverage manufacturers. Packaging technologies like QR codes, RFID, smart sensors and more can create a better customer experience and simplify operations for retailers and logistics. Integrating smart packaging can lead to safer products, less waste and heightened customer engagement.

Allergens

How Can US Food Businesses Navigate Labeling Regulations While Ensuring Compliance?

By Fred Whipp
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Allergens

With nearly 1 in 4 US citizens reporting a food allergy, the importance of mitigating against cross-contamination in-store and throughout the whole supply chain is becoming increasingly recognized. As reports of allergy tragedies related to food negligence continue to spiral, it begs the question as to whether the food industry is truly and wholly compliant with regulations, such as the FASTER Act.

The Food Allergy Safety, Treatment, Education and Research Act or FASTER Act marks the first time that food allergen labeling has been expanded since the Food Allergen Labeling and Consumer Protection Act (FALCPA). Launched on January 1st, 2023, in the US, the FASTER Act identified sesame as the ninth major food allergen, requiring manufacturers to list and specify the allergen’s presence in packaged foods.

Despite more rigorous regulations being put in place, cases relating to the misleading labeling of food products remain an issue. Earlier this year, the FDA issued a warning to Bimbo Bakery for falsely listing allergens, including sesame, on its food labels in the US. The warning comes amid reports of manufacturers adding allergens to product labels and recipes to rule out the risk of cross-contamination and cleaning procedures required by new labeling laws.

What is the FASTER Act?

The FASTER Act is both a recognition and validation of the seriousness of sesame allergies and sensitivities, promoting R&D for more effective diagnosis and prevention. The Act requires all restaurants and catering companies to ensure all food produced and packed for sale in the same premises has a complete ingredient list identifying all ingredients on the product label, including sesame, the ninth major allergen. It also requires that food manufacturers using sesame in their products ensure procedures are in place, such as thoroughly cleaning equipment across production lines, to avoid cross-contamination.

However, as we have seen, despite more stringent regulations being put in place, there have been numerous cases of manufacturers responding to new labeling laws by intentionally adding sesame as a listed allergen on previously allergen-free products to avoid the rigorous cleaning processes needed to avoid any points of cross-contamination. This practice has been criticized by various organizations, including most notably the Center for Science in the Public Interest (CSPI), which filed a regulatory petition to the FDA in 2023, urging the FDA to address manufacturers intentionally or unnecessarily adding sesame to their formulations or product labels.

Despite the introduction of the Act, reports of negligence are still occurring, exposing a somewhat backward approach to the future of food safety. Not only does this actively risk undermining customer trust, but it also further limits food choices for individuals with allergies.

Keeping compliance central

To remain compliant, food providers and catering companies must establish robust channels of communication with their suppliers to remain informed of any changes to formulations or manufacturing and production processes. Alongside this, staff training in allergens is essential, making employees aware of changes to in-house menus, recipes or stock to provide a comprehensive allergen list to customers upon request.

Manually checking ingredients across every PPDS (prepacked for direct sale) item is not always practical in large facilities, especially when multiple players in the supply chain are involved. One of the most effective ways to maintain accurate ingredient and allergen details is with the help of specialist software that automates updates to nutritional and allergen information across various systems and sites, saving valuable time while ensuring labelling remains accurate by leveraging real-time updates and data.

The future of process management platforms

Food businesses must consider using process management platforms in 2024 to not only ensure but also document that staff follow protocol stringently. This could involve assigning employees digital checklists or logbooks to complete to make certain they have understood new formulations or changes to an existing one. By automating these processes, the highest levels of compliance will be met, both assuring head offices of proper in-house operations and providing records of this in case of inspection.

By integrating IoT technology embedded in process management platforms leveraging sensors, RFID tags and smart thermostats, food businesses can ensure the real-time monitoring of food storage conditions like temperature, humidity and expiration dates, as well as improved supply chain visibility and end-to-end traceability. Examples include cold storage facilities, delivery trucks and even stockrooms equipped with IoT sensors that systematically check, log and alert staff to changes in temperatures or changes to products in the stockroom. When employees are made aware of the storage location of food products and their various allergen content within the stockroom, cross-contamination is more easily avoided, allowing for the easier identification and separation of food products and taking extra precautions to ensure packaging is kept intact when handling.

Improved supply chain traceability

Integrating advanced technologies throughout the supply chain further safeguards against food contamination and promotes confidence, compliance and thus protection from food to farm. Radio frequency identification (RFID) tags document the complete journey from origin to destination by transmitting location and sourcing data to companies, updating them on the exact whereabouts of each product throughout its journey to them. This way, any issues relating to product recall or batch contamination can be traced back through the chain, identifying locations of potential food safety breaches, such as a facility also handling other allergen products.

Installing IoT cameras in manufacturing facilities further enforces quality control by inspecting food products, flagging lapses in improper packaging or the presence of allergens in the facility, automating much of the processes behind compliance with food safety practices. Although the upfront cost of implementing such technologies is expensive, businesses will, in time, reap the benefits of reduced labour costs and improved operational consistency, bolstering their supplier-to-customer relations.

Supply chain traceability is equally important when considering downstream supply chain operations, such as in-country transportation. IoT sensors fitted in refrigerated packaging or vehicles track shipment and courier conditions in real-time, automatically alerting drivers to allergen products on board or changes in temperatures. If the reason for improper storage conditions proves challenging to rectify, drivers will be redirected to nearby facilities where food products can be temporarily stored when equipment malfunctions to ensure the longevity, hygiene and quality of perishable goods.

