Tag Archives: Focus Article

Susanne Kuehne, Decernis
Food Fraud Quick Bites

An Unwelcome Message In A Bottle

By Susanne Kuehne
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Susanne Kuehne, Decernis
Beach
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

Adulterated alcohol continues to pose serious risks to health and even life of consumers. In this latest case from the Dominican Republic, more than two dozen people have died from methanol poisoning due to a low-cost illegally made drink, and from fake brand-named products. Businesses associated with the scams were raided and closed, and arrests were made. Officials keep warning against the consumption of illegally manufactured alcoholic beverages.

Resource

  1. News Desk. (April 10, 2021). “Deaths in Dominican Republic linked to tainted alcohol”. Food Safety News.

 

James Gunn-Wilkerson, CMX
Retail Food Safety Forum

The Future Is Now: AI Takes Journey from Supply Chain to Today’s Restaurant Kitchens

By James Gunn-Wilkerson
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James Gunn-Wilkerson, CMX

Futurist Ross Dawson has said that AI and automation will shape the future of work, and it also promises to transform our lives beyond the office. According to the World Economic Forum, when AI, which provides the ability to “enable devices to learn, reason and process information like humans,” is combined with Internet of Things (IoT) devices and systems, it creates AIoT. This super duo has the potential to power smart homes, smart cities, smart industries and even our smartwatches and fitness trackers, a market estimated by Gartner to be worth $87 billion by 2023. More importantly, this “interconnectedness” will change the way we interact with our devices as well as the way we will live and work in the future.

In the restaurant industry, we’re already seeing glimpses of this interconnectedness take shape, and in the past year, we’ve experienced major technological advancements that have transformed every facet of the way food establishments work. Reflecting on those advancements, I want to take a moment to share three areas of AI impact that are bubbling up in the restaurant sector in 2021.

1: AI-powered Intelligent Kitchens

From ghost kitchens to traditional kitchens, the “back of the house” continues to be a prime target for AI and automation. While great progress has been made, in many ways it seems like we’ve only scratched the surface when it comes to how far AI can take today’s restaurants. But every now and then, we hear examples of AI powering the future of our industry. For example, Nala Robotics, Inc. will be opening what it calls “the world’s first state-of-the-art intelligent restaurant” in Naperville, Illinois this year. The company says the AI-based robotic kitchen “can create dishes from any cuisine around the world, using authentic recipes from celebrated chefs”. A press release from Nala Robotics states that its flagship restaurant is taking “the first step in the food service industry with AI-powered service, addressing many of the issues affecting restaurant owners during COVID-19,” and it will “provide consumers an endless variety of cuisine without potential contamination from human contact.” This is the new frontier in intelligent kitchens, and it couldn’t have come at a better time, with the pandemic forcing restaurants to reimagine the way they do business.

2: AI-Driven Labor Shifts.

You can’t talk about AI in the restaurant industry without also having a conversation about the implications for the modern workforce. With AI in restaurant kitchens and beyond, the impact on the labor force is undeniable. By 2024, Gartner predicts “that these technologies will replace almost 69% of the manager’s workload.” But that’s not entirely a bad thing. Instead of manually filling out forms and updating records, managers can turn to AI to automate these and other tedious tasks. “By using AI…they can spend less time managing transactions and can invest more time on learning, performance management and goal setting,” Gartner adds.Managers can also use the extra time to focus more effort on the customer and employee experience. And indeed they should: In a recent Deloitte report, 60% of guests surveyed indicated that a positive experience would influence them to dine at a restaurant more frequently.

Looking at the impact of AI on labor at all levels, from the CEO to the entry-level wage earner, the shift, at its best, will be a transition to more meaningful—and less mundane—work. The evolution of humanity has taken us to the point we’re now at now, with food production and delivery processes becoming increasingly automated. This has been an evolution generations in the making. In an ideal world, everyone at every level of the organization should benefit from this new wave of technology. For example, automation can and should be used to open the door to new training and new opportunities for low-wage earners to learn new skills that elevate career paths, increase income and improve quality of life.

3: AI and Global Supply Chain Transformation

From the farm all the way to the table, AI is now poised to transform the global supply chain. From my perspective, the biggest impact will be around driving sustainability efforts. Restaurant and grocery brands are already beginning to leverage AI to forecast their food supply needs based on customer demand, leading to less over-ordering and less food waste to support sustainability initiatives. One company in this space, FourKites, is creating what it calls “the digital supply chain of the future.” Using real-time visibility and machine learning, FourKites powers and optimizes global supply chains, making them “automated, interconnected and collaborative—spanning transportation, warehouses, stores, trucks and more.”

