Tag Archives: Focus Article

FDA

FDA Responds to Subcommittee Report on Toxic Metals in Baby Food

By Food Safety Tech Staff
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FDA

Following a report released nearly two weeks ago about the potential danger posed by toxic heavy metals found in baby foods manufactured by several major companies, FDA has issued a response. The report, “Baby Foods Are Tainted with Dangerous Levels of Arsenic, Lead, Cadmium, and Mercury”, was released by the U.S. House of Representatives Committee on Oversight and Reform Subcommittee on Economic and Consumer Policy on February 4. The Subcommittee stated that FDA should require baby food manufacturers to test their finished products for toxic heavy metals and require any toxic heavy metals be reported on food labeling. It also stated that FDA should set maximum levels of toxic heavy metals allowed in baby foods.

“The FDA has been actively working on this issue using a risk-based approach to prioritize and target the agency’s efforts. Consumers should know that FDA scientists routinely monitor levels of toxic elements in baby foods, along with other foods consumed in the country’s diet, through the Total Diet Study,” the agency stated in a CFSAN update. “Further, the FDA also monitors baby food under the FDA’s compliance program for Toxic Elements in Food and Foodware, and Radionuclides in Food and through targeted sampling assignments.”

FDA cited its work in sampling infant rice cereal for arsenic, which it says has resulted in safer products on the market, along with its recent court order to stop a U.S. company from distributing adulterated juice that had potentially harmful levels of inorganic arsenic and patulin (a mycotoxin).

The CFSAN update, however, did not specifically address the companies or baby foods called out in the Subcommittee’s report.

Stephen Dombroski, QAD
FST Soapbox

The Drive to Sustainable Food Manufacturing Begins with Three Critical Factors

By Stephen Dombroski
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Stephen Dombroski, QAD

Sustainability, without question, is one of the hottest social and political topics today. It is as complex as it is simple. Sustainability gets discussed in almost every walk of life, but in the world of food manufacturing, there are few subjects more debated than this one. It is a contentious subject because in the manufacturing arena, it is not just a social or political issue, it is a financial issue—a big financial issue. Sustainability and related issues around it are critical factors and components that are now impacting the bottom lines of food manufacturers. The impact is seen in terms of both red and black.

In a low-margin business like food manufacturing, profits are at a premium and even a minor disruption can negatively impact those profits. Adapting to all the issues that are involved in and around sustainability is, without question, a disruption for manufacturers. At the same time, manufacturers can make positive impacts through smart operational decision-making, which is where sustainability has the greatest presence. When sustainability is discussed in regards to food and beverage manufacturing, a number of topics surface. Some topics are discussed individually and some are grouped together. Consumer preferences, new foods, and packaging are three such areas. At first glance, you might ask why they are lumped together. They are lumped together because they are actually very closely related. Let’s explore those connections especially as they relate to finances.

Consumer Preferences: Paving the Sustainable Path

Consumer preferences have always been one of the leading factors determining what food and beverage manufacturers produce and send to market. For generations, countless amounts of time and money have been spent on trying to predict what consumers want and when they want it. A tremendous amount of data is painstakingly analyzed by manufacturers trying to figure out the consumer’s next move.

According to a 2018 Global Web Index survey, half of digital consumers say environmental concerns influence their purchasing decisions. Millennials—sometimes named the Green Generation—and Generation Z lead the way. About 61% of millennials and 58% of Gen Z’ers say they would pay more for eco-friendly products. Green consumers want brands to embrace purpose and sustainability, and they want their purchases to contribute to the greater good, or at least, do no harm.

These preferences started among millennials and Gen Z’ers, but with the influence of social media, they have expanded to all age groups. This expansion has contributed greatly to a change in what consumers purchase and to what manufacturers produce. In recent years, consumers have changed their eating habits in terms of what they eat, how they eat and when they eat, and those changes have impacted both food service and retail food producers. They have largely centered on healthier foods, pure ingredients and products that promote an eco-friendly culture and a sustainable world. The changes have been felt up and down manufacturing organizations, but most importantly they are reflected in the bottom line.

