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.

Seafood Analytics CQR

Leveraging Automation for Enhanced Food Safety and Compliance

By Ainsley Lawrence
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Seafood Analytics CQR

The food industry faces increasing customer demand on top of snowballing regulatory concerns, and many are calling for automation to overcome these obstacles. Automation technologies reinforce food safety practices from processing to packaging by revamping sanitation, quality control, and more.

To begin leveraging automation for food safety in your sector today, the most important areas to focus on are automated monitoring systems, growing AI/ML capabilities, and exceeding regulatory compliance.

Automated Monitoring Systems in Food Safety

Automated monitoring systems have become the titanium backbone of modern food safety, offering greater control over critical processes. With human error as a prevalent risk factor for safety incidents, companies can mitigate accidents with automated systems to mitigate this risk by standardizing processes and enforcing predefined protocols.

This paradigm shift in the way we produce food makes food safer, helps keep workers safe, and makes food quality more consistent at large. Automated monitoring systems can help reduce common errors, drive more effective sanitation, and track your most sensitive critical control points.

Error Reduction through Automated Processes

Many small, common errors can be reduced or outright eliminated with automation. In seafood processing, for example, optical sorting machines consistently identify and remove substandard products. Rather than relying on the inconsistent human eye, machines can rapidly assess each item based on precise criteria such as size, color, and texture. Automation enhances human capabilities in this way by minimizing errors due to fatigue, such as in high-volume production sites.

Seafood Analytics CQR
The CQR device from Seafood Analytics measures the freshness and quality of seafood.

 

Consistent Sanitation Procedures

Maintaining sanitary conditions is critical for safety and regulatory compliance in food production environments. Automated cleaning systems, programmed with precise chemical concentrations and application methods, guarantee thorough and consistent sanitation. These systems meticulously track each cleaning cycle, providing auditable records for compliance purposes. In food packaging, robots can make wrapping products safer, identify foreign objects like bone/shell, and greatly reduce fatigue on workers.

Real-time Critical Control Point Tracking

Automated systems excel at monitoring critical control points (CCPs) in food production, dramatically reducing spoilage. Temperature sensors in cold storage facilities transmit continuous data streams, alerting staff to deviations before spoilage occurs. Meanwhile, automated pH meters and metal detectors in processing areas operate tirelessly with pinpoint precision to ensure consistent product quality and safety.

AI and Machine Learning Applications

Automation can only go so far without insight. AI and ML are carving a niche alongside automation, supplementing raw power with vast datasets and analytic powers to identify anomalies. Together, they enable systems to recognize patterns, flag issues, and optimize processes in ways previously unfeasible.

These technologies integrate with automated systems to monitor complex food production networks, uncovering subtle irregularities that might be missed by human inspection or conventional algorithms.

Traceability in Food Supply Chains

Supply chains are notoriously complex and unpredictable to track because they often involve multiple stages, from raw material sourcing to processing, packaging, distribution, and retail. Each step can involve different suppliers, locations, and regulations, making it difficult to maintain a clear, real-time view of where a product has been and what conditions it has encountered.

AI and machine learning address this by continuously analyzing data from various points, creating an interconnected web of information that companies can use to trace products with greater accuracy than ever before. Whether it’s identifying the origin of a raw ingredient or tracking environmental conditions during transportation, AI-driven traceability systems provide granular insights that facility managers can use to make improvements.

Predictive Analytics

Machine learning models trained on historical data and real-time inputs can predict food safety risks before they appear. In food packaging operations, these systems analyze factors such as temperature fluctuations and microbial growth rates to track CCPs and identify issues. Across departments, predictive maintenance algorithms anticipate equipment failures that could lead to contamination. With this insight, managers can reduce accidents, cut waste, and intervene before incidents occur.

Setting Up for AI and ML

Preparation and a solid foundation in data management are essential to make the most of what AI and machine learning have to offer. Food processing facilities must prioritize data quality, storage capacity, and scalability to harness these technologies. Companies looking to adopt AI and machine learning should:

  • Invest in Quality Data Collection: AI and ML require high-quality data, so IoT devices and sensors are deployed to gather accurate, real-time data across production stages.
  • Choose Scalable Storage: Opt for cloud-based storage to handle increasing data volumes and facilitate easy access and integration.
  • Select Flexible AI Tools: Choose AI and machine learning platforms that can adapt to changing business needs and integrate with existing systems as smoothly as possible.
  • Train Staff with AI/ML: These technologies are only as good as the workers using them – provide training for employees on how to use AI tools effectively to maximize their potential.

AI can make workflows more efficient, but introducing it should always be met with deliberate planning and testing.

Regulatory Compliance and Automation

Automation tech plays a crucial role in helping food businesses navigate the complex regulatory landscape, which is subject to change. As food safety standards evolve, management should look to not just match but exceed regulatory compliance in anticipation of tightening requirements.

Robust food safety standards are essential for maintaining product integrity and consumer trust, but they only work when combined with automated documentation and reporting. Lastly, a new challenge facing food production is handling human-robot interaction in a Wild West-esque tech frontier.

Food Safety Standards

Regulatory bodies frequently update food safety standards to identify emerging risks and incorporate new scientific findings. Automation helps streamline this process for companies fighting a web of red tape by allowing for swift reconfiguration of monitoring parameters and control processes. For instance, AI-powered testing equipment can be remotely updated to detect new microbial threats without overhauling entire production lines. This flexibility helps companies stay ahead of the regulatory curve and slim costs simultaneously.