In addition to predictive planning, more and more brands will start to use AI to create incident risk management models to identify trends and risks in the supply chain to determine whether bad or recalled products are originating from a specific supplier, distributor, or due to an environmental variable.With all of these changes, the need for comprehensive data standards will multiply as suppliers and distributors around the world work together to bring us produce and packaged food from all corners of the globe. Data standards will be critical to traceability and the exchange of critical tracking events and key data elements, and advances in data standards will power the meta-data needed to provide better insight for food quality and regulatory compliance, crisis management, and recalls—at scale.

Research firm Forrester states that, in the end, the greatest impact resulting from an investment in robotics and other technologies that automate operational tasks is improved customer experience (CX). “Most companies believe that investment in AI, automation, and robotics for engagement will decrease operational costs. While this is true, our research shows that the revenue upside from delivering better CX could deliver a greater impact on the bottom line over time,” Forrester states.

As a business engaged in digitizing and transforming supply chain operations, our team couldn’t agree with Forrester more. But we believe it will take striking the right balance between technology and the human touch to not only drive stronger CX, but to also create a world in which AI is implemented for the greater good—a world in which people, processes, business and technology all win.

Julie Holt, Decernis
FST Soapbox

California Proposition 65: Every Company Should Know Their Risk

By Julie Holt
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Julie Holt, Decernis

Known officially as The California Safe Drinking Water and Toxic Enforcement Act of 1986, California Proposition 65 reaches far beyond state boundaries and has potential regulatory implications for almost any company that manufactures, imports, and / or sells products containing listed chemicals in the state. California Prop 65 prohibits the sale of a product in California that knowingly and intentionally exposes an individual to a California Office of Environmental Health Hazard Assessment (OEHHA) listed chemical without a specific stated warning. For many food and supplement companies, the risk of opportunistic litigation based on California Prop 65 drives the need to monitor updates, new amendments and enforcement of the law.

Prop 65 Background

California Proposition 65, also known by the shortened name Prop 65, is not a ban on products or ingredients. The law is intended to inform consumers in California about exposure to a list of chemicals exceeding a defined level in products for sale, including product packaging. The regulation mandates a warning label for exposure to chemicals at a level that could cause cancer, birth defects or other reproductive harm. Guidance for upper limits (“Safe Harbor Level”) on chemicals is based on expected daily exposure. If no Safe Harbor Level exists for a chemical, the product containing a listed chemical must include a warning, unless the exposure level can be proven to not pose a significant risk of causing harm.

With the size of the California economy and the interconnected U.S. supply chain, the state law effectively reaches other states and U.S. importers. More recently, the Prop 65 requirements impact online and catalog sales, which have increased significantly during the global pandemic.

Know Your Suppliers

All companies need to proactively evaluate and document Prop 65 risks. Enforcement occurs primarily through civil litigation, resulting in specialized legal firms profiting from a company’s ignorance of the law’s extent. Even the threat of publicity from a lawsuit can cause targeted companies to settle a case.
At each point of manufacturing and distribution—supplier, manufacturer, packager, importer or distributor—regulatory teams should ask about Prop 65 compliance. The main point of responsibility is at the manufacturer, but a retailer can also be obligated for introducing a chemical at point-of-sale.

What’s New with Prop 65

The OEHHA issues notices regarding amendments to the California Code of Regulations Title 27, Article 6, covering “Clear and Reasonable Warnings”. Recently the OEHHA requested public comments on proposed amendments that would modify the content and methods for providing “short-form” warnings. The short form was originally intended for products with restricted label space.

The proposed rule would modify the existing short-form warning provisions to:

  • Only allow use of the short-form warning on products with five square inches or less of label space.
  • Eliminate use of short-form warnings for products sold via the Internet and catalogs.
  • Clarify how short-form warnings can be used for food products.
  • Require the name of at least one chemical be included in the short-form warning.

Bottomline: Know Your Business and Risk

As an advisor with more than 20 years of regulatory compliance experience in food and food ingredients, my guidance for business best practice on Prop 65 is to be proactive, maintain supply chain knowledge, and understand risk. Regulatory or legal staff, or consultant teams specializing in Prop 65, should regularly monitor for additions to the chemical list and rulemaking changes to the far-reaching law.

FDA

FDA’s ‘Closer to Zero’ Action Plan to Reduce Exposure to Toxic Elements in Baby Food

By Food Safety Tech Staff
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FDA

Following the report released by Congress in February regarding an alarming amount of toxic heavy metals found in baby food, the FDA has released an action plan that aims to reduce the presence of those dangerous metals to the “lowest possible levels” in common foods consumed by babies and young children. The “Closer to Zero” plan takes research, regulatory and outreach into consideration and will use the following approach:

  • Evaluating the scientific basis for action levels. FDA will evaluate existing data from routine testing of food, research and data on chemical analytical methods, toxicological assays, exposure and risk assessments, and other relevant scientific information.
  • Proposing action levels for specific toxic elements in baby food categories that include cereal, formula, and pureed fruits and vegetables.
  • Working with stakeholders and federal partners on proposed action levels— including collecting data and information from workshops and scientific meetings—and assessing the feasibility of the proposed action levels and timeframes for achieving them. The FDA will use and monitor the information to finalize the action levels.