The industry has been forced to introduce healthier products, with more ethically sourced ingredients and more transparent supply chains. Younger consumers, especially, often trace a brand’s sustainability record with QR codes or smart labels. They want to know where their food originates. They don’t just want to know in which state the potato used in their organic baked potato crisp was grown. They want to know the county, town, farm, field and names of the people who picked it so they can connect with them on Facebook to determine if they practice safe hygiene principles! If a product doesn’t fit the consumers’ predetermined sustainable criteria, they buy a product from another manufacturer. Talk about an impact to profits. The consumer focus on sustainability has increased competition and costs, forced organizational changes and made food manufacturers figure out what processes and systems need to be in place to ensure their decisions keep consumers happy and their profits on the right side of the ledger. These consumer actions and attitudes are now influencing the development of new food items as manufacturers realize consumers are not just taking notice but taking actions as well.

New Foods: Where’s the Beef? Not Here!

As consumers change their food preferences for health and sustainability reasons, food and beverage producers have the opportunity, responsibility and if they want to survive, the mandate to develop new food products built on a reputation for sustainability. Brands have been working on protein alternatives for some time, but not until Burger King and McDonald’s introduced plant-based burgers did plant-based protein go “viral” so to speak. Talk about “Where’s the beef?” In addition to meeting the needs of the drive for sustainable foods, food manufacturers are developing plant-based proteins and many new foods to support the healthier lifestyle movement. As consumers embrace Keto diets, veganism, vegetarianism and other new eating and living practices, tofu, soybeans, seeds, nuts, legumes and other vegetable-based products are now being routinely used as replacements for protein, carbohydrate-heavy flours and food foundation bases.

Ten years ago, if I said in 2021 we would be eating pizza with a crust made of cauliflower, what would the public reaction have been? People in Chicago would have thrown away their deep-dish pans. Food manufacturers now introduce new products on a weekly basis and it is having a tremendous impact on sales and bottom lines. These rapid introductions also impact other key areas of the organization including supply chain, product development cycle and manufacturing cost infrastructure.

Substituting vegetables for carbohydrate-rich grains, of course, costs money. It can increase material costs, manufacturing costs, warehousing costs and distribution costs, which combine to raise retail prices. Luckily, as we have illustrated, consumers are willing to pay more for products that they perceive as having a sustainable footprint. Utilizing products differently to respond to the push for sustainability is a smart tactic that can expand the value chain, open up new markets and drive sales for food and beverage manufacturers.

Packaging Sells Products and Sustainability

Sustainable packaging can mean many things. It can mean packaging made with 100% recycled or raw materials, packaging with a minimized carbon footprint due to a streamlined production process or supply chain, or packaging that is recycled or reused. There is also biodegradable packaging like containers made from cornstarch being used for takeout meals.

For generations, packaging has had a tremendous influence on what consumers buy. Human beings are visual creatures. They are drawn to things that have visual and physical characteristics that appeal to the senses. How many products in the marketplace are known for a certain shape or color configuration? Many times, these shapes or colors can only be created using certain glass, plastic or other materials that might not meet the sustainable criteria. This has caused problems for manufacturers as consumers still want those products but are conflicted if their sustainable beliefs are compromised. Adapting new eco-friendly materials while retaining generations of packaging history and nostalgia can increase costs. But, to keep their customers, manufacturers make these changes, absorb the extra costs and try to make up for lost profits in other ways.

Packaging, especially smart packaging, can also help fight the battle against food waste. Packaging companies are creating and producing intelligent packaging for food products that have built-in sensors and monitors to determine when a product will lose its nutritional value or spoil. Smart labels are being used in conjunction with new packaging materials to monitor external factors that can influence product freshness. Packaging can be a driving force to reaching the goal of sustainability.

