Tag Archives: IoT

Brian Sharp, SafetyChain Software

How Industry 4.0 Affects Food Safety and Quality Management

By Brian Sharp
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Brian Sharp, SafetyChain Software

The food and beverage industry is moving towards a fully connected production system with more methods available to automate data collection than ever before. But with all the promises of Industry 4.0, what are the true capabilities of communicating real-time plant floor insights? This article will explain how better capturing methods and analysis can drive data-driven decision making to optimize safety, quality and efficiency in food and beverage operations.

What Is Industry 4.0?

The term Industry 4.0 has many pseudonyms, such as Industrial Internet of Things, Manufacturing 4.0, and Smart Manufacturing, but they generally all refer to the idea that manufacturers will be able to connect all operations in their plants. Where the name Industry 4.0 comes into play is the thought that manufacturing is in its fourth wave of change. In the 1780s, the first industrial revolution started with machines and the “production line” and evolved to mass production in the 1870s; manufacturing entered into a new wave after the 1950s when automation was introduced.

In this current fourth wave of manufacturing, new technology is driving the change in production and the capabilities of what can be accomplished in facilities. A report from Deloitte Insights entitled “The Smart Factory” explains this new way of operations as “ a leap forward from more traditional automation to a fully connected and flexible system—one that can use a constant stream of data from connected operations and production systems to learn and adapt to new demands.”

By way of more sensors, connectivity, analytics, and breakthroughs in robotics and artificial intelligence, the future food and beverage plants will be able to meet customers’ demands for higher-quality products while increasing productivity. However, there is a stark reality that many food and beverage manufacturing facilities are over 50 years old and dealing with legacy equipment. And if an investment in new technology is made, often it is made because food and beverage plants need to reach compliance or fill a customer’s requirement.

“Regulatory compliance is huge,” says Steve Hartley of Matrix Control Systems during a recent SafetyChain webinar. “But if you are able to attach additional business value to that compliance, then incorporating technology into the organization becomes a lot easier.”

For instance, new technology that can help a facility follow regulated processes in food manufacturing can also help to create more consistency and increase the quality of your products. Additionally, if input from the entire organization is collected when investing in more technology and automation, then multiple departments will support the budget costs.

“One of the big things that we see happening with our customers is that they are digging into that production equipment,” says Hartley. “Lots of food manufacturing facilities are filled with all sorts of wonderful processing equipment, but leveraging not only the manufacturing capabilities, but also the data collection capabilities of that equipment is really powerful.”

What Automated Data collection Systems Can Do

Because large food and beverage companies sell a high volume of goods to a large number of customers, many have already automated their data collection. These facilities also receive goods from an intricate supply chain that spans vast distribution networks, thus making automated data collection from receiving all the way through shipping a necessity.

However, many companies are going beyond this and integrating production equipment on the plant floor to provide a deeper level of production and quality data. These types of operations are generally interested in going beyond just being in regulatory compliance, but working on their continuous improvement. What this data can do is to provide better data for better decision making. By knowing what parts of the plant are operating optimally and what areas aren’t, plant managers can to make changes that will unlock more potential from the production line.

Getting the most out of operations is one of the most frequently cited needs of food and beverage manufacturers. The best way to do this is to drive plant efficiencies, which means measuring performance, setting baselines and goals, and holding employees accountable. The key here is to not confine efficiencies to just one area of the facility, but to broaden the scope to include end-to-end processes, from supplier to customer.

“Take a scope that is relevant to everyone and that is relevant to the strategy of the company,” states Daniel Campos of London Consulting Group. A company’s overall strategy should drive the focus of all departments. No one lives in a silo, and every part of your operations affects all the other parts. So any one area that is falling below the goal set takes away value from the system as a whole. This becomes more crucial as the enterprise grows even more connected and dependent on data from each other.

Shortfalls of Industrial Automation Systems

When evaluating the scope of an operation, all areas of the plant should be assessed in terms of how data is being collected. Part of this information assessment is to learn what processes aren’t covered by automated data collection. This includes equipment without sensors that can record accurate measurements and readings.

Another area that should be identified as an entry point for possible faulty or incorrect data is where an operator is required to input information. Some of this might be simply validating that SOPs were followed, such as whether a piece of equipment was cleaned or not and if detergents were actually changed when required.

The quality and fidelity of the data is directly related to the effectiveness of the decisions made. As the saying goes, “Garbage in, garbage out.” But even good data alone doesn’t drive value, but rather information gleaned from the facts collected is where the true benefits can be harnessed to improve the food safety and quality of products produced.