“Our action plan will start with prioritizing our work on those elements for which we have the most data and information – arsenic and lead – while research continues on other elements, progressing through each element over time across various categories of foods consumed by babies and young children,” stated Janet Woodcock, M.D., acting FDA commissioner and Susan Mayne, Ph.D., director of CFSAN. “During the plan’s first year (phase one), we will be proposing action levels for lead in categories of foods consumed by babies and young children, consulting with and gathering data from stakeholders and federal partners on issues such as the feasibility of meeting action levels for lead, and sharing resources with industry on best practices for reducing or preventing lead contamination. We will also complete updated sampling assignments testing toxic element levels in baby foods and evaluate the science related to arsenic exposure from foods beyond infant rice cereal. Phases two, three and beyond are outlined in our plan.” Phase 2 runs from April 2022 until April 2024 and will expand the agency’s work into cadmium and mercury, as well as finalize action levels for lead. Phase three and beyond begins in April 2024 and will finalize action levels for arsenic.

Susanne Kuehne, Decernis
Food Fraud Quick Bites

Embrace Those Curves

By Susanne Kuehne
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Susanne Kuehne, Decernis
Near infrared spectroscopy
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

Lab methods for the analysis of adulterated food can be time-consuming, expensive and impossible to use in the field. A new study shows promising results for hand-held near infrared (NIR) spectroscopy tools. The investigated method proved to be very quick and highly accurate, and could open new possibilities for remote testing. This was shown in a study with oregano samples, a common target for food adulteration.

 

 

Resource

  1. Mc Grath, T.F., et al. (to be published on August 15, 2021) “The potential of handheld near infrared spectroscopy to detect food adulteration: Results of a global, multi-instrument inter-laboratory study”. Abstract. Science Direct.
Laura Gutierrez Becerra
Women in Food Safety

We Asked, You Answered: The Voice of Women In Food Safety

By Laura Gutierrez Becerra
1 Comment
Laura Gutierrez Becerra

In an effort to continue supporting female professionals contributing to the food safety industry and better understand their feelings and experiences while going through different stages in their career, we released our first survey in September 2020. The results will help us provide better resources to address the challenges and barriers reported from the survey.

Women in Food Safety
Figure 1. (click to enlarge)

The participation received from the leaders in food safety who completed the survey was significant. We were humbled and excited to notice that within a couple of weeks of launching the survey, 201 responses were received from 19 different countries. Although the survey was intended to assess the situations and experiences women are going through or have gone through, responses from their counterparts, male leaders, were also received. Ninety six percent of the responses are from females. (see Figure 1).

The key survey results were shared and discussed during the “We Asked, You Answered- The Voice of Women In Food Safety” panel session (view complimentary webinar recording) at the Food Safety Consortium Virtual Conference Series on November 5. The following are the insights we gained from the responses.

Position Levels Percentage (%)
Senior executive 14.9
Management 61.7
Administrative/Entry level 6.5
Other (Students) 1.5
Other (CEO) 0.5
Other (Research, consulting, auditor, trainer, regulatory) 14.9
Table 1. Responses by Position Levels

The survey participants hold positions at all professional levels and years within an organization. 61.7% of the total responses are linked to management levels, but only 14.9% are Senior Executive Level (see Table 1). Years of experience were broken down into five categories (see Table 2); 68.2% of the respondents had more than eight years of experience.

Years of Experience Percentage (%)
15+ 38.8
8–15 29.4
5–8 11.9
2–5 13.4
0–2 6.5
Table 2. Responses by Years of Experience

Well-rounded questions were provided in the survey, including situational inquiries, career advancement and the obstacles presented when entering the job market. In addition, opinion-based questions were formulated to understand how extensive networking is leveraged as a developmental and career advancement tool; it also addressed some of the expectations hiring managers have when hiring talent versus what the expectations professionals had when looking for their first jobs. Last but not least, a set of experience-based questions related to the encountered barriers found throughout the career journey, what is attributed to career success, the importance of diversity, and what are the career pivot points when life and career changes come up, were also presented.

With regards to preparedness after graduating from educational training and starting a first job, similar responses were provided between females and males. Women provided three different responses: 54.2% felt they were/are not adequately prepared; 40.6% feel were/are well-prepared; and 7.7% of women did not know their level of preparation; this can be attributed to no guidance received to better navigate the transition from school to the workforce and not being able to completion an educational degree (see Figure 2). Similar to women, 55.6% of men feel they were not adequately prepared; however, the remainder of male responses (44.4%) did not find any issues with the transition to their first job from school (See Figure 3).

