Tag Archives: Focus Article

Rick Williams, JPG Resources
FST Soapbox

COVID-19: The Impact on 2020 and Beyond

By Rick Williams
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Rick Williams, JPG Resources

COVID-19 has had a major impact on the food and beverage industry this year, contributing to everything from bare shelves and supply chain issues to changes in consumer behavior to plant shutdowns, and to historic grocery cost spikes. We continue to experience changes every day, along with challenges that must be overcome. Lessons from the last year can prepare us for the years ahead, but only if we learn to adapt and anticipate.

Nearly all parts of the supply chain have been impacted, from raw material sourcing and packaging shortages to manufacturing plant shutdowns to logistics capacity to bricks and mortar store operations to consumers. At the onset of the pandemic, major industry trade shows were cancelled and postponed, along with demos and in-person sales meetings, leaving the future of shelf resets with a dark cloud hanging above them. Staying in touch virtually with buyers and providing updates proved to be a best practice and will continue into 2021.

To keep things running smoothly on the manufacturing side, assets from some logistics providers were redeployed to where they were needed most, and with consumers dining more from home, the industry saw a huge move from food service to retail, which we will touch on a bit later. Moving into 2021, brands should ensure their raw materials and supply inventories, especially those that are imported, can cover any potential and unforeseen disruptions. It is critical to prepare well in advance of shortages or surges, specifically in at-risk chains.

Despite the attempts to mitigate against shortages, even the most well-known brands faced major out-of-stock issues and consumers turned to alternative, smaller brands. The shortages came from an increase in pressure from consumers stocking up on items, not from a lack of supply as many believed. Manufacturers increased hours and scheduled capacity on production lines to maximize efficiencies to keep up until things returned to normal. When possible, production lines were reconfigured to distance operators and shifts staggered to limit contact between teams. Senators even introduced the Food Supply Protection Act to help strengthen the chain, protect workers and reduce waste, as per the United States Senate Committee on Agriculture, Nutrition and Forestry. Despite these efforts to keep shelves stocked, the unprecedented time presented smaller brands the opportunity to gain new loyal customers. The transition to e-commerce became an avenue for increased exposure for brands and continues to prove to be a vital option to explore if they have not already.

The retail sector made major headlines this year. In an effort to avoid crowds and follow stay-at-home orders, many consumers began shifting their purchasing behaviors. With today’s technology, it has been easier than ever to shop via e-commerce platforms, whether grocery pickup, delivery or takeout. We experienced temporary out-of-stocks at brick-and-mortar stores and increased wait times on deliveries due to fulfillment shortages. Consumer reaction to these changes—including stocking up on staple products such as paper towels and toilet paper—caused spikes in grocery costs. April saw the largest monthly increase in food at home indexes since February 1974, according to the U.S. Bureau of Labor Statistics.

Food service has not been exempt from the impact of 2020. With less dining out and more eating at home, restaurants, bars, college cafeterias and stadiums have had to adapt with major shifts in business operations, traffic and income, and practically hit a standstill. In September, the National Restaurant Association reported that nearly one in six restaurants, or about 100,000 nationwide had closed permanently due to the pandemic. Restaurant management had to amend all aspects of operations, including their takeout procedures and other established programs.

In order to survive, restaurants have been creative, building welcoming and distanced environments, and delivering new services to diners. The use of technology will play an even bigger role, now more than ever, to limit touch points. QR codes for menus and contactless ordering and payment options will become the new norm for establishments, if they have not already. Going into 2021, some restaurants are even revamping menus and finding ways to turn them into CPG products, a new trend that is sure to take off in the new year. In April Shake Shack announced a ShackBurger Kit, complete with all the ingredients necessary to cook the chain’s signature burgers using the same ingredients as the dine-in experience, but from the comfort of home. More recently, in November, Chipotle introduced its first digital-only restaurant, which will handle only pickup and delivery orders. Many local restaurants have adopted new best practices to serve their patrons and stay in business. When in-person dining was suspended in the spring, one of our favorite neighborhood restaurants began offering takeout for the first time. Initially, they required patrons to come in the restaurant to sign their ticket and pick up their order. They evolved into a totally online ordering and payment process, including tip, and masked touchless curbside pickup. They have continued this even as in-person dining resumed. We can expect to see more tactics like these, loyalty programs and digitized experiences in the coming year.