Automated Reporting and Documentation

Automated systems are stellar at simplifying food safety compliance, able to effortlessly generate and update detailed, real-time records of every aspect of food production and handling. From temperature logs to sanitation schedules, automated reporting tools compile data into a proper regulatory format and ease administrative burdens. While the primary goal is to demonstrate regulatory compliance, this data also proves itself a treasure trove for companies to improve their practices ahead of regulatory change.

Tackle Human-Robot Interaction

The concept of human-robot collaboration isn’t new, but it’s becoming increasingly more common, and the average food production worker is more likely than ever to work with a robot. This paradigm shift requires a new approach to work, which prioritizes streamlining repetitive or laborious tasks, clear communication, and continuous training as capabilities increase. It’s also worth noting that managers can alleviate worries about ‘being replaced with a machine’ by focusing on how technology supplements humans rather than wholesale replacing them in the workplace.

Workers production line
Workers in a factory sorting food by hand, could be assisted by new robot technology. (Unsplash image)

Final Thoughts

Automation, including robotics, AI, and machine learning, is pivotal in enhancing food safety and compliance across the industry. By using automated monitoring systems, food production sites can reduce human error and standardize processes. At the same time, AI and machine learning provide real-time data analysis and predictive insights if companies are willing to put in the work needed to prepare for automation. In that case, they can help reduce accidents, enhance efficiency, monitor food quality, and keep up with regulatory compliance at a fraction of their previous efforts.

Ensuring Food Safety at Tasting Events: Best Practices and Tips

By Ainsley Lawrence
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Tastings should be exciting events that attract attention to your business or cause. Tastings should not be dangerous events that send most of your guests home with stomach pains — or worse, to the hospital with severe health concerns. Unfortunately, if you aren’t careful to maintain the highest standard of food safety practices, your tasting event could end up like the latter.

If you are unfamiliar with the concept, a tasting event allows people to sample small quantities of a large variety of foods and drinks. Tastings are becoming increasingly popular as people clamor for the opportunity to explore new food experiences, be they new ingredients, new flavor combinations, new presentations, or new brands. Though wineries have long been known to offer tasting opportunities to guests, other types of businesses in the food industry have started to experiment with the tasting model. Because tastings tend to be fun and social experiences, charities are also organizing an increasing number of tastings to entice donors to engage with their cause.

Though people might consume less food and drink during a tasting than they would during a more traditional meal, the standard rules for food safety still apply. In planning and preparing the food and drink for your tasting event, you need to remember the following information about food safety and maintain safe practices to keep your guests safe.

Why Does Food Safety Matter?

Food safety is always a matter of life and death. Food contamination can cause debilitating and perhaps deadly diseases, even in people who were previously hale and hearty. Hundreds of thousands of people die every year after consuming contaminated food, and many of those deaths take place within our most vulnerable populations: children, the elderly, the sick, and the impoverished. The human loss and financial impact of foodborne illnesses are severe, amounting to high costs for families, companies, and countries in the form of healthcare expenses, work absences, reputational damage, and more.

A tasting may seem like a convenient, casual, and cool event option, but like other events involving food and drink, tastings must adhere to food safety standards to ensure everyone involved remains safe.

What Are Tasting-Specific Food Safety Practices?

Any professional purveyor of food or drink should understand and maintain standard food safety practices as mandated by the FDA, state health departments, and other regulatory bodies. These rules most often involve the cleanliness of personnel, sanitary facilities and equipment, and clean processes for manufacturing, processing, packing, and more. These rules and best practices remain relevant to tasting events and any retail or institutional event that provides any quantity of food and beverage.

Because tastings are less common, food service professionals may be less familiar with specific practices involved in preparing and serving food and drink at these types of events. Here are some essential practices food handlers need to adhere to when conducting tastings:

  • Food served hot must be kept at or above 140 degrees Fahrenheit prior to service.
  • Any perishable foods held at room temperature for over two hours or above 90 degrees Fahrenheit for over one hour must be discarded.
  • Tastes not in service should be covered.
  • Bare hands should never come into contact with food.
  • Different utensils should be used to transfer food from cooking or storage containers to tasting plates and from those plates to guests.
  • Utensils used for tasting must be discarded or transferred directly to dishwashing areas.
  • Any tastes that are touched by guests and returned must be discarded.
  • Parents’ permission must be acquired before children are served.
  • Any unconsumed pre-portioned tastes must be discarded once the service is complete.

Restaurants, wineries, and other organizations interested in offering tasting experiences can benefit from memorizing these more niche best practices, but in truth, many of these practices are intuitive to those with a comprehensive understanding of food safety. All businesses within the food service industry should strive to develop a safety culture in which staff respect core values of food safety and instinctively act to reduce or eliminate all potential sources of food contamination.

Do Private Tasting Events Need to Follow the Same Food Safety Practices?

Tasting events held in retail or institutional settings must adhere to the FDA’s food code and state regulations on food handling. However, individuals who prepare food at home and serve it at a private gathering are not held to the same rigorous standards, even if they are volunteers providing food to community events. Still, individuals should consider upholding a few basic food safety practices to reduce the possibility of harmful contamination during private tastings, such as:

  • Consistently washing hands, utensils, and food preparation surfaces;
  • Physically separating risky foods, like raw meats or common food allergens, from other foods;
  • Cooking foods to the safe minimum internal temperature and, if necessary, maintaining food at a safe temperature before consumption;
  • Immediately refrigerating any leftover foods.