Respondents weigh in on feeling adequate prepared when starting their first job after graduating from school. Respondents weigh in on feeling adequate prepared when starting their first job after graduating from school. Figure 4. Obstacles presented when entering the job market. Understanding the Importance of networking (female participants).
Figure 2 and 3. Respondents weigh in on feeling adequate prepared when starting their first job after graduating from school. (Click to enlarge all images) Figure 4. Obstacles presented when entering the job market. Figure 5. Understanding the Importance of networking (female participants).

The experience all participants shared regarding the obstacles presented when entering the job market revealed that, in general, 52.7% of the participants find a lack of connection with a company-experienced employee is the primary obstacle, 49.3% associate the obstacle to lack of connection to industry while attending school, and nearly 30% of participants indicate that they are lacking credentials to meet the job requirements (i.e., not having enough experience for required certifications). In this question, there two additional responses were reported: 15.4% of women did/do not know where to start and 4.5% did/do not know what qualifications the industry is looking for (See Figure 4).

The highlight between female and male responses for this question is the lack of credentials to meet the job requirements as an obstacle to a successful job initiation. In this case, a higher percentage of men (44%) reported this issue as an obstacle compared to the responses submitted by women (29%).

In terms of understanding the importance of networking, 76% of women confirm that they know how to master the skill of networking, but nearly 18% do not know how to start building their network. Additionally, there were a couple of responses from females confirming their understanding of the importance of networking; however, it is only to some extent and they have difficulty connecting with others due to the skill not coming naturally or having some limitations in terms of information sharing (see Figure 5). Only 1% of female responses reported not understanding exactly what a professional network is; whereas 100% of male respondents indicate no issues with understanding the important of networking.

When it comes to the topic of diversity and its importance within a company, 83.3% of female participants said diversity is important to them. Detailed responses are in Table 3.

Is Diversity within a Company Important to You?
11% Not important
9% Do not know
2% Do not know/Would not weigh diversity higher than finding the right candidate
Table 3. Percentages taken out of 192 female responses.

For females, significant career barriers did not fall under a single-specific category. The responses submitted identify 13 different barriers where work/life demands (41%), feeling of the glass ceiling (41%) and education/degree (5%) are found to have a greater concern among others, including students (see Figure 6.). Other barriers, such as soft skills, lack of support from management and lack of opportunity near family are categories that were mostly reported from women holding management level positions (see Figure 7.)

Figure 6. Most significant career barriers.
Figure 6. The most significant career barriers. Figure 7. The most significant career barrier among all level positions among female participants.

In the case of men, work/life demands are recognized as the career barrier of most concern among senior executives (56%). In addition , only other two reasons are reported as barriers: The feeling of a glass ceiling (reported by senior executive level and administrative/entry level) and diversity (reported by management level position) (see Figure 8).

Figure 8. Most significant career barriers among male participants. Figure 9. Career success attribution as defined by female participants. Figure 10. Career success attribution as defined by participants. Figure 11. Life and career changing concerns among female participants.
Figure 8. Most significant career barriers among male participants. Figure 9. Career success attribution as defined by female participants. Figure 10. Career success attribution as defined by participants. Figure 11. Life and career changing concerns among female participants.

Regarding the contributors to career success, self-learning/motivation is the leading category. This is followed by job experience and working with a mentor (see Figures 9 and 10). The main difference between women and men regarding their career success is educational degree, and being persistent and having patience. In this case, female responses outlined that being persistent and having patience is a success factor.

Life and career changes cause stress and disharmony in a person’s life, requiring a modification in job performance and handling of personal responsibility. The concern between men and women differs considerably. While men are more concerned about job reassignments/promotions, extensive traveling, and relocation; women reported they have 11 additional reasons to be concerned. Motherhood or taking care of dependents are the leading issues. (see Figure 11).

The survey also included inputs on what programs would better support the integration of work and life harmony within an organization. Flexible time/working location is found as the primary need from female responses in all position levels. Then, flexible/unlimited personal time off is the second identified need submitted in their responses. In addition, women in management level positions were the demographic responding to all four provided responses. This was contrary to senior executive women who found flexible time/working location as the only category to better support work integration and life harmony (see Figure 12). In the case of men, only two responses provide insight as to their need for support; 88.9% of them would like to have more flexible time/working location and 11.1% consider being part of the workload allocation process beneficial.

From all responses received, about 90% have felt stuck at least once in their position throughout their career or job. Females in management level positions with working experience of eight years or more lead the number of responses (see Figure 13). There is a higher percentage of males (22%) who have not felt stuck in their career compared to the response submitted by females (10%). Male senior executives with more than 15 years of experience have the higher number of responses (see Figure 14).