It is impossible to be certain what 2021 will bring, but what we do know is that it will require proactive planning and preparation. Learning from 2020 will play a pivotal role in survival for some brands, companies and establishments, and mitigating against breaks in the supply chain until we return to a sense of normalcy. The good news is the food supply chain has proven to be very robust and resilient. How we react to changes in the next few months is critical to maintaining a strong and secure supply chain to ensure we continue smooth operations.

Stephen Dombroski, QAD
FST Soapbox

Combating Climate Change in the Food Industry Through Regenerative Agriculture

By Stephen Dombroski
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Stephen Dombroski, QAD

Everybody has to eat. That is the mantra of many companies involved in the food and beverage industry. It sounds so simple. Yet, in recent years, especially this one, it is becoming more challenging than we ever thought it could be. Disruptions from the beginning to the end of the food supply chain are making the task of feeding the masses more difficult. The COVID-19 pandemic has made people in all walks of life question the food supply chain. It is being evaluated in new ways with the goal of ensuring that there is food available in not just crisis times but in normal circumstances, too, as the population continues to grow and more disruptions interrupt the supply chain. Climate change is one disruption that is impacting the food and beverage industry and is possibly the biggest threat to overall food sustainability. When people think about climate change they only think about weather events and global warming, but if you look at the definition of “climate,” other issues need to be considered in addition to looking out the window and checking the thermometer.

Global warming, greenhouse gases, carbon emissions, the earth’s normal evolution and consumer behaviors can all contribute to climate change. Everyone talks about limiting greenhouse gases and carbon emissions but is it really happening? Almost every day, some government agency or industrial company announces policy changes touting the drive to 100% sustainable packaging by this year and that year. “Company X announced today that it will use fully-sustainable packaging by 2035.” Fully sustainable packaging; what does that even mean? And 2035, what’s the hurry?! There are other programs in the works, but the question is, are they quick fixes that are really just Band-Aids on a gunshot wound? Are they actually long-term solutions and are they happening fast enough? The adoption of electric vehicles could have a huge impact on our climate but it is just a small piece of the solution for total carbon emission elimination. Water to be used in non-farming consumption is getting harder to come by due to climate change. Land space is eroding and available farm space is decreasing. The process of raising and harvesting livestock is getting more complex and costly, making plant-based substitution options more attractive. But is that really a long-term solution if we are already running out of traditional farming space? Consumers hope that recycling will help combat the problem but it is barely making a dent and their changing food habits impact the climate as well. The earth itself is constantly going through a geological evolution in spite of what we humans do to the planet.

Global warming is accelerating climate change and causing a number of serious issues. The earth’s poles are warming, which is promoting permafrost, causing glaciers to melt and oceans to rise, which is impacting sea levels, irrigation methods and land temperatures that promote erosion. Higher than average temperatures can potentially impact the growing of certain crops in terms of yields and even where they are grown. Climate change is impacting all areas of agriculture, the environment and the total ecosystem. Insect behaviors are evolving and these changes affect crops. The food manufacturing and farming industries have realized that a “new way” needs to be implemented to grow food in environments that can combat these changes.

Sustainability initiatives call for practices that maintain or improve soil conservation and improve the overall health of soil. Two processes, regenerative agriculture and precision agriculture, working in conjunction, may actually provide a long-term solution by combining environmental and farm science with technology. Regenerative agriculture goes beyond soil conservation. It is a process that looks to reverse the effects of climate change. The regenerative process focuses on restoring soil health, solving water issues, reversing carbon cycles, and creating new topsoils and growing environments.