Because private and community tastings might involve food and drink preparation from multiple parties, event organizers might try to coordinate food safety practices to reduce the possibility of contamination. They can rely on community event marketing tactics — such as sharing printed materials locally and strategically communicating through different digital channels — to get the word out about the event, as well as ensure food safety. Using graphics tools to produce posters or flyers explaining different food-safe practices can help everyone understand their responsibilities for the event and remind everyone of essential behaviors for keeping food safe.

What Are Other Useful Tips for a Safe and Successful Tasting Event?

Food safety is an absolute necessity for your tasting event, but it isn’t the only element you need to make it safe. Contamination should be a major concern, but other issues can also cause guests discomfort and distress, which will ultimately make your event unsuccessful. Here are some tips and tricks you might follow to make sure your first tasting goes off without a hitch:

  • Make your tasting room comfortable. Tastings typically offer a range of options for guests, who may prefer to stand, sit at bar height, or sit at dining height. The space should be accessible to all and provide the support guests need to enjoy food and drink safely.
  • Choose appropriate tableware. Guests should not need to ask for utensils for food tastes, and all beverages should be served in the correct type of glassware. Clean and proper utensils prevent contamination and ensure food and drink are optimally enjoyed. Plus, because so many beverages appear identical by sight, the right glassware can prepare guests for the flavors they are about to experience.
  • Offer labels explaining each taste. Even with a thorough explanation from a server, guests often want more information about their tastes to avoid allergens or other concerns. Labels and tasting mats can detail ingredients, flavor profiles, and more.
  • Have dump buckets available at every table. Many guests prefer to discard food and drink after tasting, and dump buckets allow them to separate their used food from fresh tastes. It may be necessary to replace them with clean buckets depending on the duration of the event.
  • Give guests plenty of water. Attentive servers, a water carafe for each table, or an accessible water dispenser — you have options for ensuring each guest remains appropriately hydrated throughout the event.

Tasting events allow people to explore new and exciting foods and beverages in a safe, comfortable space. Make sure to have proper supplies available, keep food fresh, and ensure all dishware is clean. If you understand and follow all relevant practices to support food safety, you can ensure that your event delivers on guest expectations and achieves your objectives with fun and flair.

The Importance of Auditor Calibration

By Kimberly Allison, Lindsay Walker
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Food safety audits are critical for food and beverage operations and are critical in building a strong food safety culture. Whether preparing for a retail food safety audit or striving to meet scheme or standard audit requirements, auditor calibration can provide value to ensure auditors fully understand and abide by program rules. The authors describe how auditors can utilize auditor calibration to establish a stronger food safety culture and meet certification requirements.

Food safety audits are critical in building a strong food safety culture. Whether preparing for a retail food safety audit or striving to meet scheme or standard audit requirements, auditor calibration can provide value to ensure auditors fully understand and abide by program rules.

Understanding Auditor Calibration

Auditor calibration ensures that auditor knowledge and capabilities stay consistent and current with the latest certification requirements. This process involves developing a thorough uniform checklist, proper site preparation, comprehensive auditor training and internal onboarding. This sets all parties up for success, creating a universal food safety culture with all stakeholders understanding their role in the audit process.

Many food safety standards, such as those that fall under the Global Food Safety Initiative (GFSI), require consistent, ongoing interpretation and understanding of standard requirements. Both GFSI and unaccredited programs list auditor expectations step by step. An effective auditor calibration program can ensure that auditors speak the business’ language, understand its market and follow its program rules to meet food safety standards such as GFSI.

Steps to Using Auditor Calibration

The first step to implementing auditor calibration is developing onboarding training for all parties involved. Onboarding can include basic information with customized training for each program type based on the auditors’ existing skills and experience.

Additional training should include specifics regarding the audit program’s requirements, report-writing guidance and other foundational information. An induction form can be used as a checklist and be updated over time, providing the auditor with a template document that outlines what is expected and what they have already completed.=

Once onboarding is complete, auditors should maintain regular training and professional development. For example, GFSI program leaders often hold calls on specific topics of interest, including new requirements, pain points in the audit process, the process flow and the meaning of different triggers.

Adult Learning Principles

Effective training isn’t just about information transfer; it’s about engaging adults as active participants in their learning journey. Leveraging key adult learning principles ensures that training resonates and transforms behavior. When training programs align with adult learning principles, auditors are more likely to understand, retain and apply the knowledge. This leads to better performance and a more skilled team.

Proper training grounded in adult learning principles is an investment in knowledge and the sustained growth and success of both individuals. Here are a few ways to ensure training is effective:

  • Use of Relevant, Practical Examples: Adults are more motivated to learn when the content is relevant to their work or personal lives. Training can be made practical, immediately applicable and connected to real-world scenarios to enhance motivation and retention.
  • Experience as a Learning Resource: Adults bring a wealth of life and work experience to the learning process. Leverage case studies, breakout sessions and interactive activities, allowing learners to relate new information to what they already know, and share their insights and perspectives.
  • Problem-Centered Approach: Adults tend to be problem solvers. They prefer learning that focuses on practical problem-solving rather than theoretical concepts.

Training Resources

In addition to working with an auditor training service provider, several resources can help organizations implement auditor calibration.

