Connected Factory, manufacturing
FST Soapbox

The Competitive Edge of Food Safety: A Business-First Approach

By Michael Ciepiela
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Connected Factory, manufacturing

Every food company understands that food safety is non-negotiable – but the smartest ones know it’s also a strategic advantage. A single recall can cost millions in lost revenue, legal fees, and brand damage. But beyond preventing disasters, a well-built food safety and quality assurance (FSQA) program drives day-to-day value: it cuts waste, improves efficiency, reduces corrective actions, and builds trust with customers and partners. When food safety is done right, it becomes a growth engine – not just a compliance requirement.

Establishing a strong food safety foundation at a facility isn’t always easy – but it’s essential. As industry professionals, our mission goes beyond meeting regulatory checklists; it’s about ensuring that consumers have a consistently safe and enjoyable experience with our products. That kind of trust isn’t just a moral obligation, it’s a business asset. At the site level, building a culture of food safety starts with the understanding that it’s not just the responsibility of the Quality Assurance team, it’s everyone’s job. When every employee takes ownership of food safety, it leads to fewer mistakes, more efficient operations, and ultimately, a stronger bottom line. Companies that prioritize food safety as a shared value often see long-term gains in brand reputation, customer loyalty, and operational performance. Simply put, a proactive food safety culture is not just good practice, it’s good business.

Investing in food safety and quality assurance (FSQA) technology lays the foundation for consistently producing a safe, high-quality product. Not too long ago – and in some places still today – many of us were logging regulatory data by hand, scribbling into controlled documents with pen and paper. I still get a little PTSD during mock recalls, flipping through endless pages trying to track where every raw material, packaging component, and finished product went. It’s a stressful reminder of how outdated systems can create major blind spots. And those blind spots don’t just affect audits, they impact decision-making, efficiency, and ultimately profitability.

Data management, food manufacturing

The business case for investing in the right technology is both clear and compelling. In my experience, the best way to communicate this to leadership is by focusing on three key areas:

  1. Risk Management – not just of the product, but of the company’s reputation and the integrity of the entire facility.
  2. Operational Efficiency – streamlining processes, improving throughput, and reducing labor-intensive manual tasks.
  3. Crisis Prevention – catching issues early, minimizing corrective actions, and creating a culture of proactive quality.

Risk Management

The ripple effects of a product recall extend far beyond the affected item. They can severely damage a brand’s reputation, eroding consumer trust and loyalty – not just for the specific product, but for the entire portfolio. In the spice industry, for example, it seems like every other month there’s a headline about elevated lead levels in ground cinnamon. In today’s environment, simply meeting the bare minimum for regulatory compliance – such as basic product testing – is no longer enough.

By leveraging FSQA technology and real-time data, companies can stay ahead of potential or ongoing recalls. When an alert surfaces in the media, we can quickly compare our own verified data and, if unaffected, proactively communicate with our customers through targeted email notifications. This kind of responsiveness not only minimizes confusion and concern but also reinforces customer confidence in the brand.

Investing in FSQA systems provides the transparency and control needed for modern operations. With access to real-time information, teams can make faster, more informed decisions that protect both product integrity and long-term brand value.

Operational Efficiency

As FSQA professionals, it often feels like a rite of passage to be pulled into optimizing production throughput, whether it’s assisting with product identification, staging resources, or even jumping on the line to help package finished goods. Viewing production through a Lean Six Sigma lens reinforces the value of continuous improvement and challenges us to eliminate inefficiencies at every step.

Investments in quality and production compliance software that track records directly on the line can dramatically enhance multiple areas of the manufacturing process. FSQA systems aren’t just about ensuring safety, they’re about increasing speed, accuracy, and control. By digitizing checklists, records, and monitoring tools, you reduce human error, eliminate redundant tasks, and free up your team to focus on higher-value work.

The result? Fewer production delays, faster response times when things go off-spec, and improved communication across departments. Over time, these efficiencies add up. You produce more, waste less, and consistently deliver a better product, driving both customer satisfaction and profitability.

Crisis Prevention

There’s never a “good time” for a crisis in food manufacturing. In fact, it often feels like clockwork – recalls, withdrawals, major product holds, or employee-related issues always seem to happen during holidays, PTO days, or after hours, usually hitting second or third shift when staffing is light. But as an FSQA leader, one of the most powerful things you can be is prepared.

Most crises don’t appear out of nowhere, they build over time. There are usually early warning signs: small deviations, overlooked documentation, or repeated non-conformances. That’s where digital FSQA tools make a major difference. These systems help identify patterns, flag risks, and trigger alerts to the right stakeholders before a situation spirals out of control. By monitoring data in real time, you’re no longer reacting to problems, you’re getting ahead of them.

When a crisis management plan fails, or a recall or other serious event occurs, time is of the essence. Digital documentation becomes an invaluable tool, allowing teams to quickly and efficiently gather the necessary information. With properly formatted compliance records and organized quality documentation, searching for critical data becomes seamless. And in the middle of a high-pressure recall situation, the last thing any professional needs is added stress while digging through stacks of paperwork to determine where affected products were received, processed, or shipped.

As we all know, when dealing with thousands, or even millions, of pounds of product, there are countless variables involved in producing a single finished good. The digital advantage lies in how effortlessly team members can access key records. With well-implemented FSQA software, anyone on the team can quickly locate the information they need, supporting faster traceability, better communication, and more effective crisis resolution.

Getting Past the Red Tape

When advocating for investment in FSQA technology, it is not uncommon to encounter hesitation based on perceived barriers. A frequent concern is, “It’s too expensive.” However, the long-term cost of inaction, such as product recalls, operational inefficiencies, and damage to brand reputation, can far exceed the initial investment. Others may argue, “We already meet regulatory requirements.” While compliance is essential, it represents the minimum standard, not a comprehensive strategy for quality and business growth. Additionally, some organizations may believe, “Our process isn’t that complex.” Regardless of complexity, every manufacturing process benefits from enhanced visibility, traceability, and operational control.