Adapting to changing consumer preferences, demand for new foods and new packaging materials and designs is critical for manufacturers trying to reach sustainable goals. Consumer preferences drive what manufacturers produce. Consumer preferences drive the development of new foods that consumers think they need in order to live a healthier lifestyle. Packaging is the wrapper that keeps the new foods fresh and catches the consumer’s eye, which in turn drives sales and thus drives profits. These three critical areas can be the foundation of the sustainable movement and manufacturing’s response to it. Food producers must embrace the sustainable movement if they want to stay in business. To meet this challenge, manufacturers of packaging and food need to evaluate their processes and systems and implement the ones that can help them cost-effectively transition to becoming sustainable manufacturers.

FDA

FDA Begins Phase Two of Artificial Intelligence Imported Seafood Pilot Program

By Food Safety Tech Staff
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FDA

FDA is beginning phase two of its Artificial Intelligence Imported Seafood Pilot Program. The program, which is expected to run from February 1 through July 31, intends to improve FDA’s response in quickly and efficiently identifying potentially harmful imported seafood products.

Phase one of the pilot looked at using machine learning to find violative seafood shipments. “The pilot program will help the agency not only gain valuable experience with new powerful AI-enabled technology but also add to the tools used to determine compliance with regulatory requirements and speed up detection of public health threats,” FDA stated in a news release. “Following completion of the pilot, FDA will communicate on our findings to promote transparency and facilitate dialogue on how new and emerging technologies can be harnessed to solve complex public health challenges.”

The pilot program is part of the agency’s efforts that fall under the New Era of Smarter Food Safety.

Select Subcommittee on the Coronavirus Crisis

OSHA, Tyson, Smithfield and JBS Under Investigation for COVID Outbreaks

By Food Safety Tech Staff
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Select Subcommittee on the Coronavirus Crisis

Last week U.S. Congressman and chairman of the Select Subcommittee on the Coronavirus Crisis James E. Clyburn (D-SC) launched an investigation into OSHA, Tyson Foods, Smithfield Foods and JBS USA over the nationwide coronavirus outbreaks at meatpacking plants that have led to the deaths of at least 270 employees. Nearly 54,000 workers at 569 U.S. meatpacking plants have tested positive for COVID-19, according to the Subcommittee and media reports.

Select Subcommittee on the Coronavirus Crisis“Public reports indicate that under the Trump Administration, the Occupational Safety and Health Administration (OSHA) failed to adequately carry out its responsibility for enforcing worker safety laws at meatpacking plants across the country, resulting in preventable infections and deaths. It is imperative that the previous Administration’s shortcomings are swiftly identified and rectified to save lives in the months before coronavirus vaccinations are available for all Americans,” the letter to James Frederick, deputy assistant secretary of labor for OSHA stated. “The Select Subcommittee strongly encourages you to take all necessary steps, including under President Biden’s Executive Order on Protecting Worker Health and Safety1and your other existing statutory authorities, to protect workers from the risks of the coronavirus by issuing clear guidance to employers, enacting an emergency temporary standard, and enhancing enforcement efforts.”

Clyburn and the Subcommittee issued a letter to Dean Banks, president and CEO of Tyson Foods, Dennis Organ, president and CEO of Smithfield Foods, and Andre Nogueira, president and CEO of JBS USA. Each letter pointed out the shortcomings of each company in adequately addressing the outbreaks that occurred among its workers.

“Public reports indicate that meatpacking companies … have refused to take basic precautions to protect their workers, many of whom earn extremely low wages and lack adequate paid leave, and have shown a callous disregard for workers’ health,” Clyburn stated in the letter. “These actions appear to have resulted in thousands of meatpacking workers getting infected with the virus and hundreds dying. Outbreaks at meatpacking plants have also spread to surrounding communities, killing many more Americans.”

The Subcommittee has asked OSHA and each company for documentation related to the COVID infections and deaths, as well as their enforcement of worker protections under the Trump administration.

Jason Chester, InfinityQS
FST Soapbox

Resilience for Tomorrow Begins with Digital Transformation Today

By Jason Chester
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Jason Chester, InfinityQS

COVID-19 has been a sharp wake-up call for many food manufacturers in the need for resilient production environments that can readily respond to large and sudden changes, including fluctuations in demand and disruptive external events. This means being able to optimize operations for the following:

  • Efficiency: Where you can achieve constant output even when given fewer inputs—such as in workforce availability or resources. This was especially important when the pandemic caused widespread supply shortages, as well as staffing shortages due to social distancing measures.
  • Productivity: When you can ensure that, given the amount of available input (i.e., raw ingredients, manpower, equipment availability), you can maintain a consistent output to meet demand in the marketplace.
  • Flexibility: Where you can rapidly and intelligently adapt your processes in the face of change, in ways that are in the best interest of your business, the supply chain, and the consumers who purchase and trust in your products.