  • Online Training: More online trainings are available now than ever before, with topics offered including HACCP plans, lead auditing and more. Organizations can also develop or contract a third-party provider to gain access to a learning management system (LMS) that will assign and track required training as warranted. Such systems can also incorporate videos and quizzes to gauge understanding and provide certificates to track results. Some online training sessions can also be presented in group settings to promote discussion, team bonding and better understanding.
  • Shadowing: Some food safety programs require shadow audits or supervised audits prior to a witness audit. Supervised audits can serve as a great tool to promote an auditor from a shadow auditor to a lead auditor. These field events further expose auditors to the audit process and provide learning opportunities within the audit program.
  • Witness Audits: Once an auditor has taken all the training required for their program and completed all the required shadow or supervised audits, a witness audit may be set up. A witness audit is essentially an audit of the auditor, during which the auditor is observed against a standardized set of requirements for that specific program. Comments are included where improvements need to be made.

Witness audits are conducted for new and experienced auditors. Before the audit is conducted, the basic expectations of the process, timing and expected audit document completion, and other details about the process are covered with the auditor to ensure a successful outcome. In this manner, the auditor is periodically refreshed on the expectations of their role. Witness audits are required regularly for GFSI-qualified auditors on a frequency specific to each program.

Improving Audits with Auditor Calibration

Auditor calibration can play an important role in ensuring consistent outcomes. At NSF, we have seen firsthand that by setting expectations for the audit team in a clear, concise manner, together you can meet a commitment to excellence. With a solid training program, you can develop a strong team of calibrated auditors who are consistently onboarded and trained. This consistency ensures clarity, support and access to information and smart questions, improving audit quality in the field.

Editors Note: Food Safety Auditor Training is offered at the Food Safety Consortium Conference, October 20-22, 2024 in Washington DC. This 4-part series is designed to provide the knowledge, behaviors and technical skills attributed to a competent food safety auditor. More information.

Additional Resource: What Does It Take to Be a Food Safety Auditor? On Demand Webinar

How to Improve Your Management System Through Internal Auditor Training

By Olivia Pitts
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A well-developed internal auditor training course is an exceptional knowledge source for the new or experienced auditor. A formalized training course provides the auditor with an overview of the auditing basics including audit planning, facilitation, and report writing. These concepts are the foundational elements needed to build a robust internal auditing program. Not only do training programs enhance auditor competency they also provide benefit to the business. In this article we discuss how internal auditor training improves the overall management system through process improvement, risk reduction and organizational culture.

Identify the Training Needs

Continuous improvement should always be one of the top strategic goals of an organization. With the constantly evolving business environment and evolution of technology businesses must be prepared to adapt. A straightforward way to accomplish this goal is to utilize internal auditing. The first step is to develop a strong audit team armed with the required skillset. Identify your team members and determine the training needs for each of the individuals. Auditors with previous experience may only need a refresher while those new to the role may need more in-depth training. Determine the format and structure that works best for your organization and work with the team to get the training on the calendar.

Internal auditor training is not a one-time activity. These skills require repetition to become fully competent. Auditors should put their newly acquired skills into practice as soon as possible to ensure maximum benefit. Partnering new auditors with experienced auditors is a great way for auditors to build confidence in their newly acquired skills. Take time to review the work of auditors and provide positive feedback on progress. Keep communication open around expectations and check in with your team to discuss any issues or roadblocks that may be encountered. Auditing is not an easy job. Support from top management is critical to ensure the program is a success.

Process Improvement

Having a skilled audit team will help to drive process improvements across the organization. The goal of internal auditing is to identify gaps in the management system where the organization is failing to meet a requirement. Requirements can come from a variety of sources including the management system standard, statutory and regulatory bodies, the customer, or internal standards the organization has committed to meeting. These requirements can often be complex and confusing for auditors to interpret and understand. This is where training is the most beneficial. Internal auditor training helps the participant to develop the mindset of an auditor and aid in identifying the linkage between the requirements and evidence provided by the auditee. This understanding is necessary to properly identify gaps and build a continuous improvement across the organization. When auditors have a full understanding of the requirements they can perform in-depth audits that go beyond a check the box activity.

The outcome of an internal audit is often a punch list of activities due to identified as nonconforming against the requirements. Through the identification of gaps in the system there is an opportunity to improve the day-to-day process within the site. This will not only aid in meeting the requirements but also will improve efficiency and productivity. Which in turn leads to enhanced processes that result in a stronger system overall.

Risk Management

Risks are an inherent part of business. There will always be risk therefore businesses must formulate a method to manage those risks. Internal auditing is a way to review and confirm all risks are identified for and controlled accordingly. Through internal auditing a review of the processes is conducted thus resulting in the identification of potential unidentified risks that may be lingering below the surface.

By building the foundation and understanding of risks through training the internal audit team can help to lead the business to a mindset that is focused on reducing those risks as much as possible. Training is a great way to familiarize the audit team with the risk that may impact the business. Understanding the requirements that are currently imposed upon the business by both external and internal stakeholders will help the team to identify areas of greatest concern. The continuous assessment and the implementation of preventive measures to address risk will provide substantial benefit to the organization.

Culture of Quality

Changing an organization’s culture does not happen overnight. It takes hard work and perseverance. This requires extensive communication and commitment from the employees at all levels of the organization. Building an organizational culture that has a strong focus on quality often requires providing education and exposure to new concepts. Establishing a robust internal auditor training program is a great way to instill the foundational elements of a quality focused organization for the audit team. Training should focus on the basic quality principles and meeting exceeding customer expectations. Through these concepts auditors learn the skillset needed to drive change from within the organization.