The easiest route to take when it comes to getting buy-in for the installation of digital compliance programs is looking at it from a lean six sigma standpoint. Continuous improvement is the mindset that any successful company achieves. Through means of integration and technological advances for digital modernization of compliance records, your company can start setting best-in-class precedents where others will be benchmarking against your trailblazing standards.

Another important layer to a strong ROI pitch is the value FSQA technology brings from the customer’s perspective. Whether you’re working with a major industry player or a small, independent retailer, demonstrating a robust compliance and quality management system builds confidence and credibility. As the primary liaison during customer visits, I’ve found this is the moment where I truly let our quality software system shine. Having real-time data at my fingertips for every production line, and the ability to quickly identify and troubleshoot potential issues, is something customers genuinely appreciate. It’s not just the live data that impresses them; it’s also the compliance component. The system allows us to generate and present documentation that’s properly formatted and aligned with the Code of Federal Regulations requirements, which reinforces our commitment to quality and regulatory integrity.

The Cost of a Competitive Advantage

It’s true that there can be initial sticker shock when exploring the cost of transitioning to a digital quality management system. However, the return on investment often proves to be tenfold. One of the most valuable benefits is the organization, accuracy, and accessibility of documentation. In a digital environment, critical records are no longer buried in file cabinets or scattered across spreadsheets.

Consider the stress of an audit scenario: you’re asked to produce one final, crucial document, and it’s nowhere to be found. With digital systems, a simple search, by lot code, SKU, date, or other filters, can instantly retrieve the exact file needed, saving time, reducing anxiety, and reinforcing confidence.

Moreover, the financial risk of product recalls, often amounting to millions of dollars, underscores the value of having a robust, sophisticated FSQA system in place. In many cases, the cost of the software is easily justified by the protection and efficiency it provides.

Scaling Smarter with FSQA

Food Safety and Quality Assurance is no longer just a safety net, it’s a springboard for sustainable growth. Organizations that embrace FSQA as a strategic initiative are positioning themselves as best-in-class in both operational excellence and brand integrity. These companies don’t just meet expectations, they set the benchmark for what quality and trust should look like in today’s food industry.

By implementing advanced FSQA systems, they gain efficiency, strengthen consumer confidence, and stand out in a competitive marketplace. Now is the time to shift the narrative from compliance to competitive advantage. Invest in systems that help your business do it right the first time, and become the standard others look for best practices.

Plastic Bottles
Beltway Beat

FDA Shares Testing Results for PFAS in Bottled Water

By Food Safety Tech Staff
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Plastic Bottles

The U.S. Food and Drug Administration (FDA) shared final results from their testing of domestic and imported bottled water collected at retail locations across the U.S. between 2023 and 2024 and analyzed for per- and polyfluoroalkyl substances (PFAS). The 197 samples included purified, artesian, spring, and mineral waters. Ten of the samples analyzed by the FDA had detectable levels of PFAS, none of which had levels that would have exceeded the maximum contaminant levels (MCLs) set by the Environmental Protection Agency (EPA) for PFAS if detected in public drinking water.

The FDA tested the bottled water samples for 18 types of PFAS, including the six PFAS for which EPA established MCLs in drinking water.  Of the ten samples with detectable PFAS levels, they detected a range of one to four different PFAS in each of the eight domestic bottled water samples, which were either purified or spring water, and a range of one to two different PFAS in each of the two imported bottled water samples, both of which were artesian water. Four of the PFAS detected were at levels below the EPA MCLs for PFAS in drinking water. Two of the PFAS detected do not have EPA MCLs established. The FDA has previously analyzed for PFAS in bottled water through a limited targeted survey (2016)and through the FDA’s Total Diet Study (TDS) samples. Results from the 2016 survey and TDS testing did not detect PFAS in bottled water samples.

Under section 410 of the Federal Food, Drug and Cosmetic Act (FD&C Act), when the EPA establishes new MCLs for public drinking water as part of a National Primary Drinking Water Regulation (NPDWR), the FDA is required to establish a standard of quality regulation for the same contaminants in bottled water, or make a finding that such a regulation is not necessary to protect the public health because the contaminant is not present in water used for bottled drinking water. If the FDA does not establish a regulation nor make a finding that such a regulation is not necessary, then the levels set by EPA’s NPDWR would be considered the applicable regulation for bottled water. The FDA can take action against bottled water that presents a safety concern even if there is no standard of quality for a contaminant.

Food processing and sanitation

Survey Says: Cost Control Catches Up With Food Safety

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Food processing and sanitation

For the first time in the 24 years of Food Processing magazine’s Manufacturing Outlook Survey, food safety is not the top priority for the new year among manufacturing professionals with cost control edging it out.

Cost control’s 8.11 weighted score beat out food safety’s 7.67 score, when the 100 respondents to the survey were asked “Please rank … the importance to your plant of each of the following manufacturing issues.”

Food Processing reported that food safety was still ranked the No. 1 priority by the highest number of respondents (26%), but higher second- and third-place rankings for cost control (22% ranked it first) pushed it ahead in the weighted score. 23% ranked automation first, for a weighted score of 6.64 and third place among priorities.

The survey asked who thought their facility was prepared for the FSMA 204 food traceability rule, which at the time of the survey still had the deadline of January 2026. Most respondents (62%) answered in the affirmative. Respondents comments included “Never heard of it until this question” to proclamations that they will be ready or still working on the paperwork and training to comply.