Figure 12. Better support for the integration of work and life harmony within an organization (female participants). Figure 13. Felt stuck at least once in their position throughout their career/job (female participants). Figure 14. Felt stuck at least once in their position throughout their career/job (male participants).
Figure 12. Better support for the integration of work and life harmony within an organization (female participants). Figure 13. Felt stuck at least once in their position throughout their career/job (female participants). Figure 14. Felt stuck at least once in their position throughout their career/job (male participants).

The survey also included ranking questions to understand what the expectations were/are among the participants related to their first job. Table 4 outlines the five expectations the participants chose from when answering this question, highlighting that 183 out of 201 participants place opportunities to grow at the highest level of importance. Social networking rated the lowest (81 out of 201) in importance among the total responses received.In term of gender-specific answers, both women and men identified opportunities to grow as the expectation with highest level of importance. For women, the expectation with lowest level of importance is social networking; for men, competitive salaries, and opportunities to use what you learned from school are the not-so important expectations (see Figures 15, 16, 17 and 18).

Figure 15. Importance of expectation on the first job (female participants). Figure 16. Opportunities to grow (female participants). Figure 17. Figure 18.
Figure 15. Importance of expectation on the first job (female participants). Figure 16. Opportunities to grow (female participants). Figure 17 and 18. Male participants

The expectation from participants regarding what is the level of importance when hiring new graduate employees highlights “complete the tasks as instructed” as the highest expectation among the 201 participants and experience through internships as the lowest level of importance (see Table 5).

In addition to the five options for answers, women also included three additional expectations:

  • Understanding of company culture and when is a good time to look for a new opportunity
  • Ability to solve problems, analytical thinking and get results independently
  • Learning mindset

Conclusions

Responses from 19 different countries were received from the survey with 96% being from females. Among all position levels provided their inputs, but the largest participation was from women holding management level positions (62%). With regards to the categories on years of experience, those with more than 15 years of experience had the higher percentage of participation (39%), but only 15% were senior executives.

Some key preliminary outcomes are reported as follows:

  • Self-learning and motivation are two leading drivers for career success.
  • Work/life demands and feeling of a glass ceiling are identified as the main career barrier among women and men. Educational degree is a reported concern specific to women and diversity is specific to men.
  • There are no significant differences between females and males regarding not feeling adequately prepared when starting the first job (52.4% – female; 55.6% – male).
  • 52.7% of all participants find a lack of connection with a company-experienced employee as the main obstacle when entering the job market. Lack of credentials is a significant obstacle for males (44.4%) vs. females (29.2%).
  • 100% of male responses said they mastered the skill of networking vs. 76% from female responses.
  • There are no significant differences between females and males regarding not having any issues when transitioning to their first job after graduating from school (41% – female; 44% – male). However, 7.7% of women do not know if they were/are prepared.
  • Flexible time/working location named as the primary need as people believe it would better to support integration of work and life harmony among all position levels.
  • 90% of participants felt stuck at least once in their position throughout their career or job. A higher percentage of men (22%) confirmed not feeling stuck in their career compared with the responses submitted by women (10%).
  • All responses identified opportunities to grow as the expectation with highest level of importance when first starting a career. For females, the expectation with lowest level of importance is social networking. For men, competitive salaries and opportunities to use what they learned in school are not important expectations.
  • The expectation among the 201 participants on what is important when hiring newly graduated employee report completing the tasks as instructed as the highest expectation and placed experience through internships as the lowest level of importance.
Dollar

Quantifying the ROI of Environmental Monitoring Program Automation

By Joseph Heinzelmann
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Dollar

The COVID-19 pandemic heightened the urgency for food brands to adopt technology solutions that support remote management of environmental monitoring programs (EMPs) as they strive to provide safe products to customers. While digital transformation has progressed within the food safety industry, food and beverage manufacturers often have lower profitability as compared to other manufacturing industries, such as pharmaceutical and high-tech equipment, which can lead to smaller IT spend.1 Many companies still rely on manual processes for environmental monitoring and reporting, which are prone to error, fail to provide organizations with visibility into all of their facilities and limit the ability to quickly take corrective actions.

Despite growing recognition of the value of automating testing, diagnostics, corrective actions and analytic workflows to prevent contamination issues in food production environments, barriers to adoption persist. One key obstacle is the recurring mindset that food safety is a necessary compliance cost. Instead, we need to recognize that EMP workflow automation can create real business value. While the downside of food safety issues is easy to quantify, organizations still struggle to understand the upside, such as positive contributions to productivity and a stronger bottom-line achieved by automating certain food safety processes.

To understand how organizations are using workflow automation and analytics to drive quantifiable business ROI, a two-year study that included interviews and anonymized data collection with food safety, operations, and executive leadership at 34 food organizations was conducted.

