Tag Archives: Focus Article

Susanne Kuehne, Decernis
Food Fraud Quick Bites

Mystery Meatballs

By Susanne Kuehne
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Susanne Kuehne, Decernis
Meatballs, 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, a Food Safety Tech advertiser. Image credit: Susanne Kuehne

Food fraud is rampant in pre-packaged and non-prepackaged meatballs, according to the Consumer Council in Hong Kong. A DNA investigation of beef meatballs revealed that 60% of samples contained pig derived meat, other samples contained chicken. None of the analyzed lobster ball samples showed any crustacean DNA. Consumers, especially ones with dietary or religious restrictions, are cautioned to check the ingredients lists of pre-packaged meatballs carefully and to be aware the some of the meatballs may contain undesired mystery meat.

Resource

  1. CHOICE Magazine. (January 17, 2022). “Caution for Meatball Lovers — 45 Samples High in Sodium Pig DNA Found in 60% Beef Balls and Beef Tendon Balls Crustacean DNA Absent from All Lobster Balls”. Hongkong Consumer Council.
Emily Newton, Revolutionized Magazine
FST Soapbox

Packaging Automation Can Be an Essential Tool for Food Manufacturers

By Emily Newton
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Emily Newton, Revolutionized Magazine

Food and beverage manufacturers face various challenges—including a labor shortage, rising demand and ongoing supply chain disruptions. Food packaging automation can be an essential tool for these businesses, as the technology can improve manufacturing productivity without hiring additional workers.

As demand continues to rise over the next few years, and as the labor shortage continues, packaging automation will likely become more important. This is why manufacturers are turning to the technology and how innovations in Industry 4.0 solutions may reshape food manufacturing this decade.

Food and Beverage Manufacturers Are Doing More With Less

Food manufacturers face the same market challenges that most companies are navigating right now. Even two years after the beginning of the COVID-19 pandemic, the supply chain remains unstable, demand is volatile and job openings continue to outstrip available workers.

Consumer expectations are also changing. A growing segment of American shoppers expects businesses to deliver items faster than ever, putting greater pressure on manufacturers to accelerate production and logistics operations.

These trends aren’t likely to reverse anytime soon, even as the pandemic eases and vaccines become available globally. Some experts predict that the labor shortage may be on track to last for years, and the lack of essential raw materials or components may similarly drag on well into the future. This means hunkering down and attempting to weather current market conditions will not be an effective strategy. Instead, businesses will have to experiment with new ways to improve productivity, reduce operating costs and accelerate delivery times.

Automation may become an essential strategy, especially for food and beverage manufacturing tasks that have traditionally been time-consuming and challenging to automate.

How Food Packaging Automation Helps Manufacturers Stay Competitive

Manufacturers that need to increase factory throughput may struggle to bring on additional labor necessary to improve production. Instead, solutions that help them increase productivity without hiring—like packaging automation—may help companies meet existing demand.

Packaging automation tools allow manufacturers to automate various tasks that are tedious, dull, time-consuming and potentially dangerous.

Industry 4.0 technology also allows packaging solutions to automate work that previously required human labor. For example, AI-powered automation systems can use machine vision—algorithms that enable machines to “see” objects — for quality control and manufacturing purposes. These systems may be able to automatically package items or visually inspect them for defects, allowing businesses to improve quality control processes without the dedication of additional labor.

Food packaging automation can also help make food and beverage products more consistent and safer for workers and consumers. Quality control processes are often tedious or repetitive. Throughout a shift, workers assigned to these tasks tend to slow down and make mistakes, potentially allowing defective or dangerous products to move further along the production line.

Automated packaging systems are remarkably consistent when well-maintained. They can run for hours at a time without the same risks that may come with human workers assigned to tedious or repetitive tasks.

Some internet grocery retailers are also using a combination of AI and RFID to improve package branding and drive sales. RFID allows businesses to embed unique identifiers into the packaging of every product they sell, making it possible to collect deeper information about consumer demands and purchasing habits.