One respondent said, “We are implementing new processes and investing in the required capital equipment in order to comply with the food traceability requirements.”

The survey covered many more topics than just food safety and you find read the full review of the survey on Food Processing.

Navigating Challenges of FSMA 204 Compliance

By Subhash Chaudhary
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The Food Safety Modernization Act (FSMA) Section 204—known as the Food Traceability Final Rule—aims to ensure food safety through enhanced traceability of high-risk foods. By mandating structured tracking and tracing of food products from farm to fork, the rule not only minimizes the risk of contamination but also provides a rapid recall mechanism if needed. With FSMA 204, food manufacturing companies must take a significant step toward enhancing food safety and protecting public health.

This article delves into what the new traceability rule means for food manufacturing companies, the operational challenges involved in complying with FDA’s requirements, and how advanced product traceability solutions can help organizations turn compliance into a competitive advantage.

FSMA 204 Compliance: 3 Key Components.

FSMA 204 requires food companies to implement robust traceability systems focusing on three key components:

  1. Food Traceability List (FTL):
    The FDA’s FTL identifies high-risk foods (e.g., nut butters, leafy greens, fresh-cut produce) that require enhanced recordkeeping. For instance, nut butters must be tracked carefully through the supply chain due to their inclusion in the FTL.
  2. Key Data Elements (KDEs):
    For every step, the FDA mandates the collection of detailed data:

    • Source Details: Information about where the product originated (e.g., the distributor’s business name, address, and facility details).
    • Destination Details: Where the product is being sent (e.g., the chocolate manufacturer’s facility).
    • Product Details: Specifics such as product description, lot numbers, quantities, units of measure, and packaging information.
    • TLC Source Details: In cases where a product is repackaged (e.g. when a distributor repackages nut butter and assigns a new Traceability Lot Code), the original source must be captured.
  3. Critical Tracking Events (CTEs):
    These are specific points in the supply chain where traceability records must be maintained. Examples include:

    • Shipping: For example, when a distributor ships nut butter from its warehouse to a chocolate manufacturer, the shipment date, origin, destination, and unique traceability lot code are recorded.
    • Receiving: Upon arrival, the chocolate manufacturer confirms the product’s integrity, quantity, and the corresponding lot code.
    • Transformation: When the chocolate manufacturer or its co-manufacturing partner transforms the nut butter by incorporating it into chocolate bars, details of the process—such as production dates, ingredients used, and the new lot code—are documented.

This detailed approach ensures that every touchpoint is recorded, enabling rapid identification of the product’s journey if a recall or investigation becomes necessary.

Operational Challenges in FSMA 204 Compliance

Implementing these enhanced traceability systems is not without its challenges.

  • Fragmented Data Sources: Data complexity due to various sources/formats and variable data attributes makes data management, accuracy, and accessibility across different stakeholders a challenge. For example, while a distributor might capture shipment data in one system, the manufacturer could use an entirely separate ERP to receive and transform details. This is where an ERP-agnostic product traceability solution can help enterprises with seamless ingestion and harmonization of data.
  • Data Completeness and Standardization: Without standardized data capture methods, many companies risk having incomplete records. Consider a scenario where different suppliers use varying formats for lot numbers or unit measurements, complicating the integration process.
  • Real-Time Data Visibility: The regulation demands immediate access to traceability data—which is critical during a recall or contamination event. Legacy systems, which rely on manual data entry or batch uploads, may fall short of meeting these time-sensitive requirements.
  • Interoperability Between Systems: Many companies use diverse ERP, WMS, and legacy systems that do not naturally communicate with each other. Integrating these into a single, cohesive traceability framework is a significant hurdle.
  • Supplier and Partner Readiness and alignment: Smaller suppliers or those in less digitized environments (e.g., field operations still using pen-and-paper logs) can slow down the entire compliance process, requiring additional training and technical support.  Formats and protocols to share and receive the KDE data also need to be aligned with partners.
  • Compliance Reporting and Monitoring: Businesses must generate accurate compliance reports and monitor traceability requirements continuously, which can be difficult without an integrated digital solution.

Business Impact and Analysis

Achieving FSMA 204 compliance offers more than just meeting a regulatory requirement—it creates real business value:

  • Enhanced Brand Trust:
    Transparent traceability systems boost consumer confidence. When a company can quickly and accurately trace a product’s journey—from the distributor’s repackaging of nut butter to its final transformation into a chocolate bar—it reassures consumers about the safety and quality of the product.
  • Operational Efficiency:
    Streamlined, digital systems reduce manual entry errors, cut down on time delays, and optimize the recall process, ultimately lowering costs and increasing supply chain efficiency.
  • Risk Mitigation:
    A well-integrated traceability system reduces the risk of prolonged contamination exposure, minimizes financial losses, and helps maintain a company’s reputation by enabling swift action during food safety incidents.

FSMA 204 Compliance Checklist for Your Organization

A brief checklist your organization can use to ensure continued FSMA 204 compliance:

  • Review & Update Your Traceability Plan:
    Confirm that your traceability plan clearly details procedures for recording Critical Tracking Events (CTEs) and Key Data Elements (KDEs) across all stages—from receiving nut butter to its transformation into a finished product. Include updated traceability lot code assignments and designate a clear point of contact for FSMA inquiries.
  • Verify Data Accuracy and Accessibility:
    Ensure that all records (whether electronic or paper) are complete, legible, and easily retrievable within 24 hours upon FDA request. Test your systems through internal audits and mock recalls to confirm data integrity.
  • Align with Supply Chain Partners:
    Engage with co-manufacturers, co-packers, and distributors to confirm that all parties share consistent traceability records. Establish written agreements that outline data sharing and process responsibilities for each Critical Tracking Event (CTE).
  • Invest in Technology & Traceability Solutions:
    Evaluate your current systems to determine which Key Data Elements (KDEs) are already being captured and where they reside. Identify any gaps or modifications needed to meet FSMA 204 requirements. This assessment will help you decide if your existing ERP, inventory, or traceability software needs upgrades or integration with new digital tools. Investing in dedicated traceability solutions ensures that your organization can reliably capture, manage, and share the required data across all Critical Tracking Events, ultimately strengthening your compliance and food safety efforts.
  • Staff Training and Continuous Improvement:
    Regularly train your staff on FSMA 204 requirements and recordkeeping practices. Update standard operating procedures as needed and keep documentation of training sessions to demonstrate compliance readiness.