Precision agriculture focuses on increasing the land used for farming as well as increasing the productivity of that land. It utilizes newly available IoT devices like GPS services, guidance systems, mapping tools and variable rate technologies (VRT) to optimize crop yields. These new management systems collect data that transmit valuable metrics to farmers. Every aspect of farming, from planting to harvesting, can benefit from these emerging technologies. The information about the moisture of soil, for example, is sent to a computer, which then identifies signs of health or stress. Based on these signals, farmers can provide water, pesticide or fertilizer in adequate dosages. As a result, precision farming can help conserve resources and produce healthier crops.

Climate-smart agriculture, which is an approach to dealing with the new realities of climate change, is another smart agricultural method. Climate-smart agriculture improves agricultural systems by enhancing sustainability, which leads to improved food security. Food production has struggled to keep up with erratic weather patterns and natural resources have been stretched alarmingly thin, signaling a call for action. With this new approach, crop yields can adapt accordingly and productivity will increase.

The regenerative food system market has drawn a great deal of interest from investment groups. Initial investments have focused on water and soil reconstitution and development. Restoring soil strength reduces water usage and at the same time produces stronger and more available food sources. Underground and hydroponic versions of regenerative agriculture are also emerging.

Advanced technologies like these are making their way into the food, beverage and agriculture industries. Traditional agricultural methods are being replaced with climate-smart methods. Peripheral areas like streamlining the supply chain and optimizing manufacturing operations can receive “sustainable” benefits from these new agri-methods. The good news is that smart agricultural methods are making progress in counteracting climate change and revolutionizing farming worldwide.

Regenerative and precision agriculture are without question the leading processes and philosophies being used today to help all food industries combat climate change and other disruptors to the total food supply chain. These new technologies will continue to efficiently solve farming practices. In addition, there will be rollover benefits to food processors and manufacturers who will now have improved access to data. This will enable better communication, and improved traceability at all levels of the supply chain and throughout operations, distribution and procurement. This data will allow all involved in growing and producing food to communicate better and enable society to adapt to these changes.

Food Safety Consortium

2020 FSC Episode 14 Preview: The Future of Food Safety

By Food Safety Tech Staff
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Food Safety Consortium

For those who have been with us every week since September 3—Congratulations on making it through 13 weeks of engaging and highly educational content! This week wraps up the final episode of the 2020 Food Safety Consortium Virtual Conference Series, and we are offering complimentary registration to the entire industry for the event on Thursday, December 17.

The following are highlights for this week’s session:

  • GFSI at 20 Years: Time for a Reboot? With Karil Kochenderfer, LINKAGES; Neil Marshall, The Coca-Cola Company; and Skip Greenway, Eagle Certification Group
    • “For a long time, we’ve operated businesses based on 20th century models that don’t resonate in the 21st century world. Are we at an inflection point, with both small and large businesses paying for costly and inefficient practices that no longer apply, and is it time for GFSI to change?” says Kochenderfer in her recent Food Safety Tech column on the topic.
  • Future Proofing the GFSI Ecosystem, with Erica Sheward, The Consumer Goods Forum; Kazuaki Miyagishima, GFSI Board retailer member; and Marie-Claude Quentin, GFSI
    • “GFSI looks forward to answering direct questions from participants, as taking the pulse of those within and beyond our community is an essential part of GFSI’s work, and something we have committed to do increasingly through our Stakeholder Engagement Plan. The need – and the vision of safe food for consumers everywhere – remains as vital and relevant today as it was when GFSI was founded 20 years ago,” says Erica Sheward GFSI Director, The Consumer Goods Forum.
  • The Future of Food Safety Technology, with Darin Detwiler, Northeastern University; Jennifer Crandall, Safe Food En Route, LLC; and Adam Gauthier, Northeaster University.
  • Consortium “Take Aways” Panel Discussion, with Rick Biros, Food Safety Consortium; Steven Sklare, The Food Safety Academy; Maria Fontanazza, Food Safety Tech, and Shawn Stevens, Food Industry Counsel, LLC.

The event begins this Thursday at 12 pm ET. Haven’t registered? Follow this link to receive free registration to the 2020 Food Safety Consortium Virtual Conference Series. We look forward to your joining us virtually.

