Tag Archives: Focus Article

Susanne Kuehne, Decernis
Food Fraud Quick Bites

If Fish Could Talk

By Susanne Kuehne
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Susanne Kuehne, Decernis
Seafood fraud
Find records of fraud such as those discussed in this column and more in the Food Fraud Database, owned and operated by Decernis, a Food Safety Tech advertiser. Image credit: Susanne Kuehne.

Seafood fraud is still on an almost unchanged high level in Canada. Based on a 2021 investigation by Oceana Canada, 46% of 94 DNA tested seafood samples were not what the label claimed them to be. The Oceana report describes seafood traceability in Canada, the 2021 seafood fraud investigation and results, what consumers can do, and suggestions for the federal government on how to mitigate seafood fraud. These recommendations include setting up a traceability system, labeling standards, improving testing standards and better documentation in the supply chain.

Resource

  1. Oceana. (August 2021). “Seafood Fraud in Canada: 2021 Testing Results Report”.
Scott Deakins, Deacom
FST Soapbox

Billions of Dollars Lost to Food Waste, Tech Exists to Reduce It

By Scott Deakins
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Scott Deakins, Deacom

Food waste is a massive global problem led by the United States. According to the USDA, an estimated 30–40% of the country’s food supply ends up in landfills—most of it at the retail and consumer levels. This amounted to approximately 133 billion pounds and $161 billion worth of food wasted in 2010 alone, which prompted the USDA and the Environmental Protection Agency to launch the U.S. Food Loss and Waste 2030 Champions initiative in 2016. Businesses and other organizations can join the ranks as champions by committing to a 50% reduction of food loss and waste by 2030.

That’s a noble goal, but those businesses will only be able to achieve their objective with technologies that reduce food waste in production and the supply chain. Food lost in this medium is hardly insignificant. At least 10%—or billions of pounds of food—is wasted in acts as small as over-ordering or in transport. This is, in short, the result of errors in resource planning.

After an extremely difficult year, food process manufacturers can no longer afford to generate that level of waste. Fortunately, technologies already exist to help the industry regain control of its production, storage and forecasting, and can facilitate leaner businesses and less waste.

Eliminate Human Error and System Inconsistencies

There have been a lot of changes in the way food is grown, harvested, delivered and sold over the last few decades, yet little progress has been made when it comes to unnecessary waste. The Commission for Environmental Cooperation reports that food loss and waste can occur post-harvest due to inaccurate supply and demand forecasting, grade standards for size and quality, and deficiencies in refrigeration. Even the packaging can cause problems if it is inefficient or ineffective.

These and other problems lead to waste—some up front before the product is ever sold to consumers, others down the line after an item has been purchased, leading to a recall. If inventory records are anything less than 100% accurate from formulation through shipment, additional challenges will follow. Though it is not heavily considered in an FDA audit, manufacturers still need the ability to instantaneously report on any aspect of their inventory history, regardless of the ERP software from which data is pulled. ERP systems with bolt-on modules often fail in this regard. If functionalities of the sub-systems are not designed for strict lot tracking, or if those sub-systems are not designed exactly the same, errors are inevitable.

Workarounds can be implemented, but they cannot account for processes that still need to be performed manually, which increases the likelihood that lot tracking accuracy will fall short. Inefficiencies are further exacerbated by sub-systems that handle actions differently, but the challenges don’t end there.

Problems can also develop when data has to be shared across more than one module, database or even system, which may inspire the use of outside solutions, such as an Excel spreadsheet, compounding the issues at hand. Makeshift solutions increase the risk that an incorrect lot number will be entered or that someone will forget to delete a number after a lot was de-issued and re-issued. Any of these cracks in the operational foundation will inevitably deduct from the 100% inventory accuracy that’s necessary for a smooth recall process—anything less will lead to a greater impact on the business.

The only real solution is to eliminate the potential for human error and system inconsistencies altogether—and that can only be accomplished with a configurable ERP solution that handles all business processes from one system and one database and can easily adapt to changing regulation and recipes. Without it, true strict lot control—meaning 100% inventory accuracy with perfect record keeping and the ability to instantly report on any aspect of the inventory history—cannot be achieved.