The respondents represent more than 120 facilities using advanced EMP workflow automation and analytics. Based on the interviews and the shared experience of food organization leaders, two key examples emerged that demonstrate the ROI of EMP automation.

Improved Production Performance

According to those interviewed, one of the primary benefits of EMP automation (and driver of ROI) is minimizing production disruptions. A temporary conveyor shutdown, unplanned cleaning, or extensive investigatory testing can add up to an astounding 500 hours annually at a multi-facility organization, and cost on average $20,000 to $30,000 per hour.2 So, it’s obvious that eliminating costly disruptions and downtime has a direct impact on ROI from this perspective.

But organizations with systems where information collected through the EMP is highly accessible have another advantage. They are able to take corrective actions to reduce production impacts very quickly. In some cases, even before a disruption happens.
By automatically feeding EMP data into an analytics program, organizations can rapidly detect the root cause of issues and implement corrective actions BEFORE issues cause production delays or shutdowns.

In one example, over the course of several months, a large dairy company with manual EMP processes automated its food safety workflows, improved efficiencies, reduced pathogen positives and improved its bottom line. At the start of the study, the company increased systematic pathogen testing schedules to identify where issues existed and understand the effectiveness of current sanitation efforts. With improved access to data on testing, test types and correlated sanitation procedures, the company was able to implement a revamped remediation program with more effective corrective action steps.

Ultimately, the automated workflows and analytics led to reduced positive results and more efficient EMP operations for the company as compared to the “crisis-mode” approach of the past. The associated costs of waste, rework, delayed production starts, and downtime caused by food safety issues were significantly reduced as illustrated in Figure 1.

EMP automation
Figure 1: Reduction of food safety testing costs through EMP automation. Customer Study 2016-2018. All figures courtesy of Corvium, Inc.

Quantifying the ROI of Production Performance Improvements

The financial impact of reducing production downtime by just 90 minutes per week can be dramatic when looked at by cumulative results over multiple weeks. In fact, eliminating just a few delayed starts or unplanned re-cleaning can have significant financial gains.

Figure 2 shows the business impact of gaining 90 minutes of production up-time per week by automating food safety operations. For the purposes of this analysis, the “sample organization” depicted operates two facilities where there are assumptions that down-time equates to a cost value of $30,000 per hour, and that both plants experience an average of 90 minutes of downtime per week that can be re-gained.

Production Performance Improvement ROI Calculation
Figure 2: Sample Production Performance Improvement ROI Calculation.

Reduced Food Waste

The second key insight uncovered in the two-year study was the impact that automating the EMP process had on waste. An estimated 30–40% of all food produced in the United States is wasted, and preventable food safety and quality issues account for a substantial portion of this waste.3

A key challenge shared by study participants was detecting food safety issues early enough to avoid wasting an entire production run. Clearly, the later in a processing or manufacturing run that issues are discovered, the greater the potential waste. To limit this, organizations needed near real-time visibility into relevant food safety and EMP data.

By automating EMP workflows, they solved this issue and created value. By tracking and analyzing data in near real time, production teams were able to keep up with ever-moving production schedules. They could define rules to trigger the system to automatically analyze diagnostic results data and alert stakeholders to outliers. Impacted food product could be quickly identified and quarantined when needed before an entire production run was wasted.

Companies included in the study realized substantial benefits from the increased efficiencies in their testing program. According to a food safety quality assurance manager at a large U.S. protein manufacturer, “Our environmental monitoring program has reached new heights in terms of accuracy, communication, visibility and efficiency. Manual, time-intensive tasks have been automated and optimized, such as the ability to search individual sample or submittal IDs, locate them quickly and make any necessary changes.”

Quantifying the ROI of Food Waste Reductions

Figure 3 shows how measuring the business impact of gaining back just 10% of scrapped food per week. For the purposes of this analysis, the “sample organization” depicted operates two facilities where there are 500 lbs. of finished product scrapped each week, and the value per pound of finished product is valued at a cost of $1 per pound.

Sample Waste Reduction ROI Calculation
Figure 3. Sample Waste Reduction ROI Calculation.

Conclusion

Automating EMP workflows decreases the time required to receive and analyze critical EMP data, helping food manufacturers achieve significant improvements in production performance, waste reduction and overall testing efficiency. By using these same ROI calculations, food brands can better illustrate how improved food safety processes can build value, and help leaders see food safety as a brand imperative rather than a cost center. As food organizations progress through each stage of digital transformation, studies like this can show real-world examples of business challenges and how other organizations uncovered value in adoption of new technologies and tools.