Susanne Kuehne, Decernis
Food Fraud Quick Bites

The Magic of Making Olive Oil without Olives

By Susanne Kuehne
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Susanne Kuehne, Decernis
Find records of fraud such as those discussed in this column and more in the Food Fraud Database. Image credit: Susanne Kuehne

Food forgery cases keep raising great concerns about consumers’ health and safety all over the world. The Ministry of Agriculture, Livestock and Supply in Brazil prohibited sales of nine brands of fake olive oil. A criminal organization sold soybean oil as extra virgin olive oil under fictitious labels. All oils sold under these brands are being pulled from the market and destroyed. Several Brazilian agencies were working together on this case, including the Consumer Protection Police (Decon).

Resource

  1. Ministério da Agricultura, Pecuária e Abastecimento (November 17, 2020) “Proibida a comercialização de nove marcas de azeite de oliva”. Governo do Brasil.

 

Tyson Foods

Tyson Foods Names First Chief Medical Officer

By Food Safety Tech Staff
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Tyson Foods

Yesterday Tyson Foods, Inc. announced that it is appointing Claudia Coplein, M.D. to the newly created position of chief medical officer at the company. Effective January 4, this role has been established to help the company promote a “culture of health, safety and wellness at Tyson”. Coplein will supervise the launch of Marathon Health clinics, which will be piloted at seven of Tyson’s facilities (in Texas, Arkansas, Iowa, Kansas, Nebraska, North Carolina and Tennessee) and are intended for both team members as well as their families early next year. The clinics will provide healthcare at no cost in most instances.

Tyson Foods has invested $540 million this year to establish protective measures such as walk-through temperature scanners, workstation barriers and testing services. The company has also hired 200 nurses and administrative staff to add to its occupational health staff, which now totals nearly 600 employees.

Mitzi Baum, Stop Foodborne Illness
Food Safety Culture Club

Partnerships in Promoting Prevention (of Foodborne Illness)

By Mitzi Baum
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Mitzi Baum, Stop Foodborne Illness

At Stop Foodborne Illness, or STOP, we know about collaborative partnerships. For more than 26 years, affiliating with like-minded organizations to prevent foodborne disease is the mainstay of our success and continues to provide beneficial results today.

The mission to prevent illness and death due to contaminated food resonates with our allies and aligns with their goals to coordinate and expand efforts. At any given moment, STOP is working with a diverse spectrum of individuals and industries to move the needle on foodborne illness prevention. Today, STOP’s work is focused on constituent services and food safety policy with the overarching goal of public health. Below are examples of current collaborative projects that are uniquely effective.

Alliance to Stop Foodborne Illness

The Alliance to Stop Foodborne Illness (Alliance) is an initiative of STOP, leading food companies, and other organizations committed to the goal of preventing foodborne illness. For 25 years, Stop Foodborne Illness has communicated the compelling personal stories of people and families who have experienced serious foodborne illness or the death of loved ones. The goals of communicating these personal stories are to make clear why food safety must be a central value of the food system and to help motivate people in both the food industry and government to do their best every day to reduce hazards and prevent illness. Through the Alliance, STOP and leading food companies are collaborating to expand the reach and impact of personal stories to strengthen food safety cultures and prevent foodborne illness.

The Alliance to Stop Foodborne Illness has a mission to:

  • Forge partnerships between STOP and leading food companies to build trust and support strong food safety cultures.
  • Collaboratively design and implement innovative, well-tailored programs that make compelling personal stories an integral motivational element of food safety culture and training programs.
  • Expand the reach and impact of personal stories through outreach to the small- and medium-size companies that are key contributors to modern supply chains.

Current Alliance members: Costco, Cargill, Conagra Brands, Coca-Cola, Yum! Brands, Nestle USA, LGMA, Empirical Foods, Maple Leaf Foods, Mars, Walmart, Wegmans, and Amazon.

Constituent/Advocate Engagement

Working with those who have been impacted by severe foodborne illness is base to our prevention work. We engage our constituent/advocates in many projects and continually seek additional opportunities.