Time saving without cutting corners

The FASTER Act recognizes and highlights the importance of strict quality control, regulating the accurate labeling of products and mitigating cross-contamination in manufacturing and production facilities. With the right technology and systems in place, equipping businesses with the necessary tools, such as mpro5, the task at hand becomes significantly more manageable.

Process management platforms that automate lengthy manual tasks provide time-saving benefits and further reduce the likelihood of businesses cutting corners when allergen labeling by enforcing compliance. By integrating technologies to create an IoT infrastructure from food to farm, all stakeholders will benefit from the assurance that their products are safe for consumption, whatever the dietary or allergen requirement.

By improving traceability, providing real-time data and ensuring correct storage, waste is reduced, and customer safety is rightfully centered at the heart of all operations. In doing so, food businesses can maintain compliance with safety standards and identify and address potential food safety risks within the wider supply chain whilst cultivating customer confidence and trust once the products are in-store.

Listeria

Adapting Food Safety Testing to meet Modern Demands

By Jani Holopainen
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Listeria

Confidence in food safety has hit an all-time low in the U.S., according to a recent Gallup poll[i]. Food recalls have dominated the news recently, ranging from harmful pathogens and allergy risks to non-food materials contaminating the food supply. There is a more general awareness of how our food impacts our overall physical and mental health and rising concerns over what ingredients may have the most significant effects. Now more than ever, food safety testing needs to evolve to meet current expectations—in our testing capabilities and thinking—to instill confidence in food safety testing again.

Why food safety testing needs to evolve

Like any industry, food safety trends and demands change over time, and the industry needs to evolve along with them. To keep pace with consistent threats, the industry must adapt to address emerging pathogens that pose risks to food safety. These pathogens have the potential to mutate to favorable conditions, much like any other pathogen. This means new strains of bacteria, like E. coli or Listeria, can sometimes affect the food supply but pass established food safety tests. As an industry, we must be able to quickly identify when there is a new strain of a pathogen and adapt testing methods to detect that new strain. Another way the industry needs to evolve is by keeping up with the increasing globalization of our food supply. Across industries, our world is becoming more reliant on a global supply chain. For food, this means that throughout the process of getting a specific food product to a consumer, there are several points where contamination can occur. Food safety testing needs to be able to account for these additional contamination opportunities.

Food safety testing for perishable products also presents a specific set of challenges. Testing for perishable food needs to be completed quickly due to the limited time frame in which it can be kept fresh and ready for sale in stores. Occasionally, delays in getting test results back on food samples could lead to perishable products being released before testing has been confirmed, running the risk of pathogens getting into the food supply. Food producers, particularly in produce, also need to be more vigilant against the food safety risks that come with fruits and vegetables, given they are often eaten raw. Irrigation water can contaminate produce if drawn from a source close to where livestock is being raised, and some wild animals can also contaminate the irrigation water. For other food producers, it is vital to remember that when antibiotics are used as a preventive measure in livestock, they eventually create bacterial strains resistant to a broad range of antibiotics, posing substantial human health risks.

In addition to being able to detect pathogens and biological contamination, the food safety industry also needs to be focused on combating food fraud and bad actors who intentionally adulterate food. Food fraud can happen when someone purposely leaves out, takes out, or replaces a valuable ingredient. It can also occur when someone adds something to food. For example, companies looking to save costs could mix in a cheaper substance or mislabel a food product, which could have harmful effects on consumers. Ensuring food safety relies on detecting any adulteration promptly to maintain quality standards and protect consumer health.

How we can evolve our food safety testing capabilities

While there are still critical issues that need to be addressed, we are seeing a massive shift in the technology used in food safety testing to respond to the evolving challenges. For example, qPCR-based technologies have evolved significantly and become the gold standard in food pathogen testing over the past 10 years. Next-generation sequencing (NGS) has also recently made its way into food safety and food authenticity testing. Because of its discriminatory power, NGS is a powerful tool, especially in food authenticity testing. It can also be used for microorganism strain typing, whole genome sequencing and metagenomics, all of which can help us learn more about the production environment and food we’re consuming.

Automation is also becoming more common in food safety testing. It can remove human error from the equation, improve repeatability and increase sample throughput, making it a lucrative option for mid- and large-size food safety laboratories. In the future, we can expect to see more artificial intelligence and machine learning (AI/ML) implemented into food safety workflows. AI may be able to help food safety specialists by quickly interpreting test results or identifying possible issues with tests and providing guidelines for how to correct anything that may be wrong. We may also see a world where AI can help fill knowledge gaps. It has the potential to help less experienced specialists be confident in operating the food safety workflows and in the accuracy of their results. Finally, testing on the production line, instead of sending it to internal or external labs, may become available. This “on-line” testing would shorten the time to results and mean production lines can more quickly adjust their operations if there is an issue.

How we can evolve our thinking around food safety

As we improve the technology implemented to help keep food safe, we must also ensure the food safety testing method fits the purpose. Not all tests are suitable for all processes or samples, and not all tests are identical. For example, food safety test suppliers often have certain external certifications on their workflows, like ISO 16140, AOAC PTM or AOAC OMA, and product claims to provide evidence of their methods’ performance and reliability. However, food producers should not solely rely on these certificates but verify the product claims internally to ensure the selected method performs accordingly in their own setting and, more importantly, with their samples. A sample matrix may vary by its background flora depending on the geographical region the sample originates from, which could substantially impact the target pathogen detection.

Consumers and customers are already more aware of when things go wrong, with recalls being a news focus. The U.S. Food and Drug Administration, the U.S. Department of Agriculture and other governmental organizations are very public about food recalls, and they should be. This means, however, that food safety in consumers’ minds can have negative connotations. One way food producers could address valid concerns from consumers is by becoming more visible about their food safety procedures and the efforts they undertake to improve the safety of their food.