By following these steps, your organization will be well-positioned to not only meet FSMA 204 requirements but also enhance overall operational efficiency and food safety throughout your supply chain.

Conclusion

FSMA 204 compliance requires a detailed, standardized, and real-time approach to traceability and rigorous record-keeping requirements.

This is where a cloud-based, globally scalable product traceability solution can ensure regulatory compliance in a dynamic landscape, enhance operational efficiency, food safety, and transparency, as well as collaboration among supply chain partners. Moreover, food manufacturing companies can overcome traceability challenges that impede long-term compliance by embracing digital solutions that integrate specific examples and granular data capture—from shipping details to transformation records.

Comprehensive traceability systems are thus essential as they enable food manufacturing companies to reduce the time to track product movement across disconnected supply chains, enhancing visibility and empowering both organizations and consumers to make informed decisions.

Resources:

https://www.fda.gov/food/food-safety-modernization-act-fsma/food-traceability-list

Frank Yiannas, Walmart, Food Safety Consortium
Food Safety Culture Club

Frank Yiannas and Aquatiq Partner to Expand Global Reach of Food Safety Culture

By Food Safety Tech Staff
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Frank Yiannas, Walmart, Food Safety Consortium

Frank Yiannas, a world-recognized food safety expert, and Aquatiq, an international provider of food safety solutions, are joining forces to advance global expertise in the establishment of food safety cultures in industry and government.

This is the first time a third party will be accredited to train and certify instructors to teach the Food Safety Culture Workshop© that Yiannas has been conducting for executives and regulators all over the world. The partnership aims to make food safety culture more accessible and actionable for companies and regulators worldwide.

Yiannas, a former deputy commissioner at the U.S. Food and Drug Administration and principal of Smarter FY Solutions, has long championed the importance of establishing food safety cultures to fuel and support food safety management at all levels of the global food chain. He created this workshop to provide a greater understanding of how to use organizational and behavioral science principles to influence behavior and enhance employee compliance.

“This partnership marks a significant step in making food safety culture practical and impactful for companies worldwide. Together with Aquatiq, we aim to empower organizations with the tools and knowledge to prioritize food safety at every level,” said Yiannas.

Aquatiq’s program will include a rigorous train-the-trainer process, certification, and an emphasis on measurable outcomes, ensuring high standards of training and education.

“At Aquatiq, we believe that food safety culture is the cornerstone of sustainable and responsible food production.” said Eirik Bugge, CEO of Aquatiq. “Partnering with Frank Yiannas allows us to leverage his unparalleled expertise to deliver world-class training and solutions that empower companies to embed food safety into their core values and operations.”

Before joining the FDA in December 2018 as Deputy Commissioner of Food Policy and Response, Yiannas spent more than 30 years in leadership roles with Walmart and the Walt Disney Company. And he wrote two books on food safety culture: “Food Safety Culture: Creating a Behavior-Based Food Safety Management System,” published in 2008, and “Food Safety = Behavior: 30 Proven Techniques to Enhance Employee Compliance,” published in 2015. After leaving FDA, Yiannas established Smarter FY Solutions to advise on food safety and supply chain issues.

Aquatiq provides food safety solutions across every stage of the food production value chain. With a focus on enhancing sustainability and reducing costs, Aquatiq is dedicated to helping businesses achieve excellence in food safety and operational efficiency.

 

Data protection, security

How Cyber Threats Impact Food Defense and What to Do About It

By Nazy Fouladirad
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Data protection, security

When you think about today’s cyber threats, ransomware and data breaches are among the first things that come to mind. However, there are also risks associated with our physical safety, including the integrity of global food supplies.

Cyberattacks, specifically those that target food supply chains, can pose a significant risk to our health and safety. Considering how dependent modern society has become on food production and distribution channels, major breaches in any of these areas can have critical long-term impacts on society as a whole.

Whether disrupting automated farming equipment or manipulating integrated industrial controls, it’s important to understand the ongoing risks to our food defense systems and how to better protect them going forward.

Understanding the Cyber Threat Landscape in Food Defense

Food supply chains are operated using a variety of interconnected systems and processes. While these create more opportunities for improvised agricultural development and larger distribution networks, they also create more entry points for cyber attackers.

Below are some of the areas where vulnerabilities that are currently present in food distribution sectors:

  • Farming and Food Production – Over the years, farming equipment and food production facilities have adopted a number of new technologies to make their processes more efficient. These include automated irrigation systems, livestock monitoring equipment, and other agricultural solutions. Due to their constant connectivity, they can become vulnerable to attacks that can not only manipulate data but could even damage crops or harm livestock.
  • Processing and Manufacturing – Most food processing plants leverage the use of industrial control systems and temperature monitoring devices to ensure quality control of stored products. The accuracy of these monitoring solutions is critical to minimize the development of harmful bacteria and to ensure the integrity of the products being sold. If these systems become compromised, it can lead to product contamination or major backlogs in production.
  • Packing and Distribution – Warehouse management systems are used to help food suppliers and distributors manage their logistics processes effectively to ensure timely deliveries to retail outlets. Logistics platforms and transportation networks rely on GPS solutions and temperature controls during transit to ensure transported goods maintain their quality. Hackers can compromise these systems in an effort to misroute products or cause delays in critical delivery networks.

