Tag Archives: cold storage

Steve Knuth
FST Soapbox

The Role of Temperature Monitoring and Reporting Technology in Food Safety

By Steve Knuth
No Comments
Steve Knuth

The traditional process for ensuring food safety in storage and transportation focuses on maintaining temperatures that are safe for the types of food or beverage the organization sells. Doing this without data logging technology means that the organization needs to appoint an individual to check refrigeration temperatures on a regular cadence and record that data by hand in case of an audit by the FDA.

Unfortunately, this method lacks 24/7 accountability of temperatures and allows for human error/neglect. If a refrigeration unit goes down outside of the regularly scheduled temperature monitoring cadence, the product can quickly fall outside of the designated safe temperatures. If the food is outside of the safe temperature range for an extended period, that food must be disposed of and will cost the organization a tremendous amount of time and money.

Subscribe to the Food Safety Tech weekly newsletter to stay up-to-date on the latest news and information on food safety.

This problem is equally apparent in transportation. Companies often utilize third-party transportation companies, which means they are relying on someone outside of the organization to responsibly manage and record temperatures and report back to the necessary parties. But the risk of human error and equipment failure can come into play. Temperature issues can even stem from drivers shutting off refrigeration while they sleep to save diesel fuel.

The most effective way to maintain quality control within storage and transport is by utilizing real-time data monitoring with a connected high-precision data logger. Multiple types of data loggers can be used to monitor temperatures in different scenarios. These includes traditional data loggers connected by Ethernet and wireless data loggers with Bluetooth or cellular connectivity. Each version has its role in food and beverage safety.

Connected vs. Manual Loggers

In fixed cold storage, such as within a restaurant or storage facility, an Ethernet or Wi-Fi-connected data logger is a great choice due to its affordability and reliability. For users who’d like to check temperatures on their mobile device while moving around the facility, a Bluetooth logger with mobile application support can be a strong option as well.

These loggers allow the user to get a 24/7 view of their refrigeration unit and correct issues before they lead to food disposal. For instance, if a food storage unit goes down over the weekend when no one is staffing the facility, or a restaurant is closed for a holiday, and temperatures within a refrigerator fall outside of the norm, these connected loggers will alert the user via email or text to correct the issue so they can save the product from spoiling.

One tip for using a connected logger is to set the alert feature to notify the user when temperatures reach the high and low end within the safe temperature spectrum for the food or beverage being stored. This provides an alert before the unit temperature falls outside the safe range, allowing the user to take corrective action before the product falls into unsafe temperatures.

In food and beverage delivery, transport companies are liable for temperature issues, especially if corrective action is not taken. This is where a cellular-connected data logger becomes critical. With a traditional data logger, there is no way for a consignor to know whether a temperature issue has occurred, unless it is checked manually by the driver. At that point, it may be too late to save the consignment. However, cellular-based technology allows consignors to do real-time monitoring without any interaction with the transport company.

Because many shipments are made using third-party transporters, cellular-based data loggers are becoming increasingly popular for maintaining trust between the transporter and all other segments of the supply chain. These wireless loggers also allow a trusted driver to monitor conditions while in route, allowing the driver to take corrective action before temperatures reach critical ranges.

Connected Data Loggers and FSMA

Transporters must also be fully aware of the Food Safety and Modernization Act (FSMA). These regulations make quality data loggers even more important as transporters may have to verify at any given moment that food was handled properly while in their possession. FSMA also emphasizes the importance of data logging technology. The act requires food handlers to develop a plan that meets the guidelines for Hazard Analysis and Critical Control Points (HACCP), which should involve an advanced data logger. Issues with data entry, misreading and misinformation are the responsibility of the transporter, and failure to comply with these guidelines can result in seizure, injunction and recalls, all of which can damage the reputation of the entire supply chain.

With all things considered, connected data loggers are extremely cost-effective technology options that can save thousands of dollars and hours of hassle. Because they can be monitored by multiple parties, the transporter or manager of a storage unit/restaurant can become aware of issues regarding temperature before the only safe course of action becomes product disposal.

Loggers help save money in the form of legal fees, compensation and premiums, while also drastically reducing the risks of consumer illness and public relations disasters. Some data logger companies also offer free cloud storage, allowing monitoring and analytics tracking in all locations, at any time of day.

With the high costs of noncompliance in the food industry, it is important for storage managers and transporters to understand that implementing high-precision, connected data monitoring tools can help put these issues to rest.

Milk and eggs

Undeclared Allergens Drive New Recall

By Food Safety Tech Staff
No Comments
Milk and eggs

Undeclared allergens continue to drive recalls from the USDA Food Safety and Inspection Service (FSIS). Last week, more than 22,000 pounds of frozen beef products were recalled because the products were found to contain milk, which was not declared on the label.

The USDA FSIS announced on September 17 that Valley International Cold Storage Acquisition, LLC, a Harlingen, Texas-based business, is recalling approximately 22,061 pounds of frozen beef products. The frozen products are labeled as Korean-Style Beef, but contain a chicken sausage and pepper product, which contains milk.