Other AI systems use IoT devices that gather real-time data on equipment operations to streamline or automate maintenance checks. For example, a predictive maintenance approach uses AI forecasting algorithms and IoT data to monitor machines and predict when they will need maintenance. The approach is similar to preventive maintenance but is more effective at keeping machines online. In practice, the forecasting power of a predictive maintenance algorithm can reduce downtime and maintenance costs.

Similar AI technology can also be used in the packaging design process. An AI algorithm trained on a library of packaging data may be used to create new packaging—helping businesses identify novel options when it comes to shape or material choice.

Other Advantages of Packaging Automation

Reducing the cost of packaging can also allow manufacturers to spend more money on higher-quality food wrapping—which can, in turn, improve customer satisfaction and drive revenue. For example, many manufacturers have begun to offer eco-friendly packaging materials that can be customized with branding elements. These packaging materials will attract customers who want to buy products from eco-friendly brands. They will also help manufacturers build deeper client relationships while growing additional company awareness.

Over time, these decisions can help a business transform its packaging into a branding tool. This will require an additional up-front investment, but the improvements will pay for themselves over time.
Packaging Automation Can Help Food and Beverage Manufacturers Adapt

Cutting-edge industry technology has made packaging solutions more effective than ever. The right equipment allows food and beverage manufacturers to automate various packaging, design and maintenance tasks—making individual facilities and businesswide processes much more efficient.

Alert

Family Dollar Recall Highlights Need for Sound Pest Management Plan

By Food Safety Tech Staff
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Alert

After finding evidence of rodent infestation during an inspection of a Family Dollar distribution facility in Arkansas, the FDA warned the public of usage and consumption of products purchased at certain stores from January 1 through present time. The affected products, which include food, were distributed to Family Dollar stores in Alabama, Arkansas, Louisiana, Mississippi, Missouri and Tennessee.

“Families rely on stores like Family Dollar for products such as food and medicine. They deserve products that are safe,” said Associate Commissioner for Regulatory Affairs, FDA, Judith McMeekin, Pharm.D. in an agency press release. “No one should be subjected to products stored in the kind of unacceptable conditions that we found in this Family Dollar distribution facility. These conditions appear to be violations of federal law that could put families’ health at risk. We will continue to work to protect consumers.”

The FDA inspection followed a consumer complaint and found both live and dead rodents, rodent feces and urine, and evidence of rodent presence, along with dead birds and bird droppings, throughout the facility in West Memphis, Arkansas. After fumigating the facility, 1100 dead rodents were recovered. FDA’s review of company records also revealed a history of infestation, with more than 2300 rodents collected between March 29 and September 17, 2021.

Among the range of hazards associated with rodents include Salmonella.

Family Dollar, Inc. initiated a voluntary recall of the FDA-regulated products that were stored and shipped from the infested facility. The company states that it is unaware of any reports of illnesses related to the recall.

COVID-19 has not slowed down pests, and the last thing a company needs is a failed audit due to preventable pest issues.

 

Food Safety Consortium

10th Annual Food Safety Consortium Back In-Person with New Location and Focus

By Food Safety Tech Staff
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Food Safety Consortium

EDGARTOWN, MA, Feb. 23, 2022 – Innovative Publishing Company, Inc., publisher of Food Safety Tech, has announced the dates for 2022 Food Safety Consortium as well as its new location. Now in its 10th year, the Consortium is moving to Parsippany, New Jersey and will take place October 19-21.

“COVID-19’s impact on the food safety community has been significant and its impact will continue to be felt for years,” said Rick Biros, president of Innovative Publishing Company and director of the Food Safety Consortium, in his blog about the current state of the food industry. “The goal now is not to get food safety back to 2019 levels but to build it better. These issues must be discussed among peers and best practices must be shared. This year’s event will help facilitate this much needed critical thinking and meeting of the minds.”