Reduce Inventory Variance and Grow without Unnecessary Expansions

There are aspects of food waste that can be controlled, including inventory variance, which occurs when items are lost, misplaced or miscounted. This is particularly problematic for packaging and ingredients, causing issues at the production level—finished products cannot be made if there aren’t enough items to complete the process, which is also bad for the bottom line. Inventory variance may occur if deliveries are not verified to confirm that ordered ingredients were actually received or may happen if items are entered incorrectly or simply misidentified.

Variance is more than a nuisance—it can be quite costly. For example, Silver Spring Foods encountered this firsthand when it discovered that its inventory variance commonly reached between $250,000 and $300,000. The company, which debuted in 1929 when founder Ellis Huntsinger started growing horseradish and other vegetable crops, now produces the number-one horseradish retail brand in the United States. With more than 9,000 acres of prime Wisconsin and Minnesota farmland, Silver Spring realized that it had outgrown its outdated ERP solution.

The company initially thought that it had reached capacity and could only grow further by physically expanding its building with an additional manufacturing line that would require new hires to come aboard. In reality, the company needed an ERP solution that could keep up with its impressive level of growth.

More specifically, Silver Spring Foods wanted an ERP system that could tie together several elements, including customer service, accounting, manufacturing, purchasing and shipping within a single tool. The company needed a solution that offered strong data mining and reporting functionality, as well as strong sales reporting, sustainable tech support capabilities and would not exceed ERP budget allocations. It was equally important to have an ERP solution that was configurable without customization, prioritizing speed and efficiency while offering predictable quality and cost of ongoing IT support and maintenance.

After upgrading to a solution that met all of its requirements, Silver Spring Foods was able to gather all data in one system that brought together multiple software integrations, including CRM. This allowed the firm to fine-tune its material purchases to match current production needs, sales forecasts and production schedules. More importantly, inventory variance was reduced to $90,000 during the first year and now falls within a range of just $1,800 to $2,500. By improving inventory management, unearthing new efficiencies and proving that Silver Spring had not yet reached capacity, the company was now able to grow without adding additional square footage.

Don’t Let Waste Cut into Productivity

Food growers, processors and supply chains cannot afford to let waste cut into their productivity or their bottom line. They need to be able to keep track of everything, achieving true strict lot control to limit the damage caused by a recall. They also need to be able to improve food management and reduce inventory variance. These and other advantages can only be attained with the right ERP technology, however, so businesses must choose wisely before making an investment.

Susanne Kuehne, Decernis
Food Fraud Quick Bites

A Tea Party For Fakes

By Susanne Kuehne
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Susanne Kuehne, Decernis
Fake tea
Find records of fraud such as those discussed in this column and more in the Food Fraud Database, owned and operated by Decernis, a Food Safety Tech advertiser. Image credit: Susanne Kuehne.

Tea is becoming a more and more popular target for fraudsters due to growing demand, complex supply chains, supply issues due to crop failure, sustainability problems, and underdeveloped analytical methods. Professor Chris Elliott (Director of the Institute for Global Food Security, Queen’s University Belfast) and his team are developing an analytical method based on chemical fingerprinting to determine fraud. Tea fraud can show as mislabeling of the geographical origins or type of a tea, or the addition of sometimes hazardous bulking agents like pigments or gypsum.

Resource

  1. Elliott, C. (August 10, 2021) “The challenges and necessity of tea authenticity”. New Food Magazine.
Salmonella Surveillance

Mid-Year Pathogen Surveillance and Inspection Update

By Nathan Libbey
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Salmonella Surveillance

Food Recalls

The first half of 2021 saw almost a 20% increase in recalls vs. the last 6 months of 2020 (117 vs. 96). According to a recent report by Lathrop GPM, LLC, food producers have seen an increase in food safety incidents since the pandemic began, and expect an ongoing increase over the next year.1 A majority of recalls were due to undeclared allergens or potential for allergen cross contamination. Second to allergens were potential for microbiological contaminants, including Salmonella, Listeria, E. coli, and Cyclospora.

FDA Recalls Recalls
Figure 1 and 2. The first half of 2021 saw a 26% increase of facility inspections by the FDA. Despite this jump, inspections in the first half of 2020 were 80% higher than this year’s first six months. Source: FDA Recalls, Market Withdrawals, & Safety Alerts.