Driving awareness across the site around the management system and the requirements is crucial to success. Employees often feel nervous and are reluctant to participate in audits due to the unknown. Demystify the management system by providing training to plant employees. Audit team members are a great resource to lead these types of educational sessions. It not only allows them to share the skills they have learned in auditor training but also helps to promote a culture of quality. Focus areas could include providing a basic overview of standard requirements, processes within the scope, and what to expect during the audit. By putting forth this additional effort will help to instill positive changes around quality. The site will be engaged and excited to participate in potential growth and improvement opportunities. The once dreaded internal audits will be a thing of the past.

Choosing the Right Course

There are a variety of different trainings options available regarding internal auditing. Often courses are structured based upon a management system standard and the auditing level. The best choice will depend upon each unique organization or individual. If new to the concept of auditing an introductory course may be best to outline fundamentals. Once completed the individual can move up to a more in-depth course such as a lead auditor course. If the organization is focusing on a specific standard such as ISO 9001:2015, FSSC 22000:2018 or BRC it’s often beneficial to attend a course specific to those requirements. As there is often a heightened focus on the specific details regarding requirements and expectations from certification bodies.

Editors Note: Food Safety Auditor Training is offered at the Food Safety Consortium Conference, October 20-22, 2024 in Washington DC. This 4-part series is designed to provide the knowledge, behaviors and technical skills attributed to a competent food safety auditor. More information.

Additional Resource: What Does It Take to Be a Food Safety Auditor? On Demand Webinar

Food Fraud Quick Bites

Highlights and significant changes of USDA’s revised regulations on organic foods

By Jennifer Allen
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On March 19, 2024, the USDA implemented revised regulations on organic foods. The overall purpose of the revisions is to strengthen enforcement of the regulations, with a focus on greater accountability for organic food fraud. This article does not go into every detail of the changes. That would be a long and rather dull read, and you could just as well go read the new regulations for yourself. But it does highlight some of what this writer believes are the most significant changes, and to the extent your compliance with the organic regulations has been on autopilot, this is a reminder to take the wheel and make sure you know how the new regulations affect you.

Perhaps the most significant change is to the scope of what it means to “handle” organic products. Before the revisions, handling meant selling, processing, or packaging agricultural products. Now, handling includes trading, facilitating the sale or trade on behalf of a seller or yourself, importing and exporting, as well as a number of other activities including conditioning, containerizing, and labeling. Thus, the universe of individuals and entities that could be on the hook for organic fraud, and who may need to be certified by the USDA, just got significantly larger. What this means is that even if all you do is hit buttons on a computer keyboard, and you never lay your hands on a piece of produce, you can still be responsible if the product you are trading turns out to be falsely labeled or otherwise noncompliant. There are exemptions from certification, but you still need to be compliant with the rules.

There are some changes in exemptions under the revised rule. Restaurants and stores that cook or prepare food and then sell it to consumers at the same location are exempt. But online sellers are not. Companies that store packaged and sealed products are exempt, but those who store bulk and unpackaged products must be certified. Customs brokers and logistics brokers – those who merely connect operations with carriers and storage facilities – are exempt. Likewise, businesses whose only job is to transport products are exempt, but handlers must still use audit trails and traceability to ensure that their carrier does not compromise the organic integrity of the product.

With respect to fraud, the term “organic fraud” is now defined, as “deceptive representation, sale or labeling of nonorganic agricultural products or ingredients as . . . organic.” New regulations relating to traceability make it easier to follow a product from birth to sale. New language requires certified operations to keep records that “span the time of purchase or acquisition, through production, to sale or transport and be traceable back to the last certified operation.”  And certifying agents must conduct risk-based supply chain traceability audits to trace products across multiple links in a supply chain.

These are just some of the changes that USDA has made to ensure that consumers paying a premium for organic products are getting what they pay for. If you are part of the chain of organic products, then make sure you know how the changes affect your organization.

Enhancing Food Safety: The Impact of FSMA’s Traceability Rule on the Supply Chain

By Jacob Olson
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The FDA’s Food Safety Modernization Act (FSMA) is designed to enhance food safety by establishing and regulating traceability requirements. The act mandates that all parties in the supply chain share critical information to address potential food safety issues. This article discusses FSMA requirements for comprehensive recordkeeping, including defining Critical Tracking Events (CTEs) and Key Data Elements (KDEs). It highlights the crucial role of Electronic Data Interchange (EDI) in meeting compliance and optimizing food traceability. EDI automates data exchange, improves visibility, simplifies compliance, and enables rapid outbreak response. By investing in EDI technology, organizations can establish a strong foundation for complying with FSMA regulations and ensuring food safety.

The Food & Drug Administration’s (FDA) final ruling for the Food Safety Modernization Act has introduced new stringent regulations that organizations who manufacture, process, pack, or hold foods must follow. The final rule mandates that all parties in the supply chain, from suppliers to retailers, share critical information to promptly address potential food safety issues. This ruling underscores the critical role of technology in maintaining compliance and ensuring safety throughout the food supply chain.

The latest FSMA updates require comprehensive recordkeeping for businesses involved in food production and distribution. Companies must now document key data elements (KDEs) tied to critical tracking events (CTEs) in the food supply chain. This includes manufacturing, processing, packing, and distribution activities for foods listed on the Food Traceability List (FTL). Organizations must provide this data to the FDA within a timely manner and in compliance with accepted standards.