The 2022 program will feature panel discussions and concurrent breakout sessions intended for mid-to-senior-level food safety professionals that address important industry issues, including:

  • C-Suite Communication
  • Employee Culture
  • What is the State of Food Safety and Where is it Going?
  • Audits: Blending in-person with Remote
  • Quality 4.0: Data Analytics and Continuous Improvement
  • Digital Transformation of Food Safety & Quality
  • Technology: How Far is Too Far?
  • The Days FSQA Folks Fear the Most
  • FSQA’s Role in Worker Rights and Conditions
  • Analyzing and Judging Supplier’s Human Rights and Environmental Records
  • New Trends in Food Fraud
  • Diversification of Supply Chain Capacity
  • Product Reformulation Challenges due to Supply Chain Challenges
  • Traceability
  • Preparing the Next Generation of FSQA Leaders
  • Food Defense & Cybersecurity
  • Food Safety and Quality in the Growing World of e-commerce
  • Quality Helping Improve Manufacturing Efficiency with How Does Quality Show Value to the Organization?

The event will also feature special sessions led by our partners, including the Food Defense Consortium, GFSI, STOP Foodborne Illness and Women in Food Safety.

Tabletop exhibits and custom sponsorship packages are available. Contact Sales Director RJ Palermo.

Registration will open soon. To stay up to date on registration, event keynote and agenda announcements, opt in to Food Safety Tech.

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.

About the Food Safety Consortium

Food companies are concerned about protecting their customers, their brands and their own company’s financial bottom line. The term “Food Protection” requires a company-wide culture that incorporates food safety, food integrity and food defense into the company’s Food Protection strategy.

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 conversations that are critical for advancing careers and organizations alike. Delegates visit with exhibitors to learn about cutting-edge solutions, explore three high-level educational tracks for learning valuable industry trends, and network with industry executives to find solutions to improve quality, efficiency and cost effectiveness in the evolving food industry.

Susanne Kuehne, Decernis
Food Fraud Quick Bites

You Can’t Change Your Fingerprints

By Susanne Kuehne
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Susanne Kuehne, Decernis
Olive Oil, 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, a Food Safety Tech advertiser. Image credit: Susanne Kuehne.

In the European Union, extra virgin olive oils must be labeled with their geographical place of origin. The provenance of olive oil can now be verified with newly developed method involving the analysis of extracted sesquiterpene hydrocarbons via gas chromatography and mass spectrometry. The method is highly precise and at the same time inexpensive. Sesquiterpene hydrocarbons are found in many live organisms and show characteristics based on olive tree cultivars and where the trees are grown, leading to a precise olive oil origin fingerprint.

Resource

  1. de Andreis, P. (February 9, 2022). “Hydrocarbon Fingerprinting Helps E.U. Researchers Verify Olive Oil Provenance”. Olive Oil Times.
Karen Everstine, Decernis
Food Fraud Quick Bites

Best Practices in Setting Up Food Fraud Programs

By Karen Everstine, Ph.D.
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Karen Everstine, Decernis

In 2016, the food authenticity team at Queen’s University Belfast published a study that evaluated adulteration levels in oregano—specifically, 78 samples purchased at retail.1 Almost a quarter of the samples had some adulteration. Some samples actually contained more than 70% other leaf material, primarily olive and myrtle leaves. This study was widely reported and appeared to result in drastic decreases in the levels of adulteration in oregano.

However, just last year, the Joint Research Centre of the European Commission published the results of a coordinated control plan for “fraudulent practices” in spices in which they tested 1,885 samples of 6 herbs and spices submitted from from 23 countries.2 Almost half of the 295 oregano samples were “suspicious of being adulterated.” The results of these studies imply that food fraud—especially fraud involving higher-value and further-processed products with a substance that does not make consumers sick—is a persistent risk and demands a sustained response from industry and regulators.