While recalls and issues with quality control are never 100% avoidable, we can, as an industry, keep learning, continuously assess and improve testing procedures and methods, and share the best practices to ensure our food is as safe as possible. This learning must be done in real-time and at a fast pace. We can’t anticipate every new pathogen that will impact our food, but adapting quickly and effectively can help us safeguard our food supply and ensure customers’ confidence in the food they’re consuming.

[i] https://news.gallup.com/poll/650024/trust-government-assurance-food-safety-hits-record-low.aspx

Blockchain

Future Of Food Safety: Next-Gen Technologies On The Rise

By Steve Orth
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Blockchain

Food safety is one of the biggest health concerns worldwide. The World Health Organization estimates that about one in 10 people contract an illness from contaminated food, with more than 400,000 dying each year as a result. Food contamination leads to illness, death, lost productivity, and wasted money.

Fortunately, technology to improve food safety continues to advance. The shift moves toward automation and system monitoring to improve accuracy and decrease the time that workers must attend to routine tasks. With the use of these developing technologies, commercial and industrial organizations can help to prevent foodborne illness and provide greater transparency to the consumer.

Smart Devices

The Internet of Things (IoT) provides several opportunities to improve food safety in commercial and industrial spaces. The premise behind IoT is that each device or appliance can connect to a larger hub, providing information about the contents or function of the equipment in real-time. These tools can improve food safety by performing safety checks, recording data like food temperatures, and allowing centralized monitoring of the entire system. In kitchens, restaurants and food processing plants with fewer employees, the ability to get information at a touch can simplify routine tasks and improve accuracy.

Sensors

Advanced sensor technology improves old technology by centralizing data collection and providing real-time updates. Sensors work by assessing factors like temperature or humidity within a controlled space. Older systems required workers to visually inspect the temperatures and adjust as needed. The latest models provide integrated data with the capacity to send immediate alerts when the conditions fall below safe levels. The technology minimizes food waste by prompting quick action, while giving operators the ability to confirm that the food always remains at safe levels.

3D Printing

Testing materials can be expensive, proprietary, and difficult to fit to every application, which highlights the benefits of 3D printing. 3D printing relies on the slow accumulation of material into a specific 3D design. The broad availability of designs allows organizations to contract out 3D printing of testing tools or bring the entire production in-house. The technology is revolutionizing various industries for its ability to provide custom products at a fraction of the cost of traditional manufacturing, often for much less investment.

Automated Sanitation

Automated sanitation systems improve the speed of cleaning and decrease the risk of human error. UV light systems gained notoriety for their ability to dramatically reduce the spread of pathogens like SARS CoV-2, creating benefits for commercial and industrial applications. UV and ozone sanitation improve results over liquid disinfectants and provide better results for surfaces that need to be sterilized.

The automation of these and other sanitation systems significantly cut down on the time workers must spend cleaning up. Industrial automation solutions minimize the risk of contamination, as well as shortening equipment downtime.

Blockchain

Blockchain is best known for its use in cryptocurrency, but the premise offers potential to decrease the effects of food contamination. The United States Food and Drug Administration notes that traceability presents the biggest problem for handling outbreaks of listeria or E. coli. The United Nations Development Programme argues that blockchain’s decentralized organization allows for the accurate presentation of information that cannot be misrepresented or deleted. This technology can provide detailed tracking of a food’s journey from farm to table to reduce time and money spent determining the source of a contaminated food.

DNA Barcoding

Preventing foodborne illness and the spread of pathogens involves greater effort to inspect during every step of the food’s journey. DNA barcoding presents interesting opportunities to quickly evaluate foods to classify their species and identify the presence of foreign bodies. The method highlights parts of the genome that identify a specific species, creating a barcode of sorts that can be used to verify the species. This level of detail in inspection can increase the accuracy of labeling, as well as providing a way to track the origin at a molecular level.

Automated Inspections

Human inspection can fail, especially for workers who may be operating in understaffed conditions. The increase in automated systems provides a viable solution. Visual systems can inspect each item for signs of damage or faulty production, immediately removing them from possible use. The latest technology can identify faults that are beyond human observation, increasing the accuracy of the equipment and minimizing the use of defective products.

Artificial Intelligence

Artificial intelligence (AI) has the potential to revolutionize all of these systems and more. AI uses the collection and processing of data to identify trends and highlight risks within a contained environment. The system can handle automated checks, maintenance, and other tasks that were once performed by humans. AI can use data to predict failures of systems or the likelihood of contamination, so that workers can address them in advance. With access to real-time data, AI can also provide immediate alerts to changes in food preparation or storage, to minimize food loss and the growth of foodborne illness.

Handling food in any capacity requires attention to food safety to minimize illness and death among the most vulnerable populations. In the interest of increasing food safety, researchers and manufacturers are investing in technology to automate food safety tasks such as sanitation and tracking food temperatures. While some technologies represent the vanguard of the food industry, others are gaining relevance worldwide. Exploring these technologies helps food safety professionals to evaluate the best systems to protect consumers throughout the use of their commercial and industrial spaces.