What are the Impacts of Cyber Threats on Food Defense?

Cyber threats against global food production facilities and supporting supply chain networks are more than just inconvenient or financially draining; they can also pose a question of health and safety.

Food Safety Risks

Cyberattacks can directly impact the safety of the food distributed and consumed. For example, a breach in a manufacturing facility could change certain ingredient ratios or tamper with temperature controls that keep food from spoiling or having certain contaminants.

If a cyber attacker gains access to cold storage facilities or delivery systems, they could make changes in operating temperatures that can directly impact the shelf life of large volumes of food.

Economic Issues

The economic impacts of cyberattacks on the food industry can also be significant. Supply chain disruptions caused by attacks on logistics or transportation systems can create shortages, drive up prices, and impact end users.

When considering the extensive recovery costs associated with a cyberattack, including system restoration or legal fees due to breaching certain data security or compliance standards, the long-term damage could be substantial. The cumulative effect of these disruptions can also lead to significant increases in food prices and impact both businesses and consumers.

Public Health Concerns

One of the most concerning impacts of cyberattacks on food defense is the potential for widespread illness. Contaminated or spoiled food can lead to outbreaks of foodborne illnesses, affecting large numbers of people. In severe cases, these outbreaks can result in hospitalizations and even deaths.

The potential for large-scale food recalls triggered by cyberattacks is another issue that can have public health implications. These recalls not only disrupt the supply chain but also create significant costs for businesses and inconvenience for consumers.

Effective Strategies for Mitigating Cyber Threats in Food Defense

Protecting the food supply chain from cyberattacks requires a strategic approach involving a variety of preventative measures. This includes:

1. Implementing Strict Cybersecurity Measures

Having a strong cybersecurity foundation is critical for industries. This includes implementing network security measures like firewalls and intrusion detection systems to prevent unauthorized access. This includes:

  • Employing firewalls, intrusion detection/prevention systems, and virtual private networks (VPNs) to control network traffic and prevent unauthorized access.
  • Implementing data encryption at rest and in transit.
  • Regularly scanning for vulnerabilities and applying software patches and updates as quickly as possible.
  • Educating employees about cybersecurity best practices, practicing good password hygiene, and following established security protocols.

2. Strengthening Supply Chain Collaboration

Effective information sharing and threat intelligence with all supply chain stakeholders is essential. This includes establishing various cybersecurity standards and protocols across the supply chain to ensure that all partners work from the same baseline level of security preparedness.

Employing penetration testing services to simulate real-world attacks is another important way to ensure that newly adopted security policies and procedures can withstand the latest attack methods. Simulated attacks can also help organizations prioritize their initiatives and collaborate to close critical gaps across interconnected supply infrastructure.

3. Developing Incident Response Plans

Even with the best preventative measures in place, cyberattacks can still occur. This is why developing comprehensive incident response plans is so important for improving food defense. These plans should outline clear procedures for handling cyberattacks, including identifying the incident, containing the damage, and recovering any impacted systems and data.

Creating backup and recovery systems is critical for minimizing downtime in the event of an attack. These systems should be regularly tested to ensure that they can be quickly and effectively deployed.

Effective communication strategies during a crisis should also be defined ahead of time. This includes notifying customers, suppliers, and regulatory agencies about the incident and keeping them informed about the steps being taken to resolve it.

Protecting Our Critical Infrastructure

Cyberattacks targeting the food supply chain can pose a significant threat to agricultural businesses and consumers. By implementing effective cybersecurity measures and strengthening supply chain collaboration, companies can take the necessary steps to protect critical infrastructure while ensuring the continued safety of our food supply.

Navigating the Five Biggest Challenges for Food Sector Asset Managers

By Candi Robison
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Maintenance management in a food production facility is a formidable challenge. Managing machines and people across multiple sites, ensuring compliance with health, safety and environment (HSE) regulations, driving efficiency and preventing costly downtime: the challenges are manifold. With stringent audit requirements and the constant threat of product recalls or facility shutdowns, asset managers in the food sector must embrace strategic and data-driven maintenance strategies.

According to the Enterprise Asset Management (EAM) Trend Report, uptime is the most crucial performance indicator for asset managers in industrial businesses such as food and beverage manufacturing. Yet, a lack of communication remains one of the biggest risks to uptime. With the cost of downtime exceeding $22,000 per minute (or over $1M per hour)1 it’s an issue that no-one can afford to ignore. Effective collaboration, digital transformation and proactive maintenance practices are the key answer to the five biggest challenges for food sector asset managers.

1. Enhancing Collaboration for Optimized Asset Management

Asset managers must align maintenance KPIs with overarching business goals. Effective collaboration between maintenance teams, operations, and HSE professionals creates compound benefits such as improving productivity, efficiency, communication, and data integrity.

The Circle of Collaboration is a theory that fosters alignment between departments and facilitates a seamless flow of information. To achieve this, a centralized EAM system empowers teams to share data, analyze trends, and embrace a proactive maintenance culture. This approach helps eliminate the traditional “we use, you fix” mentality and shifts the focus toward shared objectives.

By leveraging a single-source-of-truth platform, food manufacturers can move away from blame-based working cultures and embrace interdepartmental cooperation, ultimately reducing downtime and enhancing workplace safety.

2. Protecting Uptime with Proactive Maintenance

Unplanned downtime is one of the most significant threats to food manufacturing operations. It leads to production delays, financial losses, and potential food safety risks. Given the perishable nature of food products, even minor disruptions can have catastrophic consequences.