Inspection Results

The first half of 2021 saw a 26% increase of facility inspections by the FDA. Despite this jump, inspections in the first half of 2020 were 80% higher than this year’s first six months. Inspections generally lead to three outcomes; No Action Indicated (continue as you were,) Voluntary Action Indicated (voluntary to make some changes), or Official Action Indicated (OAI) (Regulatory Actions will be recommended by the FDA). A majority of inspections (56%) resulted in NAI this year, compared to 59% and 50% in the first and second halves of 2020, respectively.

Facility Inspections
Figure 3. Facility Inspections. Data from FDA.

Salmonella Surveillance

The FSIS provides ongoing surveillance of Salmonella and Campylobacter presence in poultry, both domestic and imported. Salmonella is reported by facility and each is given a category rating of 1–3. One is exceeding the standard (based on a 52-week moving average), two is meeting the standard, and three is below standard. For the 52-week reporting period ending May 30, 2021, 60% achieved category one, compared to 56% the previous 52 weeks.

Salmonella Surveillance Salmonella Surveillance
Figures 4 & 5. Salmonella surveillance data from FDA.

Listeria and Salmonella Surveillance in RTE Meat and Poultry

USDA FSIS conducts periodic sampling of Ready to Eat (RTE) meat and poultry products and reports quarterly results. Sampling is conducted both in a random fashion as well as based on risk-based sampling. In Q2 2021, 4769 samples were tested for Listeria, compared to 4632 in Q1.

Percent positive rates were .36% for Q2 and .43% for Q1. Neither quarter reported any positives for Listeria in imported RTE Meat and Poultry Products.

Salmonella samples for RTE totaled 3676 in Q2 2021, compared with 3566 in Q1. In both quarters, only 1 positive was found in the samples collected.

Routine Beef Sampling for E. coli 0157:H7 and STEC

The FSIS also conducts ongoing routine sampling of beef products for E. coli. E. coli is further classified into 0157:H7 and non-0157:H7 Shiga toxin-producing E. coli (STEC). In Q2 of 2021, 4467 samples were collected and tested for 0157:H7 versus 4268 in Q1. Of these, three were positive, compared to seven positives the preceding quarter. For STEC, a total of 8 positives were found, compared to 1 positive in Q1. No positives were found in imported goods in Q2, although in Q1 2021, 4 positives for STEC were found.

Conclusion

The first half of 2021 showed an increase in activity, which is on par with food industry survey data. Food recalls have increased, with food allergens remaining the most prevalent reason for recall or withdrawal. While inspections also increased, they have not returned to pre-pandemic levels. The impact of the spread of the Delta variant and increased restrictions is yet to be seen, but inspection activity will likely not rebound entirely by the end of the year. Pathogen tests by FSIS increased quarter over quarter for Salmonella, E. coli, and STEC, with mixed results in prevalence.

Reference

1. Lathrop GPM, LLC. (2021). Food Processing Trends, Outlook and Guidance Report. Retrieved from https://www.lathropgpm.com/report-agribusiness.html

Coronavirus, COVID-19

Tyson Foods to Mandate COVID Vaccines, Will Other Food Companies Follow?

By Maria Fontanazza
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Coronavirus, COVID-19

In a controversial move, Tyson Foods is mandating that all of its U.S. employees receive the COVID-19 vaccine. The company is requiring that the leadership team be vaccinated by September 24, office workers by October 1, and frontline employees by November 1. However, the mandate is “subject to ongoing discussions with locations represented by unions”, according to the company website.

Tyson Foods, along with other meat processors, has been plagued with COVID-19 outbreaks during the course of the pandemic. In December the company went as far as naming its first chief medical officer, a new role to help promote health, safety and wellness.

“We did not take this decision lightly. We have spent months encouraging our team members to get vaccinated – today, under half of our team members are,” stated Donnie King, president & CEO of Tyson Foods, in a company memo titled, “Our Next Step in the Fight Against the Pandemic”. Half of U.S. employees equates to 56,000 workers. Frontline employees who are fully vaccinated will receive $200.

A union representing Tyson employees, the United Food and Commercial Workers (UFCW), is concerned over the fact that the company is requiring vaccination before FDA has provided full approval of any COVID-19 vaccine. “We believe the FDA must provide full approval of the vaccines and help address some of the questions and concerns that workers have,” said UFCW International President Marc Perrone in a statement. “Additionally, employers should provide paid time off so that their essential workers can receive the vaccine without having to sacrifice their pay, and can rest as needed while their body adjusts to the vaccine and strengthens their immune system to fight off the virus.”