  • STOP’s new website houses a navigational map for anyone who is in crisis, post-crisis or managing the long-term consequences of surviving severe foodborne disease. This structured, informational composition was created by constituent/advocates that are sharing their lived experiences. This incisive work provides incredible insight into the journey that may lie ahead and how to manage the potential labyrinth.
  • With our partner, Center for Science in the Public Interest, we have created a national platform for survivors of salmonellosis and campylobacteriosis to speak about their experiences surviving these diseases.
  • The Alliance has created multiple working partnerships with individual constituent/advocates.
  • STOP’s speaker’s bureau provides opportunities for our constituent/advocates to share their personal stories with large groups in person or virtually.
  • A recent college graduate who is a constituent/advocate is leading the creation of a new program for the organization.

Dave Theno Fellowship

Dave Theno Fellowship is a partnership with Michigan State University (MSU) that provides a recent public health, food science, animal science or political science graduate (undergraduate or graduate degree) the opportunity to conduct two distinct research projects, engage in STOP programming, participate on coalition calls and earn a certificate in food safety from MSU.

STOP is working with MSU to create a new course for its Online Food Safety Program that focuses on food safety failures and the impact of those system breakdowns on consumers.

Early Detection of Foodborne Illness Research

In conjunction with North Carolina State University, Michigan State University, Eastern Carolina University and University of Michigan, STOP is engaging in research to identify gaps in knowledge and application of the 2017 Infectious Disease Society of America Clinical Practice Guidelines of the Diagnosis and Management of Infectious Diarrhea (IDSA) for healthcare workers. Our early findings have identified that most healthcare workers do not know about nor follow the IDSA guidelines, which include reporting of cases of infectious diarrhea and identification of the pathogen for identification and prevention of potential widespread outbreaks.

To support this research, STOP is completing a systematic literature review with the intent to publish.

Recall Modernization Working Group

STOP has been convening a group of experts comprised of individuals from academia, Alliance members, external industry partners, food industry associations, public health organizations, and industry consultants to deep dive into food recalls to define the current landscape, discuss systemic changes necessary for expedient and efficient execution of recalls for both industry and consumers and develop recommendations on how to accomplish those changes.

Everyone is susceptible to foodborne illness; thus, we need a varied, coordinated approach. Each of these partnerships helps our colleagues meet their goals while promoting prevention of foodborne illness by straddling both industry and consumer focused work. Executing our mission takes many forms and that requires diversity in partnerships, a shared vision and tangible, sustainable results.

Food Safety Consortium

2020 FSC Episode 13 Preview: Traceability in Supply Chain Management

By Food Safety Tech Staff
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Food Safety Consortium

This week’s episode of the 2020 Food Safety Consortium Virtual Conference Series will explore traceability as it pertains to supply chain management. The following are highlights for Thursday’s session:

  • Food Safety Recalls – Digging Deeper into FDA, CDC, USDA & Food Industry Data, with Allen Sayler, EAS Consulting
  • Preparing for Blockchain in “A New Era of Smarter Food Safety”, with Kathy Barbeire, CAT Squared
  • The Road to Traceability is Paved with Standards, with Lucelena Angarita, IPC/Subway and Liz Serti, GS1 US
  • TechTalk from Controlant

The event begins at 12 pm ET on Thursday, December 10. Haven’t registered? Follow this link to the 2020 Food Safety Consortium Virtual Conference Series, which provides access to all the episodes featuring critical industry insights from leading subject matter experts! We look forward to your joining us virtually.

James Davis, OSI Group
FST Soapbox

Applying Food Plant Sanitation Best Practices to Facility Janitorial Programs

By James T. Davis
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James Davis, OSI Group

The COVID-19 pandemic propelled food processors to scrutinize various aspects of their existing employee hygiene and environmental safety programs in an effort to protect facility workers’ health. Implementation of measures such as social distancing, illness screening, workspace barriers, additional personal protective equipment (PPE) and enhanced cleaning measures have aided the industry in reducing employee sickness and unplanned shutdowns.1 Of these actions, effective cleaning protocols in non-production areas, under the scope of facility janitorial programs, have been brought to heightened attention as a critical preventative measure for surface contamination of SARS-CoV-2.1 Through incorporation of the fundamental principles of sanitation programs utilized for food production zones, processors can elevate the effectiveness of their janitorial cleaning programs in non-production areas.