That trust is paramount, as manufacturers must continue to uphold quality and safety standards—especially during a time when public health is of the upmost importance. But between operational challenges and managing product quality, that’s a lot for manufacturers to wade through during a crisis.

To navigate the current COVID reality and improve response to future events, more organizations are looking to harness the power of data to enable agile decision-making and, in turn, build more resilient production environments.

Harnessing the Power of Data

The key to harnessing data for agile decisions is to aggregate end-to-end process information and make it available in real time. When you can achieve that, it’s possible to run analytics and derive timely insights into every facet of production. Those insights can be used to increase efficiency, productivity and flexibility—as well as ensure product quality and safety—even amidst upheaval.

When looking at solutions to aggregate data from a single site—or better yet, multiple sites—all roads lead to the cloud. Namely, cloud-based quality intelligence solutions can decouple the data from physical locations—such as paper checklists, forms, or supervisory control and data acquisition (SCADA) and human-machine interfaces (HMI) systems—and centralize what’s collected digitally in a unified repository. The data can then be accessed, analyzed, and consumed by those who need actionable insights from anywhere, at any time, and on any device, making cloud an ideal solution for connecting on-site operators and remote employees.

Digital transformation
When process and quality data are centralized and standardized on the cloud, they can be leveraged for real-time monitoring and timely response to issues—from anywhere and at any time. (Image courtesy of InfinityQS)

An Opportunity for Broader Transformation

In migrating to the cloud, manufacturers open the opportunity to break away from the legacy, manual processes of yesterday and transition to more nimble, digitally enabled environments of tomorrow. For example, manual processes are often highly dependent on individual operator knowledge, experience and judgement. As the pandemic has shown, such institutional knowledge can be lost when employees become ill, or are unavailable due to self-isolation or travel restrictions, presenting a risk to operational efficiency and productivity. But if that valuable institutional knowledge were captured and codified in a quality intelligence solution as predefined workflows and prescriptive instructions, then a manufacturer could more easily move their resources and personnel around as necessary and find comfort knowing that processes will be executed according to best practices.

For many organizations, this would be a remarkable transformation in the ways of working, where data and digital technologies can augment human capacity and flexibility. Take for instance, in traditional production environments, a lot of human effort is spent on monitoring lines to catch process deviations or events like machine anomalies or quality issues. Using real-time data, next-generation solutions can take on that burden and continuously monitor what’s happening on the plant floor—only alerting relevant teams when an issue arises and they need to intervene. Manufacturers can thereby redeploy people to other tasks, while minimizing the amount of resources necessary to manage product quality and safety during daily production and in the event of disruption.

Ensuring Quality Upstream and Downstream

One company that has succeeded in digital transformation is King & Prince, a manufacturer of breaded, battered and seasoned seafood. When the company digitized its manufacturing processes, it centralized the quality data from all points of origin in a single database. The resulting real-time visibility enables King & Prince to monitor quality on more than 100 processes across three U.S. plants, as well as throughout a widespread network of global suppliers.

With this type of real-time visibility, a company can work with suppliers to correct any quality issues before raw materials are shipped to the United States, which directly translates to a better final product. This insight also helps plant-based procurement managers determine which suppliers to use. Within its own plants, operators receive alerts during production if there are any variations in the data that may indicate inconsistencies. They can thereby stop the process, make necessary adjustments, and use the data again to confirm when everything is back on track.

During finished product inspections, the company can also review the captured data to determine if they need to finetune any processes upstream and respond sooner to prevent issues from making it downstream to the consumer level. Overall, the company is able to better uphold its quality and safety standards, with the number of customer complaints regarding its seafood products dropping to less than one per million pounds sold year over year—and that’s all thanks to the harnessing of data in a digitally enabled production environment.