UFCW also released the following figures on COVID-19 infections, exposures and deaths nationwide among its union members:

  • 482 frontline worker deaths and at least 96,600 frontline workers infected or exposed
  • 197 grocery worker deaths and at least 43,300 grocery workers infected or exposed
  • 132 meatpacking worker deaths and 22,400 meatpacking workers infected or exposed
  • 67 food processing worker deaths and 13,100 food processing workers infected or exposed

Will other companies in the industry follow suit?

Susanne Kuehne, Decernis
Food Fraud Quick Bites

It’s in Their DNA

By Susanne Kuehne
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Susanne Kuehne, Decernis
Pepper, food fraud, DNA
Find records of fraud such as those discussed in this column and more in the Food Fraud Database, owned and operated by Decernis, a Food Safety Tech advertiser. Image credit: Susanne Kuehne.

Spices have been an ongoing hot target for fraudulent activity, whether it is the addition of inedible substances like dyes, or bulking agents, such as brick powder, other plant material, sawdust and many other, potentially hazardous substances. A relatively new technology, next-generation sequencing (NGS), enables to analyze the DNA of complex samples such as spices and herbs. The DNA findings are compared to a database and allow to detect many thousands of species in one test. Currently, working groups are developing standardized methods for such authenticity tests.

Resource

  1. Woolfe, M. (July 13, 2021). “NGS (Next Generation Sequencing) is Helping to Prevent Fraud in the Herb and Spice Trade”. Food Authenticity Network.
Allergens

Key Trends Reinforce Food Allergen Testing Market Across North America

By Saloni Walimbe
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Allergens

The food allergen testing industry has garnered considerable traction across North America, especially due to the high volume of processed food and beverages consumed daily. Allergens are becoming a significant cause for concern in the present food processing industry worldwide. Food allergies, which refer to abnormal reactions or hypersensitivity produced by the body’s immune system, are considered a major food safety challenge in recent years and are placing an immense burden on both personal and public health.

In 2019, the most common reason behind recalls issued by the USDA FSIS and the FDA was undeclared allergens. In light of this growing pressure, food producers are taking various steps to ensure complete transparency regarding the presence of allergenic ingredients, as well as to mitigate risk from, or possibly even prevent contact with, unintended allergens. One of these steps is food allergen testing.

Allergen detection tests are a key aspect of allergen management systems in food processing plants and are executed at nearly every step of the process. These tests can be carried out on work surfaces, as well as the products, to detect any cross contamination or allergen presence, and to test the effectiveness of a food processing unit’s cleaning measures.
There has been a surge in awareness among consumers about food allergies and tackling the risk of illnesses that may arise from consuming any ingredient. One of the key reasons for a higher awareness is efforts to educate the public. In Canada, for example, May has been designated “Food Allergy Awareness Month”. It is estimated that more than 3 million people in Canada are affected by food allergies.

The size of the global food allergen testing market is anticipated to gain significant momentum over the coming years, with consistent expansion of the dairy, processed food and confectionary segments.

Understanding the Prevailing Trends in Food Allergen Testing Industry

Food allergies risen nearly 50% in the last 10 years, with a staggering 700% increase observed in hospitalizations due to anaphylaxis. Studies also suggest that food allergies are a growing health concern, with more than 250 million people worldwide estimated to be affected.

Although more than 170 foods have been identified as causing food allergies in sensitive consumers, the USDA and the FDA have identified eight major allergenic foods, based on the 2004 FALCPA (the Food Allergen Labeling and Consumer Protection Act). These include eggs, milk, shellfish, fish, peanuts, tree nuts, soybean, and wheat, which are responsible for 90% of allergic reactions caused due to food consumption. In April 2021, the FASTER (Food Allergy Safety, Treatment, Education, and Research) Act was signed into law, which categorized sesame as the ninth major food allergen.

This ever-increasing prevalence of allergy-inducing foods has presented lucrative opportunities for the food allergen testing industry in recent years since food processing business operators are placing a strong emphasis on ensuring transparency in their products’ ingredient lists. By testing for allergens in food products, organizations can accurately mention each ingredient, and thereby allow people with specific food allergies to avoid consuming them.