Scope of Janitorial Program

Food processing facilities should evaluate, using a risk-based assessment, all non-production areas that employees occupy on a routine basis, for inclusion into the janitorial cleaning program. Examples of areas that are routinely subject to high employee traffic and regular congregation include, but are not limited to, locker rooms, restrooms, break rooms, cafeterias, hallways, conference rooms and offices.

Additionally, specific surfaces within each of the identified non-production areas for inclusion into the program should also be evaluated in the risk-based assessment. Surfaces within these identified areas that are frequently touched, and present a greater likelihood of contamination to employees, would be considered higher-risk, and thus, command more focus during routine janitorial cleaning activities. Examples of such surfaces may include the following: Door handles, tables, desks, chairs, toilet and faucet handles, vending machines, phones, computers and other electronic devices.

Janitorial Best-Practice Examples

Sanitation Standard Operating Procedures
Sanitation standard operating procedures (SSOPs), or written cleaning instructions, should be developed for all janitorial cleaning tasks of selected employee and welfare areas, in a similar manner as those for production area equipment and infrastructure. These documents should contain pertinent information to effectively perform the desired janitorial tasks, such as the following: The individual(s) responsible for the task, appropriate chemicals, personal protective equipment (PPE) and other safety measures, frequency of cleaning, steps of cleaning execution and verification measures.

Chemical Selection & Use
Selection of chemicals for cleaning of employee and welfare areas is critically important in ensuring biological agents are effectively removed from surfaces during janitorial activities. Much like in production areas, the facility janitorial cleaning program should utilize an appropriate detergent suitable for removing residual surface soils as a base of the program. Inadequate removal of soils, such as grease or food debris in break rooms, will inhibit the effective removal of adverse biological agents.2 Additionally, the program should include an application of sanitizer or disinfectant to the target surface effective in neutralizing SARS-CoV-2.3

Cleaning Process & Frequency
An effective cleaning process for routine janitorial tasks can be modeled after the established Seven Steps of Sanitation commonly utilized in food production zones.4 Typical steps in this process applicable for janitorial cleaning should include: area preparation and dry cleaning, wiping surfaces with fresh water, application and wiping with detergent, removal of detergent with fresh water wiping, inspection verification activities and application of sanitizer or disinfectant to target surfaces for required dwell time (subsequent wiping of chemical after dwell time may be required). The frequency of cleaning and additional sanitizing activities should be validated and take into consideration times of employees breaks, level of non-production area occupancy and extent of employee contact with higher-risk surfaces. Additionally, individuals who performed the required cleaning tasks should ensure appropriate PPE is worn, not only to protect from chemicals utilized, but from biological agents that may be present on surfaces.

Master Sanitation Schedule
A master sanitation schedule, or MSS, encompassing janitorial cleaning activities that occur on a non-daily basis should be maintained either separately, or included in an existing sanitation schedule.

Sanitation, misting
Misting frequently touched surfaces with an additional disinfectant chemical approved to inactivate SARS-Cov-2. Image courtesy of OSI Group.

Examples of non-routine janitorial tasks may include:

  • Emptying and cleaning of personnel storage lockers
  • Cleaning of difficult-to-access surfaces for daily cleaning, such as ceilings, walls and around vending machines
  • Misting of frequently touched surfaces, or entire rooms, with an additional disinfectant chemical approved to inactivate SARS-Cov-2

The appropriate frequencies of these non-routine tasks should be validated through a risk-based assessment and continually verified to ensure effectiveness.

Employee Training
All employees who are required to perform routine and non-routine janitorial tasks should be fully trained and records maintained. This should not only include adequate training knowledge of required practices and documentation, but also chemical selection and handling specific to janitorial activities. Retention of knowledge should be verified and included in existing facility training programs. Routine auditing of the cleaning practices by facility personnel will ensure continued acceptable outcomes of the program.