There’s No Time Like the Present

In truth, technologies like the cloud and quality intelligence solutions, and even the concept of digital transformation, aren’t new. They’ve been on many company agendas for some time, but just haven’t been a high priority. But when the pandemic hit, organizations were suddenly faced with the vulnerabilities of their long-held operational processes and legacy technologies. Now, with the urgency surrounding the need for resilient production environments, these same companies are thinking about how to tactically achieve digital transformation in the span of a few weeks or months rather than years.

Yet while digital transformation may sound like a tremendous initiative with high risks and expenses, it’s more tangible than some may think. For example, cloud-based Software-as-a-Service (SaaS) solutions offer flexible subscription-based models that keep costs low on top of rapid scalability. Digital transformation doesn’t have to be an all-or-nothing endeavor either. In fact, it can be better to progress incrementally, starting first with the manufacturing areas that are most in need or have the most issues. This minimizes unnecessary risk, makes digital transformation more achievable and realistic over short timeframes, and avoids overwhelming already maxed out operational and IT teams.

All things must pass. The pandemic will eventually be over. But in its wake will be a permanent legacy on not just society, but also on the manufacturing sector. In my opinion, digital transformation is a fundamental basis for building resilience into the modern food production environment. Now, more than ever, is the time to address that opportunity head on.

U.S. House of Representatives Seap

House Subcommittee Releases Report on Dangerous Levels of Toxic Heavy Metals in Baby Food

By Food Safety Tech Staff
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U.S. House of Representatives Seap

Last week a report released by Congress cited dangerous levels of toxic heavy metals in several brands of baby food. Back in November 2019, the Subcommittee on Economic and Consumer Policy asked for internal documents and test results from baby food manufacturers Nurture, Inc. (Happy Family Organics), Beech-Nut Nutrition Company, Hain Celestial Group, Inc., Gerber, Campbell Soup Company, Walmart, Inc., and Sprout Foods. According to the staff report, Nurture, Beech-Nut, Hain and Gerber responded to the requests, while Walmart, Campbell and Sprout Organic Foods did not.

The findings indicate that significant levels of arsenic, lead, cadmium and mercury were found in the baby foods of the four manufacturers who responded to the Subcommittee’s requests (Nurture, Beech-Nut, Hain and Gerber). It also stated the alarming point that, “Internal company standards permit dangerously high levels of toxic heavy metals, and documents revealed that the manufacturers have often sold foods that exceeded those levels.”

The Subcommittee voiced “grave concerns” that the baby food made by Walmart, Sprout Organic Foods and Campbell was “obscuring the presence of even higher levels of toxic heavy metals in their baby food products than their competitors’ products” due to their lack of cooperation.

In addition, the report states that the Trump administration “ignored a secret industry presentation to federal regulators revealing increased risks of toxic heavy metals in baby foods” in August 2019.

“To this day, baby foods containing toxic heavy metals bear no label or warning to parents. Manufacturers are free to test only ingredients, or, for the vast majority of baby foods, to conduct no testing at all,” the report stated (infant rice cereal is the only baby food held to a stringent standard regarding the presence of inorganic arsenic).

As a result of the findings, the Subcommittee has made several recommendations:

  • FDA should require baby food manufacturers to test their finished products for toxic heavy metals.
  • FDA should require manufacturers to report toxic heavy metals on food labels.
  • Manufacturers should find substitutes for ingredients that are high in toxic heavy metals or phase out the ingredients that are high in toxic heavy metals.
  • FDA should set maximum levels of toxic heavy metals allowed in baby foods.
  • Parents should avoid baby foods that contain ingredients that test high in toxic heavy metals.

The 59-page report, “Baby Foods Are Tainted with Dangerous Levels of Arsenic, Lead, Cadmium, and Mercury”, is available on the U.S. House of Representatives’ website.