Sources

World Health Organization (WHO). (2022, May 19). Food safety. Who.int; World Health Organization: WHO. https://www.who.int/news-room/fact-sheets/detail/food-safety

Brous, P., Janssen, M., & Herder, P. (2019). The dual effects of the Internet of Things (IoT): A systematic review of the benefits and risks of IoT adoption by organizations. International Journal of Information Management, 51(1), 101952. https://doi.org/10.1016/j.ijinfomgt.2019.05.008

Pangarkar, T. (2024, May 7). 3D Printing Statistics 2024 By New Technology, Filaments, Types. Market Scoop. https://scoop.market.us/3d-printing-statistics/

US EPA, O. (2021, January 14). Disinfecting Surfaces with UV Light to Reduce Exposure to SARS-CoV-2. Www.epa.gov. https://www.epa.gov/emergency-response-research/disinfecting-surfaces-uv-light-reduce-exposure-sars-cov-2

NEW ERA OF SMARTER FOOD SAFETY FDA’s Blueprint for the Future. (n.d.). https://www.fda.gov/media/139868/download

Blockchain for Agri-Food Traceability | United Nations Development Programme. (n.d.). UNDP. https://www.undp.org/publications/blockchain-agri-food-traceability

DNA Barcoding – an overview | ScienceDirect Topics. (n.d.). Www.sciencedirect.com. https://www.sciencedirect.com/topics/agricultural-and-biological-sciences/dna-barcoding

Your Root Cause Analysis Toolbox

By Shelly Blackwell
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If the available root cause methods are viewed as tools within your toolbox, their value can be realized once the appropriate tool is selected. Consequently, with the right tool, an investigation is usually more efficient and successful.

Root cause analysis is a familiar term across various industries and a requirement at some level by most regulatory bodies. Unfortunately, the process of investigating a root cause may seem overly burdensome and consequently appropriate root cause tools are often abandoned. If the available root cause methods are viewed as tools within your toolbox, their value can be realized once the appropriate tool is selected. Consequently, with the right tool, an investigation is usually more efficient and successful.

A common definition of root cause is “The most basic reason a problem has occurred that once identified and eliminated will prevent reoccurrence of that problem.” In other words, the root cause is the “true” reason that contributed to the creation of a problem, defect or nonconformance. The critical first step in root cause analysis is identifying the problem. The problem statement should clearly state what is being investigated and be referenced by the team conducting the root cause analysis throughout the investigation to avoid getting off track. Note that I mentioned a team; often complex problems can not be properly investigated by an individual, and cross-functional input is required. Once the problem has been clearly stated and the investigation team formed, it is time to look in the root cause toolbox for the best available tool.

One of the most used root cause tools is the “Five Whys.” It is useful when you want to quickly get to the root cause of a simple problem. It can also be used prior to the “Fishbone” or in conjunction with other tools (such as “Is/Is Not”) and is typically best for lower risk problems. The Five Whys tool was originally developed by Sakichi Toyoda and used within Toyota Motor Corp during evolution of their manufacturing methods. It is a problem-solving technique that is the basis of a scientific approach in which by repeating “why” five times the nature of the problem as well as its solution becomes clear. The objective is to get the investigator to avoid assumptions and logic traps and trace the chain of causality from the problem through layers of questioning, logic, and answers to the root cause. Always ask yourself if another “why” can be asked before you conclude the investigation activity and test the conclusion by using “therefore” statements in reverse. If you can not ask another why, you can finalize the Five Why investigation activity and summarize the root cause.

Another root cause tool in the toolbox is the “Fishbone Diagram,” which can prove useful when tackling more complex problems. To use a fishbone, first document your problem statement and then draw a fish skeleton (or use a fishbone form) with spines labeled Manpower, Method, Machine, Material and Environment (or their equivalent terms). Use evidence-based techniques to identify possible causes (brainstorming, employee interviews, watching video, drawing process maps, reviewing documents, etc.) and add the facts to the correct category. Eliminate causes that don’t apply; analyze the diagram and designate the causes that do most likely apply. Use data and critical thinking to determine the root cause. It is recommended to use team input for the final selection.

When you need to focus a brainstorming session and narrow down solutions, you may want to use the “Is / Is Not” tool. The Is / Is Not tool is a comparative analysis method that can be used to determine root cause or focus an investigation and is fairly simple to use. To begin, draw a diagram with a column for “Is” and a column for “Is Not.” Next, ask “Is” questions. Gather relevant data on the problem and what actually happened and add it to the “Is” column (what is wrong, where is the problem occurring, when did it go wrong, how often does it go wrong, etc.). Then, ask “Is not” questions. Make comparisons to the “Is” column to set boundaries (what is not wrong, what else could have occurred but didn’t, what lines has it not occurred on, when could it have occurred in the past, etc.) and list these in the “Is Not” column. Look at the two columns to obtain clues for the root cause and then make a conclusion or set an investigative strategy to determine root cause. The Is / Is Not tool can be a practical way to refocus an investigation and is often used in conjunction with other tools.

Unfortunately, a common pitfall with all these tools is determining a root cause of “human error.” Do not immediately assume “human error” is the root cause, though it may seem like an easy conclusion. A thorough root cause will analyze “why” the human made the error and address that root cause. An organization with numerous “human error” root causes is a red flag to investigators and an indication that the true cause of the issue is not being properly investigated or addressed. As Dr. W. Edwards Deming wrote in his book “The New Economics”1: “People can’t perform better than the system allows.” Consider if your processes and systems are setting employees up for success or failure and address accordingly.

To summarize, there are many root cause tools available when conducting an investigation, but just like with an actual toolbox, picking the right tool for the job is critical. “Five Whys” is best for lower risk or more simple problems than can be quickly solved. A “Fishbone” diagram is useful for more complex problems, especially when there is a lot of data to organize and evaluate. “Is / Is Not” is often an auxiliary tool than can help further define a complex problem when other tools are unsuccessful or to identify boundaries of an investigation. Additionally, there are other root cause tools available, such as Failure Mode and Effects Analysis (FMEA), Control Charts, and Affinity Diagrams than can be used as a supplement to the above methods or alone. Regardless of the tool used, the key to investigational success and prevention of recurring errors is a well documented and scientifically sound root cause investigation.