Defining Critical Tracking Events (CTEs)

Critical Tracking Events (CTEs) are key checkpoints that mark the movement of food products from their origin to the retailer or consumer. These milestones offer visibility into the product’s journey through the supply chain. CTEs represent significant points in the food supply chain where specific actions occur, such as:

  • Receiving raw materials from suppliers
  • Processing and manufacturing food products
  • Packaging and labeling items for distribution
  • Shipping products to distribution centers
  • Receiving products by retailers or food service establishments
  • Selling products to consumers

Defining Key Data Elements (KDEs)

The FDA identifies Key Data Elements (KDEs) as crucial details linked to specific CTEs. This information provides essential insights into food products and their journey through the supply chain. KDEs may include:

  • Product Identifiers: Lot numbers, batch numbers, and serial numbers
  • Key Data Attributes: Ingredients, packaging materials, production and expiration dates, storage conditions
  • Chain of Custody: Records of entities handling and transporting products
  • Contact Information: Details of organizations responsible for food safety and emergency responses

Record Keeping Requirements

FSMA’s updated guidelines include specific requirements for the format and duration of recordkeeping. These records must also be available within 24 hours of an FDA inquiry and must be preserved for at least two years. The FDA mandates documentation be preserved in its original format and readily searchable electronically. Consequently, your organization must establish protocols for recordkeeping, product identification, and traceability lot code allocation.

Role of Electronic Data Interchange in Food Traceability

Electronic Data Interchange (EDI) is vital for meeting FSMA compliance and recording critical information such as CTEs and KDEs. EDI automates the exchange of traceability data by integrating with and extracting information from enterprise resource planning (ERP) or warehouse management system (WMS) solutions. EDI can ensure accuracy in KDEs to adhere to critical and time sensitive regulations. EDI also reduces potential manual data entry errors and ensures timely data management. Your suppliers and customers will have different levels of technical aptitude so remember; all types of EDI can be leveraged to achieve these outcomes, including traditional X12 EDI, EDIFACT EDI, and TRADACOMS EDI, along with other electronic data like APIs, JSON or XML, Flat Files, Spreadsheets, and web portals.

This technology streamlines the management of lot information, including its reception, translation, and distribution, and even enables direct integration of lot numbers into ERP systems. This integrated approach enables compliance and benefits all supply chain stakeholders by providing critical data for swift responses to any FDA inquiries regarding food traceability and safety.

EDI is crucial for optimizing food traceability within the supply chain by facilitating the accurate and efficient collection of KDEs and CTEs through the following:

  • Automation: EDI automates data exchanges, reducing manual input errors and facilitating efficient data management. It ensures precise tracking of food products with details such as purchase orders, invoices, and shipment notices.
  • Visibility: EDI is the foundation to providing real-time insights into product movement across the supply chain. Coupled with a modern integration platform, this enables businesses to track products from their origin to the end consumer.
  • Compliance: EDI simplifies compliance with food safety regulations by enabling the electronic recording and transmission of critical traceability data, streamlining the audit process.

Benefits of EDI Technology in Achieving FSMA Compliance

EDI offers several advantages beyond enhancing food traceability. It also positions your organization to proactively adapt to evolving regulatory landscapes. By investing in a modern, scalable EDI platform, you can establish a strong foundation for complying with upcoming FSMA regulations. To meet FSMA requirements, businesses need adaptable processes and procedures supported by technology that seamlessly integrates and automates critical data exchange. EDI integration specifically contributes to FSMA compliance by enabling:

  • Rapid Outbreak Response: EDI facilitates the quick exchange of standardized documents, simplifying the tracking of food movement and enabling a swift response to contamination outbreaks.
  • Efficient Recordkeeping: EDI automates the generation, storage, and sharing of electronic records, ensuring data accuracy and accessibility.
  • Improved Supplier and Customer Management: EDI supports real-time communication with suppliers, customers, carriers, and the other key components of your supply chain, enhancing management and simplifying compliance.
  • Risk Management: EDI integrates with other systems to enable data-driven risk assessments, monitoring critical control points, shelf life, and temperature controls to mitigate foodborne hazards.
  • Audit Readiness: EDI simplifies the capture, retrieval, and presentation of records, ensuring companies are always prepared for FDA inspections and can demonstrate compliance.

The cornerstone of food traceability under FSMA hinges on accurately identifying and documenting CTEs and KDEs. These regulations mandate electronically accessible and readily searchable records, underscoring the need for automated B2B integration technologies like EDI. EDI systems optimize data collection, minimizing errors and ensure real-time access to critical information. By automating these processes, EDI not only facilitates compliance but also enhances operational efficiency and responsiveness to potential food safety incidents.

The FSMA food traceability rules represent a pivotal advancement in safeguarding the food supply chain. By enforcing meticulous recordkeeping and rapid data retrieval, the regulation empowers authorities to swiftly identify and address food safety risks, protecting public health. Implementing advanced technologies such as EDI is essential for both compliance and operational excellence. These systems automate data sharing, improve transparency, and foster a connected supply chain all leading to improved business partner relationships, increasing revenue, and higher profitability.

As the industry navigates these rigorous standards, embracing technology will not only ensure compliance but also cultivate a more resilient and responsive food system capable of effectively managing food safety challenges.