So, if data is analyzed and found not to conform to a desired specification, then the goal is to find out why this is happening. Is the data being collected accurate? If not, why? If it is accurate, then what else is going on?
Additionally, the speed and complexity of today’s food processing plants requires this data to not just be in real time, but able to be captured in smaller increments to make better decisions. This type of data that is collected and analyzed infrequently can slip through the cracks because systems to collect and manage this category can be hard to find, unlike industrial automation systems.

One solution to this problem can be found in capturing data via mobile devices. Tablets and phones moving through the plant with operators can help collect information at the source. Plus, these devices enable managers and executives to see critical control point data as well as summaries of operational performance and out-of-spec occurrences, anytime and anywhere.

As food and beverage manufacturing plants continue to automate their data collection and increasingly connect their production processes, more data will come online in a multitude of ways, allowing for better decision making. Ultimately, this is the promise of Industry 4.0 and why digital transformation promises a higher level of food safety and quality in the future.

Ned Sharpless, Frank Yiannas, FDA

FDA’s ‘New Era of Smarter Food Safety’ to Focus on Traceability, Digital Technology and E-Commerce

By Food Safety Tech Staff
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Ned Sharpless, Frank Yiannas, FDA

“It’s time to look to the future of food safety once again,” declared Acting FDA Commissioner Ned Sharpless, M.D. and Deputy Commissioner for Food Policy and Response Frank Yiannas in a press statement released yesterday. Although progress has been made in implementing FSMA and with the development of the GenomeTrakr Network, the agency wants to move forward in taking advantage of the innovative technologies that will help make the food supply more digital, traceable and safer. With that effort comes the creation of a “Blueprint for a New Era of Smarter Food Safety”, which will speak to “traceability, digital technologies and evolving food business models”. Sharpless and Yiannas outlined the significant role that these components will play.

Attend the complimentary web seminar, “Supply Chain Traceability: Using Technology to Address Challenges and Compliance” | May 14, 2019, 1 p.m ETDigital technology in food traceability. Digital technologies could play a crucial part in rapidly identifying and tracing contaminated food back to its origin—changing the timespan from days or weeks to minutes or seconds. FDA intends to look at new ways that it can evaluate new technologies and improve its ability to quickly track and trace food throughout the supply chain. “Access to information during an outbreak about the origin of contaminated food will help us conduct more timely root cause analysis and apply these learnings to prevent future incidents from happening in the first place,” stated Sharpless and Yiannas. This means a shift away from paper-based systems.

Ned Sharpless, Frank Yiannas, FDA
(left to right) Ned Sharpless, M.D., FDA acting commissioner and Frank Yiannas, deputy commissioner of food policy and response. Image courtesy of FDA

Emerging technologies. Artificial intelligence (AI), distributed ledgers (no, they didn’t directly say “blockchain”), the Internet of Things, sensors and other emerging technologies could enable more transparency within the supply chain as well as consumer side of things. The FDA leaders announced a pilot program that will use AI and machine learning to assess food imports at the U.S. point of entry.

E-Commerce. “Evolving food business models”, also known as e-commerce, is growing fast and changing how consumers get their food. With food delivery introduces food safety issues such as those related to packaging and temperature control. FDA is exploring how it can collaborate with federal, state and local stakeholders to figure out ways to address these potential problems.

Sharpless and Yiannas emphasized the end-goal in keeping the food of American consumers safe. “So, welcome to the new era of smarter food safety that is people-led, FSMA-based and technology-enabled!”

Todd Fabec, Rfxcel
FST Soapbox

Why the Modern Food Supply Chain Needs Real-Time Environmental Monitoring

By Todd Fabec
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Todd Fabec, Rfxcel

Food supply chains are becoming more complex, as food companies are increasingly faced with blind spots such as deviations from required environmental conditions, theft, fraud and poor handling. Supply chains are global; transit routes that involve road, rail, sea and air create many potential points of failure in food safety or product integrity protocol that, until recently, were largely outside a company’s control.

Learn more about how to address risks in your supply chain at the Food Safety Supply Chain Conference | May 29–30, 2019 | Rockville, MD (or attend virtually)To maintain product quality and safety, companies should implement an environmental monitoring (EM) solution that paints a complete picture of their food products as they move through the supply chain. EM solutions that utilize devices powered by the Internet of Things (IoT) allow real-time tracking of cargo and provide actionable data that can mitigate common problems, change outcomes, and protect brands and consumer health.