References

  1. “The New Economics” (3rd edition, 2018): Book by the late W. Edwards Deming

Five Ways Technology is Enhancing Consumer Trust

By John O’Kelly
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Farm-to-table has become a popular dining concept over the last twenty years, yet the broader food and beverage industry still needs more transparency in many areas. A larger movement is now emerging to bridge this information gap, driven by consumer demand for deeper insights into the food they consume. However, a few simple technology-based solutions can make transparency possible within food distribution.

Why Consumers Want Transparency in Food

Today’s consumers are increasingly conscious of their food choices. They want to know precisely what they’re eating, where it comes from, and how ethical and sustainable it is. This growing interest in transparency is reshaping the food industry, so much so that consumers are willing to pay more for transparency from brands and even forgo buying from those that only share limited information. Luckily, technology is making it possible to meet these expectations.

According to research by NielsenIQ and the Food Industry Association, two-thirds of shoppers are willing to switch to brands that provide detailed product information. While nutrition and ingredients remain crucial, 80% of respondents said values-based details, like certifications and allergen information, also play a major role in purchasing decisions.

Some brands may hesitate to invest in transparency due to cost concerns. However, according to this DNV-GL survey, 69% of consumers are willing to pay more for products with clear quality and safety certifications. Additionally, 53% want more explicit information on food safety, content, and hygiene. These demands cultivate greater trust and loyalty, as brands prioritizing transparency often benefit from stronger consumer relationships and long-term results.

Leveraging Technology for Greater Food Transparency

Shoppers, online or in-store, are looking for a wide variety of information about food products, from nutritional data to sourcing, manufacturing processes, country of origin, and logistics data.

So, how can brands deliver better food transparency? As with many others within the supply chain, brands are turning to technology, using solutions like RFID tags, blockchain, data analytics, precise labeling, augmented reality (AV), and virtual reality (VR) to provide insights across the supply chain. Below are five of the most impactful ways these technologies are being used to enhance transparency and meet consumer expectations.

1. RFID Tags for Real-Time Traceability: Radio frequency identification tags enable detailed tracking for end-to-end transparency and traceability. Each RFID tag can store critical data, including timestamps, product descriptions, and even temperature and humidity levels. Consumers can scan RFID tags to access key information about a product’s origins, nutritional content, and any additives. In addition to giving consumers valuable insights, RFID can help prevent cross-contamination and foodborne illnesses, reducing waste and minimizing recall costs.

2. Blockchain for Secure and Transparent Records: Blockchain, a secure digital ledger, is being used to add transparency throughout the food supply chain. This technology allows items to be tracked from seed to store and offers a reliable record for certifications, such as organic labels. With blockchain, processors, distributors, and retailers can all independently verify product information, maintain accurate inventory, and prevent fraud. By sharing this data, food distributors can comply more easily with safety regulations and improve consumer confidence.

3. Using Data to Anticipate Risks: Advanced data analytics also helps companies monitor risks that could impact the food supply. For instance, advanced insights allow businesses to analyze market conditions, assess regional instabilities, and predict environmental challenges that could disrupt food production or transportation. Farmers, too, are using data-driven insights to optimize harvest times and minimize risk, creating models that others can replicate to improve efficiency and resilience.

4. Ensuring Accurate Labeling: Accurate labeling is a cornerstone of transparency in the food industry, providing consumers with the information they need to make informed choices. Whether identifying organic versus non-organic products, highlighting allergen warnings, or verifying sustainability certifications, clear and correct labeling builds trust and prevents confusion. However, manual labeling processes are prone to errors, leading to consumer dissatisfaction, regulatory penalties, and health risks. Tools like mobile-powered workstations are being integrated into food production and distribution environments that enable employees to access real-time data and print labels directly at the point of need, reducing reliance on static labeling stations and minimizing the risk of errors caused by outdated or misplaced information. These technologies enhance accuracy and operational efficiency, allowing businesses to streamline processes and maintain compliance with food safety standards. For consumers, this results in greater confidence in the products they purchase and the assurance that their choices align with their health, ethical, and sustainability goals.

5. AR and VR in Retail: AR is a type of technology that has the potential to revolutionize how customers shop for products by combining physical stores and virtual spaces. With AR, shoppers can scan products using smartphones to instantly view details like ingredient origins, sustainability certifications, and allergen information. This provides an interactive way to access nutritional information and understand the environmental impact of their choices, such as where the ingredients were sourced, the producer’s fair-trade practices, or the product’s carbon footprint.

VR takes transparency a step further by offering immersive experiences. A recent study using VR in grocery stores showed that, over time, participants who used the headset to navigate the store and buy groceries significantly increased their ability to buy healthier food and products by almost 50% compared to those who did not use a VR headset when shopping. This suggests that VR can help significantly enhance an individual’s overall health by allowing for more informed decision-making. Some stores are building virtual shopping environments, allowing customers to explore and shop for products from home while accessing the same in-depth product information. Shoppers can view this interactive data as overlays on their screens while navigating grocery aisles, paving the way for a more informed, engaging, and transparent grocery shopping experience that meets the growing demand for food knowledge and sustainable choices.

Empowering Informed Choices

As food and beverage companies strive to uphold rigorous safety and quality standards, they’re embracing innovative technologies to better balance sustainable, ethical practices with the growing expectations of informed consumers. In a world where consumers increasingly want to know how their food is sourced, produced, and transported, technology is making that information accessible and revolutionizing transparency within the food supply chain.