Construction, food safety

Food Safety Things to Consider When Renovating a Facility

By Matt Inniger
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Construction, food safety

When food and beverage manufacturers aim to increase total throughput, they often face facility size constraints. Manufacturers can either expand their current facility or move operations to a larger building.

Due to property dimension limitations and the need for substantial additional square footage, procuring a new facility is the most common approach. Due to the difficulties associated with converting an industrial facility not previously used for food processing into a space suitable for food processing, it’s important to be considerate when selecting a new facility to minimize conversion time and costs.

Product Category and Risk

Before even looking at any specific facility, it’s important to consider the category of product you manufacture and what your specific production process requires of a facility, as well as what aspects of a facility might make manufacturing easier. For instance, rigid packaging necessitates substantial dry storage, while refrigerated finished goods benefit from pre-existing walk-in architecture. Conversely, confectionery or baking does not require extensive floor drainage or water supply.

The risk level associated with the product also plays a pivotal role. Facilities for dry mixes can be older or less pristine since contamination risks are minimal, controlled primarily by production equipment. However, ice cream production facilities demand extensive environmental risk mitigation, implying higher renovation costs if starting from a subpar condition.

Floor Plan

Arguably the most important consideration when looking at a facility is, to no one’s surprise, floor plan. It’s important that the shape, size, and orientation of rooms is suitable for how people, products, and materials need to flow through the building.

It’s sounds uselessly simple, but an excellent way to quickly gauge floor plan efficiency is to take a printout of the floor plan drawing, label each room for its potential purpose (i.e. production, offices, garb-up, warehouse, QA, etc) and draw arrows color coordinated to the movement of different types of employees and different types of materials.

If these arrows intersect too much, double back on themselves, or are just generally too long, try swapping room designations. If you can’t find a layout that works, the building probably isn’t a good fit.

Walls and Ceilings

As discussed previously, this consideration depends on your product category. But for certain products, the integrity of walls and ceilings is very important to mitigate environmental risk.. Certain walls and ceiling materials like dairy brick don’t require covering, if they are minimally porous and easily cleanable.

Also, other panel materials like PVC provide alternatives to FRP that may be more inexpensive, easier to mount, or both. It’s important to examine more than just surfaces, as the internals of walls and ceiling can sometimes harbor mold or other microorganisms. Mold mitigation is an expensive proposition.

Utilities

Utility service is arguably the most important consideration when looking at a building. While adding a new utility or increasing service isn’t typically an outrageously expensive endeavor, it can be time- and energy-intensive due to long lead times on utility equipment and the hassle of working with local officials.

It’s a similar story for utility access points. While relocating electrical hookups in a single room is inexpensive and straightforward, running a three-phase line across a quarter million square foot building is not. Oversized utility service is worth its weight in gold. It offers a ton of flexibility in scaling up operations at a given facility

Truck Traffic and Docks

We’ve already discussed how important it is for people and materials to be able to move through a facility for optimal production output. But, it’s equally important, perhaps moreso, that people and materials be able to move into and out of a facility quickly and easily.

Acquiring a facility with an inadequate number of docks or poorly positioned docks can quickly become a new production bottleneck, and unlike other bottlenecks, this one can be impossible to fix.

This is why it’s important not just to carefully consider the number and placement of docks, but also the traffic pattern for trucks to get there. How long does it take a truck to maneuver into the dock? Can incoming and outgoing trucks pass each other? Are there tight turns in the road leading up to the facility that could be difficult for trucks to navigate? If there are problems upstream that aren’t on the facilities property, they could become catastrophic to growth.

Plumbing and Drainage

Finally, for product categories that require floor drainage due to process or sanitation concerns, having adequate plumbing in place from the get-go is incredibly key, as adding it is often the largest line item in a renovation budget.

This is why renovating a space that hasn’t been previously used for food production of some fashion is so rarely done. Installing plumbing and re-doing floors can balloon into six or seven figures for really large facilities.

So, for all of the readers who came into this article expecting validation for your preliminary decision to convert your warehouse space into production space, hopefully I’ve given you some things to think about first.

Conclusion

All this being said, careful consideration of these factors can prevent a food or beverage manufacturer from buying themselves a shiny new bottleneck. Proper planning and evaluation are key to ensuring a smooth and cost-effective renovation process.

Audit

Ensuring Food Safety from the farm to the table is crucial. How inspections and audits play a key role

By Don Abbott
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Audit

Food safety is an issue that is critical to millions of people’s health every year worldwide. Maintaining a high standard of hygiene is essential in preventing contamination and ensuring all people receive the safest quality food products every time. Inspections and audits are the key components to the industry’s effort to maintain these standards. These processes help identify potential risks and hazards, ensuring companies are compliant with regulatory requirements, and to ultimately protect all people’s health.

Audits and Inspections both verify the facility’s compliance with regulatory and procedural compliance, but in different ways. According to ISO definition, an audit is “systematic, independent, and documented process for obtaining objective evidence and evaluating it objectively to determine the extent to which audit criteria are fulfilled.” An inspection is the “determination of conformity to specific requirements,” such as FDA or USDA regulations.