Evaluating historical data from various sources (the scientific literature, regulatory reports, media reports, etc.) is a critical component of a food fraud prevention program, but it is not enough. A strong program will include an in-depth evaluation of what is known historically about food fraud for relevant raw materials, ongoing monitoring of food safety and fraud notifications, a fraud-focused evaluation of supplier controls, audit and testing programs that include specific anti-fraud measures, and an assessment of situational factors that could increase fraud incentive (geographic, economic, etc.).

The Food Fraud Database has tracked public reports of food fraud for almost 10 years. Many incidents are types of fraud that have occurred repeatedly, as the incident distribution from last year illustrates (see Figure 1). In addition to herb/spice fraud, frequent types of fraud include replacement of honey with sugar syrups; unregulated and counterfeit liquor; wines labeled as a more expensive varietal or with undeclared additives; milk products with added protein or fats from other sources; and fraud related to organic certification or geographic origin. Although these types of fraud appear to be “reasonably foreseeable,” the challenge is that during a time of supply chain stressors—such as the COVID-19 pandemic—risks may evolve quickly as suppliers and supply chain structures change. Re-evaluating food fraud vulnerability in response to changing conditions can be time-consuming, but is important to stay ahead of potential risks.

Food Fraud Incidence
Figure 1. Food fraud incidents reported in public sources, 2021. (Source: FoodChain ID Food Fraud Database)

We frequently work with food manufacturers to develop their food fraud vulnerability assessments. Our experience is that searching and compiling risk data and mapping a set of raw materials to the appropriate data sources for analysis can be the most time-consuming aspects of the project. Since Google searches or other manual processes are not always reliable and efficient, a helpful first step can be finding a data source that compiles and standardizes food safety and fraud data from a wide range of reliable sources. The mapping process then involves identifying each individual ingredient component of the raw materials sourced by the company and linking it to the relevant ingredient name in the data source. It is important to invest this time up front to identify the most appropriate data sources and conduct a thorough mapping process. This ensures food safety and quality assurance staff will be notified of information relevant to their particular supply chains moving forward.

Many quality assurance professionals struggle to fit in food fraud assessments and mitigation plans while managing day-to-day food safety and quality programs. A two-stage process, including an ingredient screen followed by a detailed assessment for potentially high-risk ingredients, can make the process more efficient for companies managing hundreds of raw materials (see Figure 2). Existing food safety testing and auditing programs may also have application to food fraud prevention and should also be documented in a food fraud program. Many food companies find value in outside expert guidance to set up a food fraud program so that food safety and fraud risks aren’t unintentionally missed. The goal of a food fraud program is not to add to the workload of food safety and quality assurance staff, but to enable those staff to identify the most targeted measures that will help ensure food safety, authenticity, and brand protection.

Food Fraud Prevention Program
Figure 2. Components of a food fraud prevention program (Source: FoodChain ID).

References

  1. Black, C., et al. (2016). A comprehensive strategy to detect the fraudulent adulteration of herbs: The oregano approach. Food Chemistry, 210, 551–557. https://doi.org/10.1016/j.foodchem.2016.05.004
  2. Maquet, A., et al. (2021). Results of an EU wide coordinated control plan to establish the prevalence of fraudulent practices in the marketing of herbs and spices. EUR 30877 EN. Publications Office of the European Union, Luxembourg. ISBN 978-92-76-42979-1 (online).
Alert

FDA Tells Consumers to Throw out Certain Powdered Infant Formulas due to Contamination

By Food Safety Tech Staff
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Alert

–UPDATE–March 14, 2022 — In an agency update, the FDA stated that it has removed the Salmonella Newport illness that was previously noted in the investigation. “In the early stages of this investigation, FDA included all consumer complaints of illness with exposure to products from the Sturgis, MI, facility. After further investigation, the FDA has determined that there is not enough information to definitively link this illness to powdered infant formula. CDC confirmed that this single Salmonella illness is not linked to an outbreak. The FDA and CDC are continuing to monitor for Salmonella cases and consumer complaints that may be related to this incident,” the FDA stated.