Several allergen detection methods are used in the food processing industry, including mass spectrometry, DNA-based polymerase chain reaction (PCR) as well as ELISA (enzyme-linked immunosorbent assay), to name a few. The FDA, for instance, created a food allergen detection assay, called xMAP, designed to simultaneously identify 16 allergens, including sesame, within a single analysis, along with the ability to expand for the targeting of additional food allergens. Such industry advancements are improving the monitoring process for undeclared allergen presence in the food supply chain and enabling timely intervention upon detection.

Furthermore, initiatives, such as the Voluntary Incidental Trace Allergen Labelling (VITAL), created and managed by the Allergen Bureau, are also shedding light on the importance of allergen testing in food production. The VITAL program is designed to support allergen management with the help of a scientific process for risk assessment, in order to comply with food safety systems like the HACCP (Hazard Analysis and Critical Control Point), with allergen analysis playing a key role in its application.

ELISA Gains Prominence as Ideal Tool for Food Allergen Testing

In life sciences, the detection and quantification of various antibodies or antigens in a cost-effective and timely manner is of utmost importance. Detection of select protein expression on a cell surface, identification of immune responses in individuals, or execution of quality control testing—all these assessments require a dedicated tool.

ELISA is one such tool proving to be instrumental for both diagnostics as well as research). Described as an immunological assay, ELISA is used commonly for the measurement of antibodies or antigens in biological samples, including glycoproteins or proteins.

While its utility continues to grow, ELISA-based testing has historically demonstrated excellent sensitivity in food allergen testing applications, in some cases down to ppm (parts per million). It has a distinct advantage over other allergen detection methods like PCR, owing to the ability to adapt to certain foods like milk and oils, where its counterparts tend to struggle. The FDA is one of the major promoters of ELISA for allergen testing in food production, involving the testing of food samples using two different ELISA kits, prior to confirming results.

Many major entities are also taking heed of the growing interest in the use of ELISA for food allergen diagnostics. A notable example of this is laboratory analyses test kits and systems supplier, Eurofins, which introduced its SENSISpec Soy Total protein ELISA kit in September 2020. The enzyme immunoassay, designed for quantitative identification of soy protein in swab and food samples, has been developed by Eurofins Immunolab to measure residues of processed protein in various food products, including instant meals, chocolate, baby food, ice cream, cereals, sausage, and cookies, among others.

In essence, food allergens continue to prevail as high-risk factors for the food production industry. Unlike other pathogens like bacteria, allergenic proteins are heat resistant and stable, and cannot easily be removed once present in the food supply chain. In this situation, diagnostic allergen testing, complete segregation of allergenic substances, and accurate food allergen labeling are emerging as the ideal courses of action for allergen management in the modern food production ecosystem, with advanced technologies like molecular-based food allergy diagnostics expected to take up a prominent role over the years ahead.

Susanne Kuehne, Decernis
Food Fraud Quick Bites

An X-tra Trophy for OPSON X

By Susanne Kuehne
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Susanne Kuehne, Decernis

The usual culprits are leading the list of seized feed and food counterfeits in the latest OPSON X Operation: Alcoholic beverages, dietary supplements and grain-based products, followed by produce. In the Operation OPSON activities, Europol and Interpol join forces to combat counterfeit and fake animal feeds, foods and beverages. This year’s operation unearthed 15,000 tons of potentially dangerous products, worth $60 million, an increase in 3,000 tons over the previous year.

Opson X Trophy
Find records of fraud such as those discussed in this column and more in the Food Fraud Database, owned and operated by Decernis, a Food Safety Tech advertiser.
Image credit: Susanne Kuehne

Resource

  1. Whitworth, J. (July 22, 2021). “Crackdown results in seizure of 15,000 tons of illegal foodstuffs”. Food Safety News.
Food Safety Testing Market

Processed Meat and Poultry Applications Drive Food Safety Testing Industry

By Hrishikesh Kadam
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Food Safety Testing Market

The food safety testing industry is constantly experiencing new developments, technological advances and regulatory pressures as the burden of foodborne illness remains a prevalent concern. Growing consumer preference for convenience and processed foods is a pivotal trend augmenting the industry outlook.

The World Health Organization (WHO) reports that every year nearly $110 billion is lost across middle- and low-income countries due to unsafe food. From the health risk perspective, pathogens, pesticides or toxins cause more than 200 diseases, ranging from diarrhea to cancers. Since most foodborne illnesses are preventable, WHO and other public health organizations worldwide are taking necessary action to establish strong and resilient food safety systems and enhance consumer awareness.