As transparency becomes a core principle in the food industry, these technologies empower consumers to make more responsible choices, fostering a stronger connection between buyers and brands. Embracing these tools also allows companies to earn trust, build loyalty, and stand out in a competitive market that increasingly values openness and accountability.

Lettuce

Traceability in Agriculture Labeling

By Jenna Wagner
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Lettuce

As consumers become more conscious of the origins of their food and demand greater transparency, the need for traceability systems has never been greater. Labels play a large role in this process, serving as the primary means of tracking products through the supply chain, from farm to table. This article explores the importance of traceability in agriculture, how labels enable it, and the emerging trends shaping the future of agricultural traceability.

The importance of traceability in agriculture

Traceability in agriculture is more than just a buzzword; it’s an important component of modern food production and distribution. Here’s why:

Food safety – Traceability in agriculture is essential for identifying and isolating products that may be contaminated or unsafe. If a safety issue arises, such as contamination or inaccurate allergen labeling, traceability systems enable fast identification of the affected products, allowing them to be isolated and removed from circulation before they reach consumers. This minimizes health risks and helps prevent foodborne illnesses, ensuring only safe products reach the market.

Compliance with regulations – Regulatory agencies often require proof of origin, handling practices, and proper labeling, especially for products that carry organic, non-GMO, or other certifications. Traceability systems make sure that all necessary information is documented and easily accessible, allowing businesses to meet compliance with local and international food safety standards.

Efficient recall management – In the event of a product recall, traceability enables companies to quickly and efficiently remove affected products from the market, minimizing risk to consumers and reducing financial losses. Food recalls due to safety concerns cost companies an average of $10 million per recall in direct costs, according to the Grocery Manufacturers Association (GMA) and the Food Marketing Institute (FMI) [1]. Enhanced traceability can help mitigate these risks.

Combatting counterfeiting – Traceability helps combat counterfeiting in the agricultural industry by verifying a product’s authenticity at each stage of the supply chain. With unique identifiers, batch numbers, and secure tracking systems, traceability ensures that each product can be traced back to its origin. This makes it difficult for counterfeit goods to sneak into the market. This helps protect consumers from the potential dangers associated with counterfeit foods, such as lower quality or unsafe ingredients.

Building consumer trust – The consumer demand for food transparency is increasing, especially when it comes to ethical and environmental considerations. A study by Label Insight found that 94% of consumers are likely to be loyal to a brand that offers complete product transparency [2]. This highlights how transparency is becoming a key factor in building consumer trust.

How labels on agricultural products enable traceability

Tracing agricultural products would not be possible without accurate labels. Here’s how labeling helps traceability in the agriculture industry:

Assignment of unique identifiers – Unique identifiers on labels, such as a barcode (e.g., UPC, EAN), QR code, RFID tag, or a custom alphanumeric string, play a big role in agriculture labeling traceability by assigning a distinct code to each product or batch. This allows for tracking of items from the point of origin through every stage of the supply chain.

Providing critical information – Labels on agricultural products provide critical information, such as the product’s origin, batch number, ingredients, and expiration date to help aid in traceability. This information allows every product to be linked back to its source and production history, facilitating the tracking process at every step of the supply chain.

Enabling supply chain tracking – As an agricultural product moves through different stages—harvesting, processing, packaging, and distribution—its label is scanned at key checkpoints. This scanning process updates the product’s status in real-time, allowing businesses to monitor its location, conditions such as food temperature, and movement. This tracking capability improves inventory management, optimizes logistics, and makes sure that products reach their destination efficiently and safely.

Four future trends in agricultural traceability and labeling

The landscape of agricultural traceability is rapidly evolving, with new technologies and consumer demands driving innovation:

Blockchain technology – Blockchain offers a secure way to record and share traceability information. With data that cannot be manipulated, blockchain enhances the trust of traceability systems. A report by Juniper Research found that blockchain technology, which enhances traceability, is expected to save the food industry $31 billion by 2024 by reducing fraud and errors and improving food safety [3].

Internet of Things (IoT) – IoT technology allows for real-time monitoring of critical factors such as temperature and humidity during transport. This ensures that products are stored in optimal conditions, further enhancing traceability.

Growing consumer demand for transparency – As consumers continue to demand more transparency, agricultural businesses must adapt by providing detailed information about their products’ origins, production processes, and supply chains.

Smart Labels – Smart Labels, which feature QR codes or RFID tags, allow consumers to scan and view additional product information that may not fit on a traditional label. This technology is becoming more popular as consumers seek.

How label design software helps with traceability

As consumer demand for transparency continues to grow, agricultural businesses must adapt by implementing traceability systems. Labels play a large part in this process, and with the right label design software, businesses can create, manage, and track labels that meet the highest standards of safety, compliance, and consumer trust.

References

[1]: https://www.foodmanufacturing.com/safety/article/21123459/reducing-the-risk-of-recalls

[2]: https://nielseniq.com/global/en/landing-page/label-insight/

[3]: https://www.juniperresearch.com/press/blockchain-to-save-the-food-industry-31-billion/

Honey in spoon

Ensuring honey authenticity: the role of NMR spectroscopy

By Léa Heintz
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Honey in spoon

Honey is a key component in many households, valued for its health benefits, antibacterial, and antioxidant properties. However, its premium price point and resource-intensive production has led to the rise of honey fraud – the intentional adulteration of honey. This poses a significant challenge to the global honey industry by impacting beekeepers’ livelihoods, who cannot compete with cheaper adulterated alternatives, and damaging consumer trust.[i]

Traditional testing methods, which are focused on the detection of only one or a few parameters cannot reliably detect counterfeit honey products due to fraudsters finding new methods to bypass the tests. Nuclear magnetic resonance (NMR) spectroscopy has proven effective at uncovering a wide range of adulteration methods thanks to the multitude of parameters tested.