–END UPDATE–

Earlier this week Abbott issued a recall of infant powdered formulas (including Similac, Alimentum and EleCare) that were manufactured at the company’s Sturgis, Michigan plant. The company received consumer complaints in infants who had consumed powdered infant formula manufactured in this facility—specifically, three reports of Cronobacter sakazakii and one report of Salmonella Newport. All cases resulted in hospitalization, and one death was reported.

FDA began onsite inspection at the facility and thus far has found several positive Cronobacter results from environmental samples and reported adverse inspectional observations. “A review of the firm’s internal records also indicate environmental contamination with Cronobacter sakazakii and the firm’s destruction of product due to the presence of Cronobacter,” FDA stated in a CFSAN update.

The recalled Similac, Alimentum and EleCare products can be identified by their 7-to-9 digit code and expiration date:

  • First two digits of the code are 22 through 37 and
  • Code on the container contains K8, SH, or Z2, and
  • Expiration date of 4-1-2022 (APR 2022) or later.

In a company announcement published on FDA’s website, Abbott stated, during testing in our Sturgis, Mich., facility, we found evidence of Cronobacter sakazakii in the plant in non-product contact areas. We found no evidence of Salmonella Newport. This investigation is ongoing.” It added that “no distributed product has tested positive for the presence of either of these bacteria” but that the company will continue to conduct testing.

Parents and caregivers can find out whether the product they have is included in the recall by visiting the Similac recall website.

Berk Birand, Fero Labs

Is the Future of Food Quality in the Hands of Machine Learning?

By Maria Fontanazza
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Berk Birand, Fero Labs

Is the future of food quality in the hands of machine learning? It’s a provocative question, and one that does not have a simple answer. Truth be told, it’s not for every entity that produces food, but in a resource, finance and time-constrained environment, machine learning will absolutely play a role in the food safety arena.

“We live in a world where efficiency, cost savings and sustainability goals are interconnected,” says Berk Birand, founder and CEO of Fero Labs. “No longer do manufacturers have to juggle multiple priorities and make tough tradeoffs between quality and quantity. Rather, they can make one change that optimizes all of these variables at once with machine learning.” In a Q&A with Food Safety Tech, Birand briefly discusses how machine learning can benefit food companies from the standpoint of streamlining manufacturing processes and improve product quality.

Food Safety Tech: How does machine learning help food manufacturers maximize production without sacrificing quality?

Berk Birand: Machine learning can help food manufacturers boost volume and yield while also reducing quality issues waste, and cycle time. With a more efficient process powered by machine learning, they can churn out products faster without affecting quality.

Additionally, machine learning helps food producers manage raw material variation, which can cause low production volume. In the chemicals sector, a faulty batch of raw ingredients can be returned to the supplier for a refund; in food, however, the perishable nature of many food ingredients means that they must be used, regardless of any flaws. This makes it imperative to get the most out of each ingredient. A good machine learning solution will note those quality differences and recommend new parameters to deal with them.

FST: How does integrating machine learning into software predict quality violations in real-time, and thus help prevent them?

Birand: The power of machine learning can predict quality issues hours ahead of time and recommend the optimal settings to prevent future quality issues. The machine learning software analyzes all the data produced on the factory floor and “learns” how each factor, such as temperature or length of a certain process, affects the final quality.

By leveraging these learnings, the software can then help predict quality violations in real-time and tell engineers and operators how to prevent them, whether the solution is increasing the temperature or adding more of a specific ingredient.

FST: How does machine learning technology reveal & uphold sustainability improvements?

Birand: Due to the increase in climate change, sustainability continues to become a priority for many manufacturers. Explainable machine learning software can reveal where sustainability improvements, such as reducing heat or minimizing water consumption, can be made without any effect on quality or throughput. By tapping into these recommendations, factories can produce more food with the same amount of energy.