FDA

FDA to Test Yuma-Grown Romaine Lettuce for E. Coli and Salmonella

By Food Safety Tech Staff
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FDA

Today the FDA announced a new plan to collect samples of romaine lettuce as part of its ongoing surveillance after the spring 2018 multistate outbreak of E. coli O157:H7. The samples, which will be tested for Shiga toxin-producing Escherichia coli (STEC) and Salmonella, will be collected from commercial coolers in Yuma County, Arizona during the current harvest season.

FDA plans to collect and test about 500 samples (each of which will consist of 10 subsamples), beginning in February and continuing through the end of the harvest season. In order to reduce the time between sample collection and reporting results, an independent lab close to the collection sites in Arizona will be testing the samples. FDA expects to receive test results within 24 hours.

“Helping to ensure the safety of leafy greens continues to be a priority of the FDA. This assignment adds to other work underway in collaboration with stakeholders in the Yuma agricultural region to implement actions identified in the Leafy Greens Action Plan, including a multi-year study to assess the environmental factors that impact the presence of foodborne pathogens in this region. Consistent with the action plan, the agency will engage with industry on conducting root cause analyses for any positive samples found during this assignment. Root cause analyses are important in that they seek to identify potential sources and routes of contamination, inform what preventive measures are needed, and help prevent outbreaks of foodborne illness,” FDA stated in a release.

COVID-19 precautions will be taken during the sampling plan. Agency investigators will preannounce visits and wear PPE while conducting the work.

2021 Food Safety Consortium

2021 Food Safety Consortium Virtual Conference Spring and Fall Series Announced

By Food Safety Tech Staff
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2021 Food Safety Consortium

Over the past 9 years, the Food Safety Consortium Conference & Expo has built a reputation for delivering perspectives and insights from the most knowledgeable and influential experts in food safety. As a result of the COVID-19 pandemic, last year’s event was converted from an in-person event into a 14-week series of virtual themed-episodes during the fall. Continuing the momentum from 2020, the 2021 Food Safety Consortium Virtual Conference Series will take place as a four-week Spring and five-week Fall program. Both the Spring and Fall programs will feature critical thinking topics that are for industry veterans and knowledgeable newcomers.

“As you know, the online experience is very different than in-person, so last year we deconstructed our in-person program and re-engineered it for virtual. Instead of having a virtual conference for three straight days, we set up our program in short 2.5-hour themed episodes that ran every Thursday in the fall. We received great feedback from attendees, speakers and sponsors. I think we were one of the few conferences that successfully pulled off the pivot to virtual,” says Rick Biros, president of Innovative Publishing and director of the Food Safety Consortium.

Building on the strong success of the 2020 Food Safety Virtual Conference Series, the 2021 Consortium will be presented into two seasonal programs. “This will allow us to continue the conversation throughout the year, while also taking into consideration the busy lives of food safety professionals,” Biros adds.

Food Safety Tech is the media sponsor and will feature exclusive content from the event.

Read the Top 10 from the 2020 Food Safety Consortium Virtual Conference Series

The Spring Program will run every Thursday in May, with each episode starting at 12 pm ET. The weekly episodes will tackle a range of critical topics in foods safety, including FSMA and traceability, food protection strategies, COVID-19’s lasting impact on the food industry by segment, audits and supply chain management. Frank Yiannas, FDA deputy commissioner for food policy and response, is the confirmed keynote speaker for Thursday, May 6.

The Fall Program will run every Thursday beginning on October 7 at 12 pm ET through November 4. Episode topics include food safety hazards (emerging threats and new technologies), food defense strategies, an FDA update, and personal development, training and mentorship.

Registration for the 2021 Food Safety Consortium Spring and Fall Virtual Conference Series is open now.

TechTalk Sponsorship

Companies that are interested in sponsoring a 10-minute technical presentation during the series can contact Sales Director RJ Palermo for more details.

About Food Safety Tech

Food Safety Tech is a digital media community for food industry professionals interested in food safety and quality. We inform, educate and connect food manufacturers and processors, retail & food service, food laboratories, growers, suppliers and vendors, and regulatory agencies with original, in-depth features and reports, curated industry news and user-contributed content, and live and virtual events that offer knowledge, perspectives, strategies and resources to facilitate an environment that fosters safer food for consumers.