Documentation

Completion of all janitorial cleaning activities should be documented and records maintained following similar practices for sanitation in production areas. As a best practice, documentation, such as checklists, should be made visible to employees who utilize the welfare areas as a means to convey facility hygiene practices and ease potential health concerns.

Validation & Verification of Cleaning Effectiveness
To ensure an established janitorial cleaning program for non-production areas is effective in achieving appropriate hygiene outcomes, the facility must validate and routinely verify the process. Validating the effectiveness of janitorial programs can be undertaken in much the same manner as performed for the traditional sanitation process in food production zones. A combination of visual inspection, environmental sampling and other methods should be utilized both during the validation and subsequent routine verification process. Specific to the COVID-19 pandemic, several contract laboratories offer surface environmental testing for SARS-CoV-2 (via RT-qPCR) that should be incorporated into janitorial validation and verification protocols.2,5 Routine absence of the virus will assist in demonstrating effectiveness of the facility janitorial cleaning program.

Conclusion

With the increased scrutiny of employee welfare during the COVID-19 pandemic, maintaining effective facility hygiene remains a critical goal of food processing facilities. Through incorporation of current sanitation best practices utilized in food production zones, facilities can elevate the outcomes of their janitorial cleaning programs, ensuring effective hygiene.

References

  1. North American Meat Institute. (November 12, 2020). Significant Events and Progress Involving the Meat and Poultry Industry during the COVID-19 Pandemic.
  2. American Society for Microbiology. (October 8, 2020). Detecting SARS-CoV-2 in the Environment.
  3. United States Environmental Protection Agency. (November 25, 2020). List N: Disinfectants for Coronavirus (COVID-19).
  4. International Association of Food Protection. (December 7, 2017). Cleaning, Sanitizing and the Seven Steps of Sanitation [Webinar].
  5.  IEH Laboratories & Consulting Group. (December 2020). SARS CoV-2 Environmental Monitoring.
Susanne Kuehne, Decernis
Food Fraud Quick Bites

Many Bad Apples Spoil the Bunch

By Susanne Kuehne
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Susanne Kuehne, Decernis
Rotten apples
Find records of fraud such as those discussed in this column and more in the Food Fraud Database. Image credit: Susanne Kuehne

Food fraud can have a substantial impact on a consumer’s health, like in this case of fruit juice that was sold (including to school lunch programs) in spite of contamination with arsenic and mycotoxins. The fruit used for the juice was decomposing, and also processed in a facility that unacceptably violated hygiene and food safety standards. The FDA filed a lawsuit against the company, which in the meantime has ceased operations.

Resource

  1. Vigdor, N. (November 10, 2020) “School Lunch Program Supplier Sold Juice With High Arsenic Levels, U.S. Says in Lawsuit”. The New York Times.

 

Adam Serfas, R.S. Quality
FST Soapbox

Tips for Creating an Inclusive Color-Coding Plan for Food Manufacturing Facilities

By Adam Serfas
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Adam Serfas, R.S. Quality

Color-coding as a quality assurance and safety measure has been on the rise since the passage of FSMA in 2011. Now, 10 years later, color-coding is being used in a wide range of industries from food manufacturers and processors to pharmaceutical developers and even brewers. As the popularity of the practice of color-coding has increased, so too has the market for color-coded tools. Nowadays, those in the industry can find virtually every high-quality cleaning tool under the sun, and a hygienic tools storage option for that tool in the color needed. The improved quality and availability of these products is wonderful, but nice tools alone cannot ensure a successful color-coding plan. Color-coding compliance is only possible when there is team-wide buy-in. That means meeting the team where they are—making the plan important to every single employee who steps onto a production floor. To do that, it needs to be introduced in an inclusive manner. The following are some tips for creating and implementing an inclusive color-coding plan.

Draw Up the Plan With Folks Beyond Management

Before you ever lock in a color-coding plan—whether you plan to color-code by zone, by allergen or by shifts—you first need to consult a wide range of team members. One common mistake is developing a color-coding plan with only quality assurance experts and those in management. This presents a problem for a couple of reasons.