Implementing proactive maintenance strategies helps mitigate these risks. By transitioning from reactive maintenance to predictive and risk-based approaches, organizations can optimize asset reliability and reduce costly breakdowns.

The Maintenance Maturity Model illustrates how companies can evolve from reactive repairs to predictive analytics-driven strategies, leveraging IoT technologies to monitor asset health in real time. With data-driven insights, asset managers can anticipate failures, schedule maintenance more efficiently, and extend the lifespan of critical equipment.

3. Controlling Costs Through Data-Driven Decisions

Maintenance budgets must be managed meticulously to ensure cost efficiency without compromising safety or productivity. However, relying on offline data records makes it challenging to understand how budgets are spent and which assets cost the most to maintain. Optimizing asset performance then becomes a guessing game.

A robust EAM system provides reliable data on asset operation and service history, allowing asset managers to make confident decisions. By automating maintenance tracking, organizations can pinpoint underperforming assets, identify inefficient maintenance practices, and allocate resources effectively.

With full visibility into maintenance costs, food manufacturers can get the most value out of their assets by spending the budget in the most impactful manner. In doing so, they optimize asset utilization and achieve greater financial control.

4. Simplifying HSE Compliance

Ensuring regulatory compliance is a top priority for food manufacturers. With ever-evolving safety regulations and stringent hygiene standards, food production facilities must integrate asset management and HSE processes effectively.

An EAM system supports this by enabling real-time monitoring of asset health and maintenance history, as well as providing a transparent record of compliance. It also aids in enforcing safety protocols, streamlining maintenance actions, and ensuring documentation is readily available for audits or investigations.

By centralizing data, organizations can reduce the risk of regulatory breaches, making it easy to confidently demonstrate compliance, avoid penalties, and maintain food safety standards.

5. Building Resilience with Digital Transformation

Resilience in food manufacturing is more critical than ever, especially in the wake of global disruptions such as COVID-19. Organizations with well-planned maintenance processes, remote capabilities, and digital management strategies hold a significant competitive advantage.

Innovative solutions, such as mobile-enabled EAM systems, provide real-time access to maintenance data, ensuring continuity even during disruptions. By digitizing maintenance workflows, companies can streamline operations, enhance decision-making, and improve overall agility.

The lessons learned from pandemic-related shutdowns underscore the importance of digital transformation in asset management. Investing in connected maintenance solutions not only improves operational efficiency but also strengthens business resilience against future uncertainties.

Case Study: Agristo’s Digital Maintenance Transformation

Agristo, a leading manufacturer of frozen potato products, faced significant challenges in managing maintenance across multiple production sites. The company struggled with operational inefficiencies due to a lack of structured maintenance processes and digital records.

By implementing the Ultimo EAM system, Agristo transformed its maintenance operations, achieving full visibility over maintenance tasks and asset health. In 2020 alone, the company logged over 53,695 maintenance jobs, ensuring proactive asset management and minimizing downtime.

Crisp conveyor

Agristo’s adoption of a centralized maintenance platform resulted in a 5 percent increase in uptime, improved data-driven decision-making, and enhanced compliance. According to Steven Volckaert, Group Maintenance Manager at Agristo, “Being able to show in a clear and structured way how the essential maintenance and safety processes are managed and stored can be a selling point to new customers.”

Case Study: AVO-Werke

AVO-Werke August Beisse GmbH is a market-leading spice specialist, serving many major food manufacturers, B2B operators in the food trade, and artisan butchers across Europe. The company produces approximately 50,000 tonnes of raw herbs and spices annually and boasts a portfolio of around 8,000 products, including organic and processed spices, spice blends, marinades, seasoning sauces, and dressings as well as food processing products such as nets and casings for ham and sausages.

AVO wanted a solution that would cover all vital asset management processes but also offer a simple user interface to allow quick uptake amongst employees and enable a mobile and largely paperless operation.

Previously, the technical department relied on various Excel spreadsheets for an overview of files, spare parts and the maintenance status. Switching to Ultimo has revolutionized the process. “Simple order management, visibility over the availability of spare parts, and access to key documentation on mobile devices are just some of the improvements that make our daily work significantly easier. During audits, we are able to provide the requested information very quickly.”

“All our maintenance processes from order management and reporting to cost control, procurement, and the management of spare parts are much better organized with Ultimo,” says Dr Kurt Höfelmann, Technical Manager, AVO-Werke. “We get an excellent overview of the condition of our plants, which enables us to reduce downtime. Everything runs more efficiently, and that has a positive impact on our employees’ motivation.”

“The new EAM solution allows us to be more flexible, working on the computer and processing orders on mobile devices using the Ultimo Go+ app,” explains project manager Denis Roor, Technical Purchasing, AVO-Werke. “It’s ingenious how you can create an order on the go, process it, and then report it as completed. It eliminates many steps and phone calls, the time saved can be used more productively.”

Cover all vital asset management processes

Food sector asset managers face immense pressure to maintain uptime, ensure regulatory compliance, and control costs while ensuring asset availability and food safety. By fostering collaboration, embracing digital asset management solutions, and transitioning to proactive maintenance strategies, organizations can navigate these challenges effectively.

Investing in EAM technology enables food manufacturers to streamline maintenance processes, enhance data-driven decision-making, and build resilience in an increasingly complex industry landscape. Implementing a robust EAM system is the first step toward sustainable, long-term success.

  1. https://www.manufacturing.net/home/article/13055083/the-22000perminute-manufacturing-problem
Recall

Even With a New Administration, Food Companies Still Need To Be Recall Ready

By Roger Hancock
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Recall

As the new administration moves to make regulatory changes, food recalls remain a constant, with donuts, potato chips, chocolate, chicken nuggets, and more being recalled in the first few months of 2025. In fact, recalls are at a five-year high. Tech-driven recall readiness will prepare food businesses and supply chains for an uncertain future.