These items were produced on July 22, 2022. The following products are subject to recall [view labels]:

  • 9.25-oz. cartons labeled as “Healthy Choice POWER BOWLS Korean-Style Beef” with lot code “5246220320” and a “best if used by” date of 04-18-2023.

The products subject to recall, which were shipped to retail locations nationwide, have establishment number “34622” on the end flap of the carton.

On September 16, the USDA FSIS issued a public health alert for certain raw, ready-to-cook chicken entrée products that may contain egg, which is not declared on the finished product label. The agency noted that a recall was not requested because the products are no longer available for purchase.

The bacon-cheddar chicken entree products were produced on Sept. 9, 2022 and are labeled as [view labels]:

  • 12 oz. plastic wrapped metal containers containing “aprons READY TO COOK MEAL FOR ONE BACON-CHEDDAR SMOTHERED CHICKEN” with a use by date of 9/21/2022.

The products bear establishment number “P-48176” inside the USDA mark of inspection. These items were shipped to Publix locations in Alabama, Florida, Georgia, North Carolina, South Carolina, Tennessee and Virginia.

Consumers with an egg allergy who have purchased these products are urged not to consume them. These products should be thrown away or returned to the place of purchase.

FDA

FDA and USDA Investigate Seasonal Factors Contributing to E. Coli Outbreaks Linked to Romaine Lettuce

By Food Safety Tech Staff
No Comments
FDA

CFSAN and the USDA’s Agricultural Research Service are conducting research to better understand the factors, including seasonal effects, that could be contributing to E. Coli O157:H7 outbreaks linked to bagged romaine lettuce. FDA and USDA scientists presented findings in the BMC Environmental Microbiome, which revealed that E. Coli O157:H7 survived “significantly better in cold-stored packaged romaine harvested in the fall than on the same varieties harvested in late spring.” In addition, the researchers showed that the microbiome present on bagged lettuce changes based on the season, level of deterioration of the lettuce and whether survival of the pathogen on the lettuce was high or low. They also found that the pathogen survived better in lettuce that was harvested in the fall versus lettuce harvested in the spring during cold storage. “This is a significant step toward closing the knowledge gaps identified in the FDA’s Leafy Greens STEC Action Plan and helping the agency and its partners to reduce foodborne illness linked to the consumption of leafy greens,” CFSAN stated in an agency update.

The study, “Seasonality, shelf life and storage atmosphere are main drivers of the microbiome and E. coli O157:H7 colonization of post-harvest lettuce cultivated in a major production area in California”, has been published on the Environmental Microbiome’s website.

Emily Newton, Revolutionized Magazine
FST Soapbox

As Demand for Frozen Food Surges, Cold Storage Facilities Must Continue to Prioritize Safety

By Emily Newton
No Comments
Emily Newton, Revolutionized Magazine

Frozen food demand has skyrocketed. Although COVID-19 was a catalyst, there are many reasons why the trend will likely continue going forward. The pandemic forced people to eat at home more, which was largely responsible for the hike in food sales, especially frozen goods. Higher availability and food quality enhancements have also contributed to the spike, prompting suppliers to upgrade and expand cold storage warehouse solutions—whether that means creating extra space or utilizing existing space more effectively.

One of the more important changes, prioritized across the industry, is food preservation and safety. It has always been crucial that frozen food reaches its destination clean, healthy and still frozen — just as it went in. However, preliminary data from the CDC’s Foodborne Diseases Active Surveillance Network reveals that foodborne illnesses are up 15%. The primary or most common form is Salmonella, but COVID-19 has consumers and food safety professionals thinking more closely about cleanliness and proper sanitation.

It has pushed a tight focus on safety overall, with new innovations looking to enhance sector controls.

Necessity Breeds Creativity

Recent events have played a role in the industry’s continued focus on safety, but so have consumer demands, as more and more people look to frozen meals, foods and items as part of their normal routines.

People love convenience. But as the pandemic hit, and people were forced to isolate and remain home more, and restaurants and stores closed as a safety precaution. What was once about convenience became even more about safety. People still wanted freedom and ease of use, but it wasn’t a necessity nor was it a priority. Safety became even more important, which is why curbside pickup, deliveries and online transactions became so popular.

What does this have to do with frozen foods? Everything. Because of the pandemic, we’ve all had to eat at home more often, which means preparing meals, snacks and other items, with minimal exposure to the outside world or even local grocery stores. Naturally, consumers turned to easily cooked and pre-prepared frozen foods and meals.

Safety is the Priority

It makes sense that more frozen foods being purchased and consumed would shift priorities in the market. In a 2021 report released by Acosta, 14% of respondents say they consume frozen food nearly all the time. About 46% say they consume frozen foods often.

During the pandemic, the share of U.S. core frozen food consumers rose to 39% in 2020, up from 35% in 2018. “Core” consumers are defined as those who either eat frozen food daily or every few days.

What’s more, 42% of households that buy frozen foods did so online, up from 23% in 2018. And online frozen food sales jumped 75% last year, with the top purchases including frozen dinners and entrees, meat, poultry and even seafood.