The Importance of Inspections and Audits

Inspections and audits are vital in the food industry for many reasons:

  1. Preventing Foodborne Illnesses: Regular inspections and audits help the industry identify and mitigate risks that have the potential to lead to foodborne illnesses. This is a very crucial task in preventing outbreaks that can cause severe health issues and even fatalities.
  2. Regulatory Compliance: The food industry is subject to stringent regulations set by governmental and international bodies. Inspections and audits help to ensure companies are complying with these regulations consistently, avoiding any legal penalties and maintaining consumer trust.
  3. Quality Assurance: Inspections and audits help ensure food products meet quality standards also, which is very important and essential for companies maintaining brand reputation and customer satisfaction.
  4. Risk Management: Identifying personal hazards and implementing corrective actions during inspections and audits helps the companies manage and reduce risks associated with food production and distribution.

Inspection Process

Food inspections and audits involve a thorough examination of facilities, processes, and products. The process typically includes the following steps:

  1. Preparation: Inspectors will review relevant documents, any previous inspection reports, SOPs, and compliance records, to better understand the facility’s history and operations.
  2. On-site Inspections: Inspectors will visit the facility in order to observe operations, interview staff, and inspect all equipment and outside premises.
  3. Sampling and Testing: Samples of food products may be collected for laboratory testing to detect contaminants or verify compliance with safety and quality standards.
  4. Documentation and Reporting: Inspectors will document their findings and provide a detailed report outlining any observations of non-conformances.
  5. Follow-up: A follow-up inspection may be conducted to ensure all non-conformances have been closed and corrective actions have been implemented and the facility is compliant with all regulations.

Audit Process

Audits are systematic and independent examinations of records, processes, and systems to ensure compliance with specific standards. There are several types of audits in the food industry, including internal audits, supplier audits, and third-party audits. The audit process generally involves the following steps:

  1. Planning: The audit scope, objectives, and criteria are defined. An audit plan is developed, detailing the audit schedule and then areas to be examined.
  2. Execution: Auditors will review documents, conduct interviews, and observe operations to gather evidence. They assess compliance with regulatory requirements, industry standards, and company policies.
  3. Analysis: Auditors analyze the evidence collected to identify areas of non-compliance, potential risks, and opportunities for improvement.
  4. Reporting: A comprehensive audit report is prepared, highlighting findings, conclusions, and recommendations for corrective actions.
  5. Follow-up: Auditors may conduct follow-up audits to verify all corrective actions have been implemented and compliance has been achieved.

Food Recalls

Food recalls are an integral part of the food safety system, initiated when a product is found to be contaminated or mislabeled. They are often the result of inspections and audits that identify serious issues. Here are a few notable statistics.

  • There were 547 Food and Drug Administration (FDA) food recalls in 2023, a five-year high for the industry and 19.6% more events than were recorded in 2022. FDA recalls are on track in 2024 to be consistent with 2023. U.S. Department of Agriculture (USDA) recalls also increased, rising 31% from 2022. The volume of units recalled also increased a more notable 132.8% from 2022 to 2023.
  • In 2023, 313 food products (224 from FDA, 89 from USDA) were recalled, over 1,100 people were sickened and 6 people died from foodborne illness recalls (based on data collected). The two largest recalls, lead-tainted applesauce sickened 519 children in 44 states, and Salmonella contaminated cantaloupe sickened over 400 people. CDC estimates 48 million people get sick, 128,000 are hospitalized, and 3,000 die from foodborne diseases each year in the United States.
  • 2% of all FDA recalls stemmed from undeclared allergens, a 27% increase from 2022. One reason for the increase in allergen recalls is as of Jan. 1, 2023, manufacturers had to disclose sesame in their foods. The most common undeclared allergens — wheat, shellfish, eggs, fish, peanuts, milk, tree nuts and soybeans — account for 90% of all food allergic reactions. Listeria was listed as second and Salmonella third for the most recalls.
  • Unsurprisingly, as the nation’s largest producer of food, California was found to be responsible for the largest share of all recalls. Over 16.3% of recalls originate from California products. Followed by New York at 8.1% and Texas at 6.5%. California customers are also most frequently affected by recalls. 39.8% of all recalls nationally impact residents in California, followed by New York at 36.4% and Pennsylvania at 35.8%.

The Role of Technology in Inspections and Audits

Advancements in technology have significantly enhanced the effectiveness of inspections and audits in the food industry. Some key innovations include:

  1. Data Analytics: Big data analytics enable companies to identify trends and potential risks by analyzing large volumes of data from various source, such as inspection reports, consumer complaints, and laboratory results.
  2. Blockchain: Blockchain technology provides a transparent and immutable record of the entire food supply chain, making it easier to trace the origin of products and detect potential issues quickly.
  3. IoT Devices: Internet of Things (IoT) devices, such as sensors and RFID tags, provide real-time monitoring of conditions like temperature and humidity, ensuring that products are stored and transported under optimal conditions.
  4. Mobile Inspection Tools: Mobile applications and digital platforms streamline the inspection process by allowing inspectors to record findings, take photos, and generate reports on-site, reducing paperwork and improving efficiency.

Inspections and audits are indispensable components of the food industry’s efforts to ensure safety, quality, and compliance. They play a crucial role in preventing foodborne illnesses, managing risks, and maintaining consumer trust. As the technology continues to advance with properly trained and calibrated auditors, the effectiveness and efficiency of inspections and audits will only improve, further safeguarding the food supply chain from the farm to the table.

By understanding the crucial role inspections and audits play, stakeholders in the food industry can better prepare to meet the high standards necessary to ensure that food products are safe for consumption. The continued evolution of these processes, bolstered by technological advancements, promises a safer future for consumers worldwide.

Reference:

  1. Trace One analysis of 2020–2024 FDA and USDA data