Digital solutions are transforming recall management, helping food businesses reduce response times, improve information-sharing, and ultimately protect public health. Automation, real-time monitoring, and cloud-based platforms provide the agility needed to adapt to regulatory shifts while ensuring an effective recall process. Companies that adopt tech solutions will not only mitigate risk but also be better equipped to handle whatever policy changes lie ahead.

Communities that are resilient, even amid uncertain regulatory and political climates. Tech solutions are central to this effort. Here’s how to build a tech-driven Recall Ready Community with your supply chain:

Prioritize food safety

Strong food safety protocols should always be the foundation of your recall strategy, even as policies evolve. Using traceability software and predictive analytics helps you detect risks early and act swiftly when a recall is necessary. Ensure your team is trained and prepared, with clear procedures in place, knowing that a recall could happen at any time.

Work collaboratively with your supply chain

Align with your trading partners to improve speed and accuracy – streamlining the recall process for smoother, more effective responses. Use interoperable systems, supplier verification platforms, and cloud-based communication platforms to elevate data-sharing, transparency, and accuracy. Share expectations for action, and practice your recall process with your supply chain to reduce delays and confusion when a recall occurs.

Standardize data and processes

Standardized data sets ensure all stakeholders (e.g., regulators, trading partners, consumers, the media) have access to accurate, actionable information. Traceability and recall management platforms should use standard data sets (like GS1 standard), and your team should be trained on clean and secure data practices.

Practice in advance

Conduct recall simulations so your team knows exactly what to do in a real-world recall situation. Recall management platforms that allow mock recall simulations and VR training tools create lifelike sample scenarios ideal for effective practice with your supply chain. These simulations help identify and close gaps (like whether you have current contact information for your stakeholders), so you can reduce confusion, build confidence, and ensure preparedness for actual recalls.

Communicate clearly

Even as Federal health agencies paused communication, you can proactively alert consumers and other key stakeholders about recalls. Use automated notification systems and customer loyalty programs to quickly disseminate key messages about recalls to your customers. Provide clear, actionable messaging about what happened, why it happened, and what to do next.

Conclusion

By embracing digital solutions, food businesses can stay agile, respond quickly, and maintain consumer confidence. Don’t wait for Congressional decisions or court rulings around food safety and recalls. Be proactive to protect your brand and consumers, no matter what the future holds. Today’s tech solutions are affordable, accessible, and user-friendly. Now is the time to invest in technology that strengthens your recall strategy and builds a more resilient industry.

Building a Resilient Food Supply Chain: Lessons in Streamlining Operations

By Ainsley Lawrence
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Supply chain stability has a great deal of influence over food safety and security across global markets. When food networks experience disruptions, the consequences affect production, distribution, storage conditions, and consumer well-being. Recent events, such as the COVID-19 pandemic, have demonstrated the urgency of developing adaptable food supply systems that maintain strict safety standards under pressure.

Modern food supply chains must balance operational excellence with strategic planning to respond to market shifts and evolving safety requirements. An ideal approach integrates vendor partnerships, technological solutions, and risk management practices to create robust networks that protect business value and public health. Successful food supply networks blend time-tested operational practices with smart innovation, maintaining quality standards through every market shift and challenge.

Streamlining Operations for Efficiency

Food supply networks depend on seamless coordination between multiple moving parts, from initial production to final delivery. Each step in the process — from cold storage management to transportation scheduling — requires precise timing and careful quality control. Optimizing these operations demands attention to two critical areas: building strong vendor partnerships and integrating smart technology solutions.

These core elements create reliable, efficient systems that maintain food safety while reducing operational costs. Success begins with cultivating strong partnerships throughout the vendor network and amplifying these relationships through strategic technology adoption. Striking this balance requires careful attention to supplier relationships and smart implementation of digital monitoring tools.

Building Strong Vendor Networks

Strong vendor relationships start with clear performance standards and consistent communication practices. Regular quality assessments and collaborative planning sessions help create lasting partnerships built on mutual success. These relationships become especially valuable during supply chain challenges when quick responses and flexible solutions matter most.

Effective vendor invoice processing reduces costs through automated systems and standardized procedures. This streamlined approach eliminates common error sources while freeing staff to prioritize strategic improvements. Well-managed vendor documentation also supports compliance efforts by maintaining clear records of all transactions and quality verifications.

Technology Integration for Safety and Efficiency

Advanced digital systems monitor food safety throughout storage and transportation, offering precise control over environmental conditions and product tracking. Modern IoT-driven sensor networks provide continuous updates on temperature, humidity, and other critical factors that affect food quality. These systems also utilize AI technology to analyze and formulate rapid responses to potential issues before they affect product safety.

Digital platforms also improve communication across the supply chain, connecting vendors, transporters, and facility managers through unified data systems. Real-time updates and automated alerts help maintain product integrity while reducing waste. Supply chain managers use this precise, real-time data to reinforce both immediate decisions and strategic planning.

Risk Mitigation and Flexibility in the Supply Chain

Food distribution networks face persistent challenges from multiple sources. Seasonal storms disrupt transportation routes, equipment failures compromise cold storage systems, and sudden demand spikes strain production capacity. Each type of disruption presents unique challenges to food safety and quality control, requiring specific strategies and response protocols.

Effective risk management combines two essential capabilities: systematic vulnerability assessment and operational flexibility. Organizations must develop methods to spot potential problems before affecting product quality. They then need adaptable systems that can quickly adjust to changing conditions without compromising safety standards.