References

  1. CSIMarket, Inc. (2021). Total Market Profitability.
  2. Senkbeil, T. (2014). Built to Last: Maintaining Reliability and Uptime of Critical Connected Systems in Industrial Settings. Anixter.
  3. USDA. Food Waste FAQs.
FDA

FDA Publishes Report on Fall 2020 E. Coli Outbreak in Leafy Greens

By Food Safety Tech Staff
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FDA

Today the FDA released a report on its investigation into the E. coli O157:H7 outbreak involving leafy greens during the Fall 2020. The report also identified three reoccurring trends in the contamination of leafy greens grown in the Central Coast of California related to the outbreak strain, region and issues with activities on adjacent land.

In January, FDA released preliminary findings, which linked cattle feces to the outbreak strain—located uphill from where contaminated leafy greens were grown.

“In the investigation, the FDA recommends that growers of leafy greens in the California Central Coast Growing Region consider this reoccurring E. coli strain a reasonably foreseeable hazard, and specifically of concern in the South Monterey County area of the Salinas Valley,” stated Frank Yiannas, deputy commissioner for food policy and response, in an agency news release. “It is important to note that farms covered by the Food Safety Modernization Act (FSMA) Produce Safety Rule are required to implement science and risk-based preventive measures in the rule, which includes practices that prevent the introduction of known or reasonably foreseeable hazards into or onto produce.”

The 2021 Food Safety Consortium Virtual Conference Series kicks off on May 6 with a keynote address from Frank Yiannas, deputy commissioner of food policy and response at FDA The FDA also recommends that the region’s agricultural community work to determine where the reoccurring strain of the pathogenic E. coli is persisting, along with the probable contamination route(s).

“Although the FDA is keenly focused on taking steps to help mitigate recurring leafy green contamination events, we alone cannot fix this issue. Industry leadership and collaboration among growers, processors, retailers, state partners and the broader agricultural community is critical to reducing foodborne illnesses,” Yiannas stated. “At the FDA, the safety of leafy greens remains a top priority, and we are committed to working with all stakeholders to address this significant public health issue and further protect consumers.”

The Report, “Factors Potentially Contributing to the Contamination of Leafy Greens Implicated in the Fall 2020 Outbreak of E. coli O157:H7”, can be downloaded from FDA’s website.

Susanne Kuehne, Decernis
Food Fraud Quick Bites

Olive Oil Detectives in the Lab

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

Canola oil, sunflower oil or soybean oil, colorants and low-quality olive oil, anyone? Olive oil, especially extra virgin olive oil adulteration is rampant, since the risk of getting caught is low and the profits are huge. A new expert-reviewed Laboratory Guidance Document on olive oil, published by the Botanical Adulterants Prevention Program (BAPP), lists a variety of laboratory methods at different levels of complexity, as well as the most common methods of adulteration. This Laboratory Guidance Document is an indispensable guide for regulatory and research personnel in the food, supplement and cosmetics industries.

Resource

  1. Mailer, R.J. and Gafner, S. (March 2021). “Botanical Adulterants Prevention Program Publishes Olive Oil Laboratory Guidance Document”. Botanical Adulterant Prevention Program.
Roberto Bellavia, Kestrel
FST Soapbox

How Integrated Compliance Management Systems Maximize Efficiency

By Roberto Bellavia
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Roberto Bellavia, Kestrel

Managing the complexities of a management system is challenging for any food and beverage company, particularly for the team tasked with implementing the system throughout the organization. That is because every regulatory agency (e.g., FDA, USDA, OSHA, EPA) and voluntary certification (e.g., GFSI-benchmarked standards, gluten-free, organic, ISO) calls for companies to fulfill compliance requirements—many of which overlap. Supply chain and internal requirements can create further complications and confusion.

In today’s “New Era of Smarter Food Safety,” having a common system to organize, manage and track compliance offers an ideal solution. Dynamic tools are becoming available—systems that can manage employee training, pest control, laboratory testing, supply chain management tools, regulatory compliance and certification requirements, etc.

Unfortunately, these systems are often not set up to “talk” to each other, leaving company representatives to navigate many systems, databases, folders, and documents housed in many different locations.

The Solution: Compliance Management Systems

An integrated compliance management system (CMS) is intended to bring all these tools together to create one system that effectively manages compliance requirements, enables staff to carry out daily tasks and manage operations, and supports operational decision making by tracking and trending data that is collected daily by the team charged with implementation.

A CMS is used to coordinate, organize, control, analyze and visualize information to help organizations remain in compliance and operate efficiently. A successful CMS thinks beyond just access to documents; it manages the processes, knowledge and work that is critical to helping identify and control business risks. That may include the following:

  • Ensuring only authorized employees can access the right information.
  • Consolidating documents and records in a centralized location to provide easy access
  • Setting up formal business practices, processes and procedures
  • Implementing compliance and certification programs
  • Monitoring and measuring performance
  • Supporting continuous improvements
  • Documenting decisions and how they are made
  • Capturing institutional knowledge and transferring that into a sustainable system
  • Using task management and tracking tools to understand how people are doing their work
  • Enabling data trending and predictive analytics

CMS Case Study: Boston Sword and Tuna

In early 2019, Boston Sword and Tuna (BST) began the process of achieving SQF food safety certification. We initially started working with BST on the development, training and implementation of the program requirements to the SQF code for certification—including developing guidance documents for a new site under construction.