Instead of restricting eating habits, consumers have turned to frozen foods to spruce up their meals, create new at-home dishes, and so on. It has boosted the demand for all kinds of frozen foods. It also necessitates the need for improved quality and safety. Implementing and maintaining strict controls as to how the food is transported, handled and preserved, can prevent contamination on all fronts.

With that rise in dependence, on frozen foods specifically, it is imperative that supply chain operators are delivering goods in a safe, healthy condition. Allowing foods to thaw during the transport process can introduce more problems than just contamination, especially with COVID remaining a major influence.

Imagine how bad it would be if the world experienced a major foodborne outbreak, right now. Most scenarios can be prevented through smarter food handling and better, data-driven controls.

New methods are being implemented to chill and prepare foods earlier on in the supply process. Many cold chain providers are adopting low-temperature chillers, like a food processing chiller, for example. They can freeze prepared foods quickly to ensure they are safe, disinfected and stored appropriately. From there, it’s just a matter of keeping them cold-locked during transport, storage, delivery, and beyond. That’s precisely where some of the latest innovations come into the picture.

Cold Storage Warehouse Innovations

To keep up with the demand and ensure frozen foods and other goods stay fresh in the cold chain, the industry is seeing rampant innovation, thanks to modern technologies. Think IoT-equipped fleets and storage systems to facilitate faster time to market and better transparency. Or, machine learning and AI-driven tools that help discern bottlenecks, locate faster and more effective solutions, and so on.

At the heart of it all is data, or rather digital content and information. The smarter and more contextually driven operations are, the better efficiency is all around. The following are some of the technologies making this happen:

  • IioT. The Industrial Internet of Things (IIoT) involves connected devices that continually collect, transmit and sometimes process performance and contextual data. In the cold chain, it can be used to track goods, prevent theft or fraud, monitor processes, discover bottlenecks and more.
  • Machine Learning. An offset of artificial intelligence, machine learning and neural networks can be used to ingest and analyze massive swarms of data in ways, and at speeds, that humans never could. What’s more, the technology can empower highly advanced automation systems to take action, respond, or act based on algorithmic rulesets.
  • Electric and autonomous vehicles. Revolutionizing logistics and conventional transport, electric and fully autonomous vehicles will significantly improve fleets with better safety, stop-free trips and more.
  • Smart shelving. Imagine Amazon’s Kivo bots, or something similar, implemented within cold storage warehouses. The entire system is designed to improve inventory management, order picking, and general logistics.
  • Co-bots. Beyond delivery, ground-based drones or advanced robots can be used to transport and move heavy goods, large or bulk orders, and organize the warehouse. When outfitted with the appropriate hardware, they can reach high shelves and storage areas or move through hazardous locations, improving safety for manual workers.

Innovation Brings New Challenges

Of course, there are the general challenges facing the cold storage industry, such as how to keep foods fresh throughout the journey, proper packaging solutions, and maintaining more sanitary conditions, but there are new challenges presented by the adopted technologies.

For example, IIoT devices aren’t typically designed to be exposed to extremely frigid temperatures, which may sometimes affect the measurements and data collected. A malfunctioning device can lead to serious problems, especially when it’s the sole method for maintaining temperatures and ensuring food is properly stored.

Bringing these devices up to a sufficiently resistant level is a challenge, as is keeping them running optimally. Failing to do so could increase food contamination, the spread of foodborne illness, or worse.

Another challenge involves the expansion or development of new cold storage facilities. As warehouses and locations grow to accommodate larger inventories, the cold storage systems must become more sophisticated and powerful. What’s more, even the slightest temperature drop because of a system failure can have sweeping repercussions in such a large facility. A single refrigeration unit going down can drop temperatures across the entire warehouse.

Designing smarter spaces to keep the cold temperatures contained is one solution. Installing the supporting systems is another, which keeps things operational even when a negative scenario plays out. Automation and smart, data-driven technologies can be incredibly helpful in this area.

Finally, the bigger the cold storage solution, the higher the power draw and the more resources needed to keep things running. In turn, it’s necessary to install and implement smart technologies to reduce the carbon footprint. Cutting energy usage wherever possible becomes vital to sustainability. It can call for solutions like smart or timed lighting, smart thermostats for the refrigeration units, or upgraded systems that reduce emissions — think electric fleets and renewable energy platforms.

Backup solutions are even a part of the mix, when power outages can bring an entire operation down in seconds, and expose food to long-term risk.

Frozen Food Demand: A Steady Climb

Things may change, and there are never any guarantees, but right now it looks as though high demand for frozen food will continue, and may even grow steadily. Market conditions are partly responsible, but consumers are now more focused on quality and healthy foods, above eating out or ordering in. As the economy continues to open, people will want to get back out there and explore. But that doesn’t necessarily mean frozen food demand will decline.

Cold chain and cold storage warehouse providers must be prepared for the continued growth, which includes finding new and innovative ways to preserve, package and safely store frozen foods.