Identifying and Addressing Vulnerabilities

Effective risk prevention begins with regular assessment of potential weak points. Transportation delays, equipment malfunctions, and storage complications can all threaten product integrity. Maintaining food safety during disruptions requires systematic monitoring and clear response protocols. Organizations particularly benefit from detailed contingency plans that anticipate various scenarios and outline specific actions for each situation.

Quality control teams must stay alert to subtle indicators that might signal developing problems. This vigilance includes monitoring supplier performance metrics, tracking delivery patterns, and analyzing temperature control data. Early detection of potential issues allows swift intervention before minor concerns escalate into significant disruptions.

Building Adaptable Systems

Flexible distribution networks accommodate sudden changes without sacrificing safety standards or operational efficiency. This adaptability stems from strategic redundancy in critical areas, including backup supplier relationships and alternative transportation routes. Cross-trained staff members provide additional flexibility, allowing quick reallocation of resources when specific areas need extra support.

Clear communication channels prove essential during periods of adjustment. Team members at every level need accurate, current information about changing conditions and modified procedures. Staff training drills sharpen emergency response skills and build team confidence. Well-prepared personnel protect food quality standards while smoothly executing needed process adjustments.

Branding and Consumer Trust in Food Safety

Consumer confidence grows from consistent safety practices paired with open communication. Food producers and distributors sharing detailed information about quality control measures build lasting market relationships. Today’s consumers look beyond basic safety claims — they want to understand specific handling procedures, storage protocols, and quality certifications. This heightened interest in food safety creates opportunities for meaningful dialogue with customers about quality assurance practices.

Meeting these expectations takes a coordinated approach that spans internal operations and external communications. Organizations can build consumer trust by creating clear, accessible messages about safety standards and fostering active participation in safety practices across all stakeholder groups. From employee training programs to consumer education initiatives, each element of safety communication plays a vital role in building and maintaining market confidence.

Communicating Safety Commitments

Clear messaging about food safety practices builds credibility with consumers and retail partners. Documentation of safety protocols, quality certifications, and handling procedures demonstrates dedication to product quality. Promotional products highlight your brand values while educating consumers about specific safety measures, from temperature monitoring to contamination prevention. If possible, tailor your materials to match the relationship in question.

Safety communication involves more than standard product packaging and labels. Websites, social media, and print materials collaborate to share detailed quality control processes and safety innovations. Using multiple communication methods helps consumers find accurate safety information wherever they look. Generally speaking, it’s better to have more information available than you need than to be too opaque.

Engaging Stakeholders in Safety Culture

Food safety excellence starts in warehouses and continues through every delivery route. Quality control teams conduct hands-on training sessions, from temperature monitoring to contamination prevention, to simulate real-world challenges. Staff members contribute valuable insights through structured feedback programs, often identifying practical improvements to daily operations. Employee recognition programs celebrate exceptional safety practices, spurring healthy competition and innovative approaches to quality control.

Safety education has far-reaching effects throughout the distribution network. Distribution centers conduct specialized training sessions for retail partners, teaching proper handling techniques for various food categories. Store staff learn optimal storage methods for different products and then pass this knowledge to customers through clear guidelines and practical tips. Local food safety workshops bring together warehouse teams, retail staff, and consumers, creating collaborative learning environments.

Final Thoughts

Strong food supply networks emerge from careful attention to three core elements: operational precision, risk readiness, and stakeholder engagement. Organizations that excel at vendor management while integrating advanced monitoring systems create reliable distribution channels that withstand market pressures. Clear safety protocols and quick-response capabilities maintain food quality through unexpected challenges.

Safety-focused communication strengthens every link in the food supply chain. Informed employees can spot potential issues early, trained vendors can follow precise handling procedures, and educated consumers can make smarter storage decisions. When each participant understands their role in maintaining food safety, the entire system benefits through consistent quality, reduced waste, and increased market confidence.

Ask The Expert

Top Questions to Ask When Selecting Your Food Safety Consultant

By Jennifer Lott
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In the dynamic and complex food industry landscape, the role of a food safety consultant is crucial. They provide expert guidance, advice, and assistance to ensure food safety, hygiene, and compliance with industry standards and regulatory requirements. Below are essential inquiries to ask your food safety consultant to ensure optimal results and mitigate potential risks and challenges.

  1. Are you familiar with our specific segment within the food industry? The food industry encompasses various sectors, each with unique challenges. Familiarity with your specific sector, such as dairies, bakeries, meat, confectionery, or packaging, will prove advantageous, allowing the food safety consultant to tailor their advice and solutions to your specific needs.
  2. Can you help develop and implement a robust food safety management system (FSMS)? An effective FSMS is key to ensuring the safety and quality of food products. You can gauge the consultant’s potential effectiveness by evaluating their ability to design and implement an FSMS based on relevant standards like HACCP or ISO 22000.
  3. How well-versed are you in risk analysis and hazard identification? The food chain has various potential hazards, from raw material sourcing to processing and distribution. The consultant needs expert knowledge in identifying potential risks and implementing measures to control them.
  4. How do you approach problem-solving when a food safety issue arises? Every consultant should have a systematic approach to mitigating food safety crises. This approach may incorporate principles from Six Sigma, Lean Manufacturing, or Kaizen, which are methodologies for problem-solving and continuous improvement.

Selecting a food safety consultant requires careful consideration. By using some of these questions as a framework for objectively assessing potential candidates, you can confidently select a consultant who will provide the knowledge, expertise, and strategic guidance your operation requires. This proactive approach to food safety ensures the well-being of consumers, compliance with regulatory standards and the longevity and reputation of your brand.

Do you have a pressing issue but don’t know where to start? Let SGS help you meet customer expectations with our tailored solutions.