The impact and implications of honey adulteration

Economically motivated adulteration (EMA) is the intentional act of adulterating food for financial gain.

Some examples of EMA include the deliberate mislabeling of honey origin or variety and the addition of foreign sugars to the honey. The difficulty in detecting honey manipulation and the potential for economic gain provide attractive fraud opportunities for dishonest business operators.[ii]

A significant amount of imported honey is suspected to be adulterated and falsely labelled and goes undetected in the European market.[iii] There has been a significant rise in cases of honey adulteration in the EU in recent years. In 2017, more than 14 percent of tested honey samples had been adulterated;[iv] and, in 2023, 46 percent of honey samples were suspected of being adulterated with syrups.[v] The increased rates of honey adulteration could be attributed to the challenge of monitoring and keeping pace with evolving fraudulent practices. Consequently, non-targeted and multi-marker methods, which are not specific to a particular type of adulterant, are being increasingly adopted.

Current testing methods

There are several testing methods that currently exist to detect sugar syrups in honey. These methods involve detecting foreign enzymes that convert starches into sugars or specific markers present in syrups. However, there is evidence that these methods can be bypassed by fraudsters to allow adulterated honey to continue being undetectable.

Stable carbon isotope ratio analysis (SCIRA) can detect corn and sugar cane derived syrups. However, it is unable to detect other adulterants, such as syrups derived from C3 plants (for example beet, rice or wheat sugar).[vi] This is a significant limitation as fraudsters are able to bypass testing by adulterating using C3 sugars.

Another testing method is liquid chromatography-high resolution mass spectrometry (LC-HRMS) which is used for marker detection. However, its targeted approach means it can only detect known syrups, which have been measured before.

NMR: an effective tool for honey analysis

NMR is a rapid screening method which can detect signs of adulteration and other potential manipulations of honey. It provides a molecular ‘fingerprint’ of a honey sample, giving definitive information about its molecular composition and the presence of adulterants, such as foreign sugars.

NMR has the capacity to determine the country of origin and botanical source of honey[vii] which is useful for identification and detection of adulteration, and to ensure quality control.[viii] Other benefits of NMR analysis include its speed, reproducibility and the fact that sample preparation is very simple.

Thanks to the multiparametric approach offered by NMR, and its potential to uncover new markers, masking adulteration and misleading the analysis is difficult and its high reproducibility allows precise sample matching against databases of authenticated samples.

Case study: Estonia introduces measures to protect the honey industry

In 2019, the Estonian government declared NMR as the official testing method of honey products in Estonia.

Estonian beekeepers that were ethically producing authentic honey were unable to compete with the price of adulterated honey, causing them to lose business. In support of beekeepers, the Estonian government introduced measures to protect the honey industry.

This support has had a positive impact on the Estonian beekeeping industry, with producers able to sell their products at a reasonable price, allowing them to maintain their beehives and livelihoods.

The government collaborated with local beekeepers, food testing laboratories, honey packagers and retailers to remove fake honeys from the local market, including both locally sourced and imported products. The adoption of NMR testing could help ensure standards are met and address the widespread issue of honey fraud.

A bright future for the honey industry

Food fraud continues to be a global issue. Fraudsters are constantly finding new methods to bypass existing testing methods, which affects food production worldwide. In the case of honey, despite some governments implementing measures to prevent false labelling and protect the livelihoods of beekeepers, the lack of standardized regulations across different geographical regions allows counterfeit honey to avoid detection. NMR proves to be a highly reliable alternative to traditional testing methods. By providing detailed insight into a sample’s molecular composition, NMR is playing a role in safeguarding the honey industry and ensuring its sustainability.

References

[i] European Commission. “Official Controls: Food Fraud – Honey, Questions and Answers.” 2021. https://food.ec.europa.eu/document/download/7186ec16-8f9d-4459-b155-f424ee6c7e3e_en?filename=official-controls_food-fraud_2021-2_honey_qandas_en_0.pdf.

[ii] European Commission. “Official Controls: Food Fraud – Honey, Questions and Answers.” 2021. https://food.ec.europa.eu/document/download/7186ec16-8f9d-4459-b155-f424ee6c7e3e_en?filename=official-controls_food-fraud_2021-2_honey_qandas_en_0.pdf.

[iii] European Commission. “Honey: 2021-2022.” https://food.ec.europa.eu/safety/eu-agri-food-fraud-network/eu-coordinated-actions/honey-2021-2022_en.

[iv] European Commission. “Honey: 2015-2017.” https://food.ec.europa.eu/safety/eu-agri-food-fraud-network/eu-coordinated-actions/honey-2015-17_en.

[v] EU Coordinated Action. “From the Hives” (Honey 2021-2022). Food Safety. March 22, 2023. Accessed November 22, 2023. https://food.ec.europa.eu/safety/eu-agri-food-fraud-network/eu-coordinated-actions/honey-2021-2022_en.

[vi] Mai, Z.; Lai, B.; Sun, M.; Shao, J.; Guo, L. Food Adulteration and Traceability Tests Using Stable Carbon Isotope Technologies. Tropical Journal of Pharmaceutical Research 2019, 18 (8), 1771–1784.

[viii] Schepartz, A. I., & Subers, M. H. “Honey Composition and Properties.” Journal of Food Science and Technology (2019). https://www.tandfonline.com/doi/full/10.1080/87559129.2019.1636063#d1e891.