Since 2012, Food Safety Tech audiences have learned to respect and expect our high-quality content—via FoodSafetyTech.com, our weekly newsletter and by attending our educational programs. Food Safety Tech keeps professionals current with the latest information about technology, best practices and regulations, and how innovative solutions and approaches can be leveraged to further advance food safety across the globe.

About the Food Safety Consortium Conference

The Food Safety Consortium is an educational and networking event for Food Protection that has food safety, food integrity and food defense as the foundation of the educational content of the program. With a unique focus on science, technology and compliance, the “Consortium” enables attendees to engage in sessions that are critical for advancing careers and organizations alike. Over the past 9 years the Food Safety Consortium has built a reputation for delivering the most knowledgeable and influential perspectives in food safety. The speaker line-up has driven key food safety decision-makers to the event (both in-person and virtually)—facilitating an environment for vendors, suppliers, food industry professionals, and consultants to network and build long-lasting business relationships.

Due to COVID-19, the 2020 Food Safety Consortium was converted to a virtual conference series that featured specific topics in a weekly episode series. The 2021 Food Safety Consortium Virtual Conference Series will feature a Spring and Fall program, running in May and October, respectively.

Judy Black, Orkin
Bug Bytes

Food Safety Audits During a Pandemic: What You Should Know and How to Prepare

By Judy Black
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Judy Black, Orkin

The coronavirus pandemic has impacted the food industry on several fronts from production to consumer purchasing habits to in-restaurant dining adjustments. While facility operations might look different, the demand for product is certainly still high, so operations should be tighter than ever.

Unfortunately, pest activity has not slowed down during the pandemic. From rodents and cockroaches to stored product pests and birds, your facility is susceptible to pest disruptions. With shipments coming and going and limited staffing, it’s also highly likely you don’t have time to prioritize your pest management program. An unchecked, contaminated shipment leaving your facility and making it into the homes of consumers is all it takes to wreak havoc on your business.

Food processing, pest management
Your goal, and the goal of your pest control partner, should be that your facility is ready for an audit at any time. (Image courtesy of Orkin)

If you already have an integrated pest management (IPM) program in place, you’re heading in the right direction with securing your facility. IPM programs help food processing facilities keep pests from entering and destroying your product by applying preventive measures such as identifying potential and existing sanitation opportunities and regularly evaluating the state of facility maintenance.

The last thing you need right now is a failed audit due to preventable pest issues. Failing a first, second or third-party audit can lead to many consequences such as a damaged reputation, reduced profits and worst of all, lost customers. With most regulators resuming on-site audits, offering remote options or a hybrid of the two, ensuring your facility stays within regulations is still possible, and highly encouraged. After all, pest control plays a significant role in all major food safety audits and can account for up to 20% of your score.

Food Safety Audits during the Pandemic and New Changes

Not only do facility managers have to regulate operations during a pandemic, but they also must maintain strict food safety standards to ensure that the food supply chain stays healthy. With the arrival of COVID-19 vaccines, there is some hope that the pandemic may be under control soon, but it is not over yet, and food safety audits should not be avoided because of a pandemic. To accommodate, many auditors implemented new measures such as remote and hybrid audits for food processing facilities, in addition to on-site audits.

If your facility is still unable to conduct on-site audits at this time, special accommodations can be made. The following auditors have made updates to their food safety audits amid the pandemic:

  • BRCGS: In addition to blended audits, BRCGS is offering certificate extensions for up to six months with a risk assessment and review. Although not benchmarked by GFSI, remote assessments are also available and involve a video audit of your facility’s storage and production areas in additional to reviewing internal audit results and documentation.
  • SQFI: SQFI is postponing certifications for extenuating circumstances and implemented additional processes for risk assessments. Certifying bodies will have to conduct risk assessments to determine whether a certificate extension is needed.
  • FDA: After temporarily suspending all facility inspections last March, the FDA has resumed domestic inspections on a case-by-case basis when safe to execute. Foreign inspections have not yet resumed so, take extra care if your facility regularly receives foreign shipments.
  • FSIS: Inspections of meat, poultry and egg facilities continued through the pandemic. These regulated facilities continue to require sanitation SOPs to help maintain food safety and prevent the spread of diseases.