The process of attaining SQF certification included the development of a register of SQF requirements in Microsoft SharePoint, which has since evolved into a more comprehensive approach to overall data and compliance management. “We didn’t plan to build a paperless food safety management system,” explains BST President Larry Dore, “until we implemented our SQF food safety management program and realized that we needed a better way to manage data.”

We worked with BST to structure the company’s SharePoint CMS according to existing BST food safety management processes to support its certification requirements and overall food safety management program. This has included developing a number of modules/tools to support ongoing compliance efforts and providing online/remote training in the management of the site and a paperless data collection module.

The BST CMS has been designed to support daily task activities with reminders and specific workflows that ensure proper records verifications are carried out as required. The system houses tools and forms, standards/regulatory registers, and calendars for tracking action items, including the following:

  • Ambient Temperature
  • Corrective and Preventive Action (CAPA)
  • Chemical Inventory/Safety Data Sheets (SDS)
  • Compliance Management
  • Customer Complaints
  • Document Control
  • Employee Health Check
  • Food Safety Meetings Management Program
  • Forklift Inspections
  • Good Manufacturing Practices (GMP) Audit
  • SQF Register
  • Maintenance (requests/work orders/assets/repairs)
  • Nightly Cleaning Inspections
  • Operational/Pre-Operational Inspections
  • Sanitation Pre-Op Inspections
  • Scale Calibration
  • Sharp/Knife Inspections
  • Shipping/Receiving Logs
  • Thawing Temperature Log
  • Thermometer Calibration

Key Considerations for Designing a Successful CMS

An effective CMS requires an understanding of technology, operational needs, regulatory compliance obligations and certification requirements, as well as the bigger picture of the company’s overall strategy. There are several key considerations that can help ensure companies end up with the right CMS and efficiency tools to provide an integrated system that supports the organization for the long term.

Before design can even begin, it is important to first determine where you are starting by conducting an inventory of existing systems. This includes not only identifying how you are currently managing your compliance and certification requirements, but also assessing how well those current systems (or parts of them) are working for the organization.

As with many projects, design should begin with the end in mind. What are the business drivers that are guiding your system? What are the outcomes you want to achieve through your system (e.g., create efficiencies, provide remote access, reduce duplication of effort, produce real-time reports, respond to regulatory requirements, foster teamwork and communication)? Assuming that managing compliance and certification requirements is a fundamental objective of the CMS, having a solid understanding of those requirements is key to building the system. These requirements should be documented so they can be built into the CMS for efficient tracking and management.

While you may not build everything from the start, defining the ultimate desired end state will allow for development to proceed so every module is aligned under the CMS. Understand that building a CMS is a process, and different organizations will be comfortable with different paces and budgets. Establish priorities (i.e., the most important items on your list), schedule and budget. Doing so will allow you to determine whether to tackle the full system at once or develop one module at a time. For many, it makes sense to start with existing processes that work well and transition those first. Priorities should be set based on ease of implementation, compliance risk, business improvement and value to the company.

Finally, the CMS will not work well without getting the right people involved—and that can include many different people at various points in the process (e.g., end user entering data in the plant, management reviewing reports and metrics, system administrator, office staff). The system should be designed to reflect the daily routines of those employees who will be using it. Modules should build off existing routines, tasks, and activities to create familiarity and encourage adoption. A truly user-friendly system will be something that meets the needs of all parties.

Driving Value and Compliance Efficiency

When thoughtfully designed, a CMS can provide significant value by creating compliance efficiencies that improve the company’s ability to create consistent and reliable compliance performance. “Our system is allowing us to actually use data analytics for decision making and continuous opportunity,” said Dore. “Plus, it is making remote activities much more practical and efficient”.

For BST, the CMS also:

  • Provides central management of inspection schedules, forms, and other requirements.
  • Increases productivity through reductions in prep time and redundant/manual data entry.
  • Improves data access/availability for reporting and planning purposes.
  • Effectively monitors operational activities to ensure compliance and certifications standards are met.
  • Allows data to be submitted directly and immediately into SharePoint so it can be reviewed, analyzed, etc. in real time.
  • Creates workflow and process automation, including automated notifications to allow for real-time improvements.
  • Allows follow-up actions to be assigned and sent to those who need them.

All these things work together to help the company reduce compliance risk, create efficiencies, provide operational flexibility, and generate business improvement and value.