Let’s take a deeper look into the problems that food manufacturers and distributors are facing how EM solutions can minimize or eliminate them altogether.

Current Hurdles for Food Supply Chains

As the global network of food trade expands, the diverse challenges facing suppliers, manufacturers, distributors and logistics companies present even more of a threat to supply chains and revenue.

According to PwC agribusiness advisory partner, Greg Quinn, worldwide food fraud results in losses of at least $65 billion a year. Luxury products such as Japanese Wagyu beef and Italian olive oil are regularly counterfeited and incorrectly labeled, and buyers often have no way to trace the origins of what they are purchasing.

Companies in the food and beverage industry also face diversion and theft, which can happen at any of the many blind spots along the supply chain. In fact, food and beverages were among the top commodities targeted by thieves in North America last year, accounting for 34% of all cargo theft, according to a report by BSI Supply Chain Services and Solutions.

Food product quality and safety are also seriously compromised when cargo is poorly handled while in transit, with hazards such as exposure to water, heat and cold, or substance contamination. These types of damages can be particularly acute in the cold chain, where perishable products must be moved quickly under specific environmental conditions, including temperature, humidity and light.

Furthermore, inefficiencies in routing—from not adhering to transport regulations to more basic oversights such as not monitoring traffic or not utilizing GPS location tracking—delay shipments, can result in product spoilage and/or shortened shelf life, and cost companies money. Routing and EM have become more important in light of FSMA, which FDA designed to better protect consumers by strengthening food safety systems for foodborne illnesses.

In short, businesses that manage food supply chains need to be on top of their game to guarantee product quality and safety and care for their brand.

How Does Product Tracking Technology Work?

Real-time EM solutions are proving to be an invaluable asset for companies seeking to combat supply chain challenges. Such product tracking capabilities give companies a vibrant and detailed picture of where their products are and what is happening to them. With EM in the supply chain, IoT technology is the crucial link to continuity, visibility and productivity.

So, how does integrated EM work? Sensors on pallets, cases or containers send data over communication networks at regular intervals. The data is made available via a software platform, where users can set parameters (e.g., minimum and maximum temperature) to alert the system of irregularities or generate reports for analysis. This data is associated with the traceability data and becomes part of a product’s pedigree, making it a powerful tool for supply chain visibility.

EM Combats Supply Chain Stumbling Blocks

EM allows companies to monitor their supply chain, protect consumers and realize considerable return on investment. The technology can show companies how to maximize route efficiencies, change shippers, or detect theft or diversion in real time. Tracking solutions transmit alerts, empowering manufacturers and suppliers to use data to halt shipments that may have been adulterated, redirect shipments to extend shelf life, and manage food recalls—or avoid them altogether. Recalls are a particularly important consideration: One 2012 study concluded that the average direct cost of a recall in the United States was $10 million.

The IoT-enabled technology provides real-time information about how long an item has been in transit, if the vehicle transporting it adhered to the approved route, and, if the shipment stopped, where and for how long. This is crucial information, especially for highly perishable goods. For example, leafy greens can be ruined if a truck’s engine and cooling system are turned off for hours at a border crossing. With EM and tracking, businesses are able to understand and act upon specific risks using detailed, unit-level data.

For example, a company can find out if pallets have dislodged, fallen, or have been compromised in other ways while in transit. They can receive alerts if the doors of a truck are opened at an unscheduled time or location, which could indicate theft. Thieves target food cargo more often than other products because it’s valuable, easy to sell and perishable, and evidence of the theft does not last very long. In fact, the U.S. Federal Bureau of Investigation estimates that cargo theft costs U.S. businesses $30 billion each year, with food and beverage being one of the primary targets. Businesses need to get smart about preventative actions.

All of this actionable data is available in real time, allowing businesses to make decisions immediately, not after the fact when it’s too late. When necessary, they can divert or reroute shipments or take actions to remedy temperature excursions and other environmental concerns. This saves money and protects their reputation. Furthermore, third-party logistics firms and contracted delivery companies can be held accountable for incidents and inefficiencies.

Conclusion

As the benefits of global supply chains have grown, so have the risks. With the FSMA shifting responsibility for safety to food companies, real-time EM is a vital step to ensure cargo is maintained in the correct conditions, remains on track to its destination, and is safeguarded from theft and fraud. With the advent of IoT-enabled tracking and EM technologies, supply chain operations can be streamlined and companies can prevent waste and financial losses, protect their investments and brand identity, and gain an advantage in the marketplace.