Whether your facility is able to resume onsite audits or needs to switch to a remote or hybrid option, pests will still be trying to take advantage. Working with your pest control provider to ensure your documentation and pest management measures are in order is one of the best ways to ensure any audit or risk assessment goes smoothly. While each auditor has specific requirements, here are some key considerations for your next third-party inspection.

Implement an IPM Program

We cannot stress enough the importance of a proactive pest management program for food processing facilities. The best way to reduce pest issues is to build them out. Your pest control partner will identify and communicate to you on ways to reduce, or in some cases even eliminate food, water and harborage for pests. Ensure your contract specifies the roles and responsibilities of your pest control partner and you, the scope of service and a risk assessment plan. If you’re unsure of what your contract entails, now is the time to get in touch with your pest control partner.

Invest in Your Employees

Train your staff to spot and record signs of pest activity so you can address them immediately with your pest control partner. This is particularly important if you had to adjust employee schedules during the pandemic to enforce proper social distancing. Fewer staff means fewer opportunities to spot pest issues, so making sure all employees are trained can help you in the long run.

Keep Up with Documentation

Your documentation is an integral part of your audit process because it shows third-party auditors that you can verify that you have an effective pest management plan in place. Three types of documents are needed for your audit: Proof of training and certification, pesticide documentation and general facility documentation. Most pest control providers now maintain digital documentation for their partners which makes it easier to track and monitor for pest trends, treatments and updates to your plan. Even with a proper pest management program in place, facilities can still lose points for not having proper documentation so don’t overlook this part.

Hold Practice Runs

A good pest control partner will encourage test audits to ensure you’re prepared for the real deal. An annual assessment is one of the best ways to make sure your pest management program is still working and to address any gaps if it isn’t. Don’t forget to review your documentation during test audits in addition to joining your pest control partner for a physical inspection of your facility (socially distanced, of course).

Prepare your Facility

Your goal, and the goal of your pest control partner, should be that your facility is ready for an audit at any time. However, if you have an upcoming scheduled audit, a week before your audit, work with your pest control partner to conduct interior and exterior inspections as well as a documents review. Make sure you are familiar with how to access your customer web portal so that you can access data if requested. During these inspections, make sure any monitoring devices meet auditor requirements and are properly placed and maintained. The day before your audit, make another run through the facility to be sure your facility is ready. You don’t want your auditor finding cobwebs in your storage room or debris showing up in the background of a video audit.

Food safety should be a top priority for your business—your reputation depends on it after all. As the food industry continues to navigate operating in a post-pandemic climate, maintaining a successful pest management program and updated records will give you a head start when it comes to audits no matter the format. With public health concerns at an all-time high, consumers and suppliers alike will be grateful for your increased attention to maintaining industry regulations.

FDA

FDA Issues Update on E. Coli Outbreak Involving Leafy Greens

By Food Safety Tech Staff
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FDA

FDA has completed its investigation of the multistate outbreak of E. coli 0151:H7 that occurred last fall and was linked to leafy greens. The FDA and CDC found the outbreak was caused by an E. coli strain that was genetically related to the strain found in the fall 2019 outbreak involving romaine lettuce (Salinas, California). Despite conducting environmental sampling at dozens of ranches in the area, the FDA was unable to identify a single site as the source of the outbreak. However, the analysis did confirm “a positive match to the outbreak strain in a sample of cattle feces,” which was located uphill from where the leafy greens identified in the agency’s traceback investigation were grown, according to an FDA release.

Although the FDA’s investigation has ended, the agency will be reviewing the findings and release a report in the “near future” with recommendations. “In the meantime, as recommended in our Leafy Greens Action Plan, the FDA continues to recommend growers assess and mitigate risk associated with adjacent and nearby land use practices, particularly as it relates to the presence of livestock, which are a persistent reservoir of E. coli O157:H7 and other STEC,” FDA stated in the update.