Susanne Kuehne, Decernis
Food Fraud Quick Bites

Wake Up And Seize the Coffee

By Susanne Kuehne
No Comments
Susanne Kuehne, Decernis
Coffee, 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, a Food Safety Tech advertiser. Image credit: Susanne Kuehne

Twelve thousand packs of adulterated coffee that did not match quality standards were seized in Brazil. The coffee was not labeled correctly, and in addition contained foreign matter, such as bark and wood. This investigation is part of a larger operation that altogether seized 15 tons of adulterated coffee, which contained corn, did not adhere to quality standards, and was packaged with a counterfeit purity seal.

Resource

  1. Brito, J. (January 18, 2022). “De milho a madeira na composição: 12 mil pacotes de café são apreendidos no ES”. Espirito Santo.
Food Lab

Four Testing and Detection Trends for 2022

By Wilfredo Dominguez Nunez, Ph.D.
No Comments
Food Lab

COVID-19 continues to pose challenges for every industry, influencing how they will need to adapt to the future. The food manufacturing industry specifically is continuing to see problems with plants shutting down due to outbreaks, labor shortages and domino-effect supply chain issues, forcing them to adjust in order to continue meeting the demands of customers and supplying safe food to the public.

With these adjustments in mind, changes in testing and detection in labs have arisen, influencing four main trends within food manufacturing labs expected throughout 2022.

1. Testing levels continue to increase. In 2021, some customers intentionally planned to cut testing and production in plants to balance out the loss of employees due to the pandemic-induced labor shortages within manufacturing roles.

However, following the trends of rising employment in manufacturing, 2022 should see an increase in testing, raising the baseline of production levels in the plants. According to the Bureau of Labor Statistics, manufacturing jobs saw an increase of more than 113,000 employees in Q4 of 2021. Although still below employment levels of February 2020, the continued increase is positive news for the food manufacturing industry.

2. Food testing labs turn to automation technology. Even as labs begin to see their numbers in employees rise, the demand for automation technology during 2022 will continue to climb given its proven ability to increase productivity in the lab and meet the demands of customers. With automation technology, lab technicians can multi-task thanks to the ability to step away from tests, increasing the amount of testing that can be done despite the lack of people in labs.

Additionally, utilizing ready-to-use products has cut down on the time it takes to prepare for testing. Rather than spending hours preparing Petri dishes and using an autoclave, ready-to-use Petri films or Petri dishes create easy to follow protocols with significantly less steps for a lab technician to complete.

3. Third-party labs gain popularity. With food manufacturing, tests will either be conducted on-site or at a third-party lab. Taking labor shortages into account, many manufacturers still do not have the staff numbers to maintain a dedicated on-site testing facility. As a result, manufacturers will turn to third-party labs to help increase testing volumes and productivity.

Not only have third-party labs aided manufacturers with testing, but the labs also often have the capabilities to run confirmation tests on products, tests that may not have been possible if conducted on-site. And as third-party labs have seen numerous consolidations in recent years, their capability to move products around for necessary testing is much more simplified and achievable than if testing was conducted on-site.

4. Shifting to locally sourced products. With supply chain issues continuing into 2022, the food manufacturing industry could source more products from local farmers and other local product suppliers in order to better keep up with demand.

Right now, it is much harder to receive and send products across the globe with countries and states enforcing COVID-19 restrictions and dealing with their own labor issues. Not only are labs looking to rely on locally sourced products to assist in getting products to their final destination, but consumers are also increasing their demand for locally sourced products. Specifically, consumers are looking for the reliability of food on the shelves, shorter time spent between farmer and grocery stores, as well as simply fewer people touching product throughout the chain.

Challenges in food testing labs that arose in the past couple of years are still prevalent in 2022, but from adversity comes innovation and change. With more attention on automation technology, more food manufacturing employees returning to work, and adjustments to ongoing supply chain issues, 2022 is looking more hopeful in working to return to the level of productivity food manufacturers were meeting prior to the pandemic.