One, you’re missing out on the perspective of those who will most often be asked to execute the plan. Say you choose the color purple as one of the colors in your color-coding plan, and you purchase all of the tools you think you will need in that color. You roll out the plan only to find out there’s an essential tool you need, and it doesn’t come in that color. You now have a problem on your hands, and a costly one at that, as you’re going to need to start over with a new color and new tools.

Beyond needing that on-the-ground perspective, you miss out on a key opportunity to gain buy-in early on from those who will be directly involved in carrying out the plan. Do yourself a favor and invite shift leaders to the table. Explain to them what you would like to do with a color-coding plan and listen to any advice they might have on executing a plan everyone is going to want to see succeed. Generally speaking, it pays to go with a big-tent approach to planning, so spend some time thinking about which parties should be represented in the planning process to capture all of the varying viewpoints of those at your facility.

Ensure the Plan Is Color-Blind Friendly

As selecting colors is one of the most important things you do in drafting a color-coding plan,pay special attention to the colors themselves. Color-blindness affects 1 in 12 men and 1 in 200 women—certainly not a negligible amount, and something you want to take into consideration.

Once you figure out all of the tools you need, determine which colors can accommodate those needs. From that list, try to avoid the most commonly confused color pairings in your plan. Red and green, green and brown, green and blue, blue and gray, blue and purple, green and grey, and green and black are the most commonly confused. If possible, avoid using those color combinations. Instead, opt for high-contrast options such as orange and purple, purple and yellow, or blue and yellow to name a few.

Some people will also look to shades to help achieve a higher contrast. For example, lime green and a maroon red is much better for a color-blind person than your standard royal red and shamrock green. These days more tools are available in varied shades but, again, you need to ensure that you’re able to get every tool you need now—and in the foreseeable future—in the color you pick.

Should you need to use colors that are not high-contrast, do your best to keep those tools separate. If you are color-coding by zone, use the most commonly confused color combinations on the opposite ends of the facility, where they are less likely to swap places. You can also help by using tool storage boards such as shadow boards or wall racks that are color-coded to match the tools. That way, tools always go back to the same place after each use.

Employ Multilingual Trainings and Signage

Generally speaking, the food industry is particularly diverse, and many facilities employ staff whose first language is not English. Work with your HR team and managers to identify which languages are primarily spoken among your staff and ensure you can offer trainings on the color-coding plan in all of those languages. Frequently, facilities have employees who are multilingual and can therefore translate during a training session. If not, it may be wise to hire a translator. This presents a nominal fee, whereas an employee failing to follow a color-coding plan could have disastrous consequences.

It is also important to ensure that any signage you have explaining the color-coding plan is available in the primary languages of the employees.

Make Use of Different Teaching Methods

Just as in the classroom, employees come to work with different learning styles. It’s up to the employer to meet those different needs with varying teaching styles and materials that speak to the importance of the color-coding plan. For the auditory learners, an all-hands meeting where a leader explains the importance of color-coding is going to be great. For the visual learners, handouts and permanent signage throughout your facility will be appreciated.

Meanwhile, tactile learners might want to run through a practice of grabbing tools, seeing where they will be used and returning them to their designated storage spot to see the plan in action. While asking employees to go through these different teachings might draw some eye-rolls for those who feel they grasped the concept the first time, the exercise might help make the color-coding plan click for someone who struggled to understand what they were being asked to do. Additionally, repetition helps all learners, so revisit these trainings to refresh veteran staff and bring newer folks up to speed.

Invite Feedback

Finally, invite employees to share feedback with you along the way. An inclusive culture is one that allows everyone to have a voice. Make it clear that team members are welcome to share any feedback they have on the color-coding plan, the trainings and tools along the way. Once again, in the interest of accommodating everyone, it’s a good idea to offer multiple avenues for feedback reporting. You might like to invite employees to share feedback directly with managers and also offer an anonymous suggestion box that gets checked regularly. Every facility and every staff has unique needs, so listening to the suggestions that come your way can help shed light on important considerations.