Food products may become contaminated at any stage of production, supply or distribution. Testing food and beverage products for safety is a critical component of the food and beverages sector. In terms of annual valuation, the global food safety testing market size is anticipated to hit $29.5 billion by 2027.

Food Safety Testing Market
Food Safety Testing Market. Figure courtesy of Global Market Insights, Inc.

Pathogen Testing Demand Rises as E. coli, Salmonella Infections Persist

Pathogen testing is of utmost importance to the food & beverage industry, as there remains a large number of virus and bacteria causing pathogens and microbial agents responsible for foodborne illnesses. Numerous instances of pathogen contamination have come to light recently, augmenting the need for food pathogen testing, especially during a time when COVID-19 poses a significant threat.

For instance, in July, the CDC and the FDA announced that they are working with other public health agencies to investigate an outbreak of E. coli O121 infections across 11 states. Meanwhile in the European Union, several countries have started investigating Salmonella illnesses linked to imported tahini and halva. Since 2019, about 80 people are estimated to be affected in Germany, Denmark, Norway, Sweden and the Netherlands.

Pathogen testing demand will likely increase across North America and Europe with further spread of infections. These regions are among the major consumers of processed meat, seafood and poultry products, augmenting the need for reliable food safety testing solutions.

Meat, Poultry and Seafood Consumption Drive Foodborne Infection Risks

Globally more individuals are consuming processed poultry and meat products at home, in restaurants, fast food restaurants, and other locations. The worldwide meat consumption is estimated to reach 460 to 570 million tons by the year 2050, as per data from The World Counts.

It is essential to ensure optimum product quality during meat processing to minimize the perils of foodborne microorganisms. Meat quality testing standards are continuously evolving to ensure that food manufacturers bring the best-quality products to the market. In July this year Tyson Foods recalled more than 8.9 million pounds of ready-to-eat chicken products due to potential Listeria monocytogenes contamination. The significant recall quantity itself represents the scope of pathogen testing requirements in processed meat sector.

E. coli O157 is considered to increase the risk of toxins that lead to intestinal problems and can cause significant illness among geriatric people, pregnant women and other high-risk populations. Earlier this year, PerkinElmer introduced an E. coli O157 pathogen detection assay to be used for testing raw ground beef and beef trim. The solution is greatly suited for food and beverage sector customers that need to test high volumes of food samples regularly. The development indicates an incessant fight to offer effective food safety testing products to tackle the threat of pathogen-related illnesses.

USDA’s FSIS also recently revised guidelines for controlling Salmonella and Campylobacter infections in raw poultry. The updated guidelines provide poultry establishments with best practices that they may follow to reduce the risk of such infections in raw products.

Food Safety Testing Trends amid COVID-19 Pandemic

Food safety testing demand has experienced a notable uptick since the outbreak of the coronavirus pandemic, as food security and sustainability have been recognized as key areas of focus.

Globally, a rise in online orders of groceries and restaurant meals has been observed. Major food regulators such as the FDA have released food safety protocols and guidelines for food companies, hotels and restaurants. These practices help ensure optimum food quality as well as the safety of employees, staff and consumers.

The FDA has been working with the USDA and FSIS as well as state authorities to investigate foodborne illnesses and outbreaks amid the pandemic. Many regions are also updating food safety policies to help overcome the challenges of the pandemic. While pathogen and toxin testing demand are growing in most regions, the inadequacy of food control infrastructure may limit food safety testing industry expansion in emerging economies.

Drawbacks of existing technologies and the need to reduce sample utilization, lead time and testing cost are driving new innovations in food safety testing. Ongoing developments are focused on providing accurate results in limited timespan.
The food safety testing market landscape will continue to evolve as new regulations are introduced, public awareness rises, and food consumption patterns change. The rapid testing technology segment, which includes PCR, immunoassay and convenience testing, is estimated to hold a major share of the overall industry owing to faster results provided, which benefits the organizations in terms of productivity and processing costs. In addition to previously discussed PerkinElmer, Eurofins Central Analytical Laboratories Inc, Bio-Rad Laboratories, Intertek Group PLC, Bureau Veritas SA, and SGS AG are some of the other notable names in the industry.

Emily Newton, Revolutionized Magazine
FST Soapbox

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

By Emily Newton
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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.