Gisli Herjolfsson, Controlant
FST Soapbox

How Supply Chain Digitalization and Data Helps Prevent Costly Recalls

By Gisli Herjolfsson
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Gisli Herjolfsson, Controlant

Recalls are something that food brands plan for but hope to never experience. They are an important public safety issue, but they also have a significant economic impact as well. At best, a product recall is a benign mistake that causes little more than aggravation and inconvenience for a few angry customers. At worst, the consequences can be tragic, both in terms of human and financial impact.

Industry research conducted by the Food Marketing Institute and Grocery Manufacturers Association places the average cost of a single recall at $10 million. That calculation includes only the direct costs of a recall. For the full, long-term costs, including direct and indirect liabilities, you’d need to further account for the immediate loss in sales, litigation costs, as well as any long-term damage caused from a loss in consumer confidence in your brand.

Consumers’ relationship with food is ever changing. They demand transparency about its contents, origin and safety, and for good reason. The World Health Organization estimates that nearly 1 in 10 people are sickened yearly from eating contaminated food, leading to 420,000 deaths. Consumers have long memories for businesses that poison them. The larger the size of your company and the more attention it receives, the potentially greater impact on your long-term business prospects. With the recent E. coli outbreaks tied to romaine lettuce, food safety is top of mind for consumers, and it is impacting entire market segments.

One of the easiest ways to prevent recalls associated with perishable foods is to ensure that food and beverage products are safely produced and continually kept at the right temperatures. Sounds easy, right? In reality, it is far from it.
Gaining end-to-end supply chain visibility can help you prevent costly recalls altogether. Data that today’s technology provides will be important for mitigating risk and protecting a brand’s reputation.

Get Proactive

The idea of prevention is paramount to FSMA. It’s clear that the FDA expects that once a producer or supplier discovers that something has gone wrong, they go back and figure out exactly what happened so that they can put measures in place to prevent it from happening again.

While current FDA guidelines and various EU safety regulations generally require that food can be tracked one step up and one step down the supply chain, this remains a very siloed approach to traceability and is open to risks—risks that producers, food retailers and restaurant brands cannot afford to take.

For USDA-regulated products, HACCP employs a similar process. Prevention is key, and if your monitoring measures miss an issue that could compromise food safety, you’ll need to go back and determine the root cause of the problem.
A cold food manufacturer can do a lot to control risks under its own roof, but how do you avoid costly recalls with ingredients or with temperature abuse after a product leaves the facility? Regulations or not, knowing where your ingredients and food products come from and being assured of their safety is critical in protecting your brand and company from the financial and reputational damage caused by a food recall.

Looking forward in the supply chain, maintaining the cold chain is necessary for many products, including fresh produce, frozen and deep frozen foods, and also those that must be kept at room temperature but still require temperature control. Even if you and your suppliers are incredibly careful and practice prudent safety measures, you may not have full visibility over who else is handling your products. If temperature mishandling by someone else necessitates a food recall or results in a food safety incident, it is still associated with your brand, even if you weren’t the direct culprit.

For many food retailer and restaurant chains, it is common practice for them to share their internal food safety guidelines with their suppliers and partners, and require that they prove a product’s source of origin, lifespan, how those products are stored and transported from point A to point B, as well as the environmental conditions in which foods are kept. Allowing suppliers and logistics partners to self-manage their supply chain does nothing to proactively ensure that they and a food brand aren’t in the headlines due to a food safety incident.

Digitally Connect the Supply Chain

This is where technology and data can play a critical role in managing your temperature-controlled food and beverage products. More and more food enterprises are utilizing Internet of Things (IoT) technologies that talk to the internet so they can collect supply chain data into dashboards and access it on demand.

IoT can be considered as a central nervous system for the supply chain. Through IoT, you can track shipments or trace temperature, moisture or other factors that can have an impact on food quality. Not only can you discover problems more rapidly with this technology, you can narrow the scope of recall. For businesses transporting temperature-sensitive products, this means they can manage product movement data in real-time and respond to issues before they lead to a food safety incident or product waste.