Robotic technology, automation

Robotics Technology for Small Food Manufacturers

By Matt Inniger
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Robotic technology, automation

Robotics technology has been a staple of certain manufacturing subsectors (automotive, aerospace, etc) since the 1950s, far longer than most people think. Food and beverage manufacturing isn’t a subsector most of the general public would associate with robotics.

However, robotics are widely used in the largest food manufacturing facilities worldwide, in a variety of use cases. The benefits of robots aren’t limited to food manufactures with sky high capital budgets. Thanks to advances in the past decade, food and beverage manufacturers of all sizes can leverage the benefits of this technology.

Use Cases

Let’s start with walking through the most popular use cases for robotics in most food manufacturing facilities, of any size. While these are the most common, it’s not an exhaustive list. If you’re considering a use case that isn’t discussed here, consider whether the physical operation is both predictable and repeatable. Is the target object of the physical operation presented in the same way every time? Does the target weigh the same? Is the path that a robotic arm would take to accomplish the task identical for reach repetition? If so, it’s likely a good fit for robotics.

By far the most common use case in food manufacturing is end of line packaging, firstly palletizing followed by case packing. These are so popular because once most food products are fully enclosed, they’re identical to any other widget from an operational standpoint. This means that palletizing cells designed and utilized primarily in other CPG sectors are plug-and-play for food manufacturing.  Case packing can be more complicated, depending on the packaging for a specific product. Products without rigid packaging can be tough for robotic arms to securely grasp with traditional tooling, and products in very small containers can present a speed problem that would require multiple robots in a single cell to overcome.

Front end pick and place operations like depalletizing, conveyor loading, etc. are also excellent applications for robotics, but are much less common generally in food and beverage outside certain product categories.

Use cases that are far less common, but still completely feasible depending on the specifics of different production processes, are food contact applications. The most feasible food contact applications for robotics are product agitation for specialty liquid or bulk solid products where container agitation isn’t available or sufficient, or pick and place on exposed product, usually container packing.

Food contact applications are more uncommon, for some reasons that are good and some that aren’t. While concerns around end of arm tooling affecting delicate products and robotics keeping up with required throughput are perfectly reasonable, concerns about cleaning robotic arms and end of arm tooling are mostly based on a lack of understanding.

Food Safety Considerations Around Robotics

If we consider the end-of-line packaging use cases presented initially, these operations typically happen outside of the sanitary production room, most of the time in spaces with just minimum GMP protocols. With fully enclosed food products, this means that the robotic cells themselves can be treated like any case erector or sealer and cleaned minimally, since risk is low.

For food contact applications, any robotic cell would need to comply with the cleaning regimen for the specific production process. Full washdown environments would seem to present an issue for the precise electronics required for robotic systems. However, washdown certified arm cowling and custom design soft shell shrouds for CPUs allow robotic cells to operate reliably without additional maintenance in high water environments.

Different Robotics Solutions

So, let’s discuss what a robotic solution for any given use case might actually look like. While there are a myriad of specialized robotic types and five fixed-type industrial robot categories recognized by the International Federation of Robotics, we’ll focus on the types most commonly used, especially in food and beverage. These are articulated, delta, and collaborative robots.

Traditional, fixed-place, industrial articulated robotic arms are exactly what most people think of when they picture a manufacturing robot. These arms usually have six axes to provide a high range of motion, can extend to a very long reach, and can also handle the highest amount of weight. While these units are robust and capable, they generally aren’t a good fit for small or midsize food manufacturers unless the use case deals with a very heavy pick and place operation or the ROI on the use case is very high. These units are expensive, take up a lot of space, and require a substantial amount of guarding to operate effectively, drastically reducing the flexibility of the overall production process.

Delta robots are lightweight, high-speed robots that are generally mounted over the top of production lines for pick and place operations that require high cycle frequency but not excessive range of motion. These robots specialize in container packing use cases, especially in multi-unit cells that handle high throughput lines. However, this capability comes at a high price, often with the highest initial investment of the three robot types we discuss today.

Lastly, let’s discuss collaborative robots, the category that is the best fit for a large majority of use cases in small and midsize food manufacturing facilities. Collaborative robots are similar to articulated units, in that they are multi-axis arms that are compatible with a variety of end of arm tooling. However, there are key differences. Collaborative robots are smaller, generally are not fixed (which is to say they are often mounted on wheels or rails), have a more limited reach and max weight capacity, and most importantly require zero safety guarding. This is because collaborative robots are force-limiting, they are built with sensors that detect nearby obstacles and objects in order to prevent collisions. This makes collaborative robots safe for human operators to work “in collaboration” with, and allows for easy one-to-one automation of some manual tasks. Collaborative robots also have lower utility requirements, often running on 120V outlets, and cost far less, with entry level models starting in the $30,000 range.

These unique aspects of collaborative robots make them a great fit for small and midsize food manufacturers to automate the low hanging fruit that is end of line packaging and palletization. In fact, this is such a great value that multiple robot integrators build off-the-shelf palletizing cells that incorporate feed conveyors and integrated controls all for under $100,000. This type of plug-and-play solution is an incredible value for almost any small food manufacturer still manually building pallets.

Additionally, collaborative robots are available in full washdown configurations for food contact applications. CIFT uses a FANUC CRX collaborative robot at our shared-use commercial kitchen in a full washdown environment for food contact tasks.

Conclusion

Robotics can offer a significant amount of value to food manufacturers of all sizes. Collaborative platforms provide the best bang for the buck and are a great place to start for most companies. Lastly, don’t be afraid to utilize robotics in food contact applications, if the use case is feasible otherwise.