From a food production standpoint, IoT solutions can substantially reduce recalls from issues like labeling, processing and contamination. One of the primary causes of a food recall is microbiological in nature, with the majority of cases involving fruits and produce. IoT data can help detect issues further upstream in the supply chain and, since products will change hands several times before they reach a consumer, it can give you a complete picture of the product’s lifecycle—something that cannot be done with clipboards and ad hoc or periodic inspections.

Through cloud technology, food businesses can connect their end-to-end supply chain, analyze data, discover trends, illuminate weak points and directly respond to them to improve their overall processes.

Track and Trace Everything

Continuous and consistent tracking and tracing through technology not only simplifies recalls, it helps prevent them altogether. The only thing worse than being faced with a food recall is not knowing which products are affected or where exactly they are located.

Real-time temperature monitoring and product movement traceability technology can give you the confidence that foods are continuously kept at their required temperatures and remain safe for consumption. When you need to track and trace an ingredient or product, time is often of the essence. Delays may mean more resources and efforts are spent in producing something that may be rejected, or worse, recalled, or that the potentially impacted product isn’t isolated in time.

The digital integration of suppliers and other partners is vital if a food enterprise wants to have more control over its cold chain. Consumer demand for social responsibility and ethical business operations means that businesses need to provide greater visibility and transparency into the origins of their products. With today’s supply chains, having data—essentially, a horizontal IT layer that lets people share and access data—removes the barriers of communication among stakeholders.
IoT serves as a tool to remove the barriers to collaboration between food manufacturers, food logistics businesses, restaurant and food retail chains, regulatory agencies, and the end consumer. It increases the transparency of information and helps to deliver better products throughout the food supply chain.

Get Started

Acknowledging that most food companies have limited resources, food brands can still face their efforts only on the suppliers and customers that are of the greatest concern. Often this means looking at the combination of “high-risk product” with “high-risk supplier/partner” and prioritizing that part of the supply chain. This prioritization will help food brands allocate their resources and focus their time and money on the highest risks to their customers and brand. Once they’re able to reap the benefits of a preventive food safety program, they’re better able to justify allocating additional resources to other parts of the cold chain.

While IoT, cloud monitoring and traceability technology has been around for some time, real-time data is now becoming standard. Traditionally, the cost of IoT technology and data infrastructure could be quite expensive. However, different business models like subscription are on the rise, which lower the cost of entry for new prospects and can connect a broader range of products, not only high-value goods.

Although many food brands already have some proactive food safety programs in place, it only takes one incident to lead to a major food recall—even if it isn’t your company’s product—and it can negatively impact your business.
As an industry, food brands need to continue raising the bar in terms of what is considered standard and “best practice” when building an effective, proactive food safety strategy. Utilizing best-in-class technology can ensure the delivery of safe foods to the market, prevent recalls, protect business interests, and most importantly, protect consumers.

Stuart Gavurin, Misson Data
Retail Food Safety Forum

The Internet of Things: More Than Just Food Safety

By Stuart Gavurin
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Stuart Gavurin, Misson Data

When it comes to food safety and temperature monitoring, the appeal of automation is crystal clear. Why continue to depend on a costly and unreliable manual process with clipboards, binders, spreadsheets and guesswork when the latest Internet of Things (IoT) technology continuously monitors conditions and sends actionable alerts in real time?

Industry experts note that temperature sensors are the most likely IoT devices to scale throughout the enterprise. While food safety and temperature monitoring are critically important and must meet health code regulations, it is not the only information that needs to be tracked and monitored in a restaurant, grocery store or other foodservice facility.

Although the cost of IoT technology has dropped significantly, the challenge for many newcomers to IoT technology lies in building a business case that the C-suite will accept. To solidify an understanding of the value, organizations should consider the variety of critical operations that can be optimized by IoT connectivity.

Beyond installing a few smart devices IoT platforms are designed to provide a set of common but critical functionality and services—broadly, a software-based infrastructure that can be used as a utility. For IoT, this means the software platform can support interactions with distributed sensors and automation. It is the software that tracks and interprets things like temperature, humidity, energy or movement data and then integrates in a manner that can be incorporated into core business processes that are executed by staff.

The platform approach has the effect of reducing complexity, shortening the learning curve, and enabling the enterprise to focus on its core competencies, rather than getting bogged down trying to understand how to implement, use and maintain the IoT components and technology. The benefits of this approach are that it reduces time to deploy, investment and risk. The result is a business operations-focused IoT-enabled platform that abstracts the complex details, is easy to use, and intelligently focused on delivering maximum value.

For instance, consider a large supermarket chain outfitted with a variety of sensors and gateways that goes beyond monitoring cold and hot food storage temperatures. The suite of hardware and software deployed can be expanded to monitor functions such as: lighting and energy usage, HVAC conditions, customer wait times, open/closed doors, water levels, and fluid flow volume at beverage dispensers. All of this data can be integrated with other back-office software, such as employee scheduling, inventory management, business intelligence, and more, achieving a true 360-degree view of foodservice operations.

Condition tracking systems can be combined with task management functionality to ensure that data is not just monitored, but action is taken as needed. Text message (SMS) or email alerts can be set for anomalies based on customizable threshold values and complex rules. Task flow checklists can be automated, and a digital record is available to bring transparency to execution timing, stop violations, and ensure critical problems are remediated.

Ultimately, as IoT evolves, the enterprise becomes focused less on devices and infrastructure and more on platforms supporting functionality and improving customer experience. As your organization considers investment in IoT, look for solutions that go beyond hardware to encompass software platforms, applications and, most importantly, the business goals of delivering great services and products while making and saving money. Before you spend the money and effort to deploy connected things, decide how IoT will help your business increase efficiencies and provide new value propositions.

Steven Burton, Icicle Technologies
FST Soapbox

Automation Is Happening—Don’t Miss The Boat

By Steven Burton
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Steven Burton, Icicle Technologies

Successful businesses move fast. They stay ahead of their competition by keeping their eye on the newest and most innovative emerging technologies. Failure to embrace the newest, fastest means of production and communication allows other businesses to muscle ahead of slow-to-change competitors, especially in the food industry. This is why embracing automation—even if it requires a commitment from you and your whole organization — is absolutely necessary for every food company.

Guarantee Growth and Compliance with the Internet of Things

The innovation at the forefront of automation technology is the Internet of Things (IoT): Multiple devices interconnected to monitor, communicate and control in real time. Today, a farmer can monitor a crop located in Australia from North America. Ingredients from anywhere in the world can be brought together in a matter of days and distributed just as quickly. Agricultural robots that reduce the risk of contamination and food safety expectations have risen as a result. As exciting as it is to be a part of a constantly innovating food industry, it’s also becoming more challenging to keep up and adapt.

It’s also becoming more necessary. Regulatory agencies are working to keep pace with technological innovations. The standards of food safety—more global than ever—have grown in complexity and will continue to grow as improved, real-time monitoring of products and facilities extends into every type and size of food production company. Properly planned and applied food safety programs are vital to ensuring that globally sourced ingredients and production facilities adhere to regulations to avoid the consequences of failed audits and expensive recalls.

Even for those on top of their regulatory requirements, IoT and other automation technologies are friends, not foes. Automation means that preparation for audits and inspections is reduced to bare minimum, eliminating the need for binders, spreadsheets and months of prep work. Furthermore, one of the greatest challenges of today’s food chain is ensuring not only your own compliance, but the compliance of your vendors. Dealing with hundreds or thousands of incoming ingredients and other materials at any given time is a massive undertaking, let alone dealing with vendor certifications. Integrated, automated systems for food production management streamlines processes and communication and reduces the risk of error and recall throughout the supply chain.

Don’t Be Paralyzed by the F-word: Fear

It is clear to see that staying competitive and staying in business in an interconnected world is possible only if the newest technology is embraced. Why are some companies reluctant to adapt, even when they know it is crucial to a successful future?

Some fear that their managers and employees may not adapt, that their functioning programs already in place may be interrupted, and that ever-present fear of a price tag.

To alleviate these fears and embrace the power of the future, it is vital that the company’s new automation and IoT utilize a software that is:

  • User-friendly so that employees, new or existing, can hit the ground running
  • Capable of building upon an existing food safety program and continue its success
  • Able to improve existing food safety programs to ensure updated compliance
  • Cost-effective and a good business decision when compared to the cost of manpower and recalls

One of the most common reasons a company chooses not to implement a new technology concerns the last point: Cost. To maximize the benefit of automation and IoT, expenses like laptops, tablets and phones are advisable in addition to software. The cost of the software itself when there is a paper or spreadsheet system that is working may seem unnecessary—after all, why buy a telephone when the telegrams are working just fine? In the high-speed world we now live in, a low-speed business approach is fatal.

There is good news when it comes to automation adoption: In response to the growing need for technology and the reluctance of companies to take on the expense, new incentives are being put in place in order support businesses and keep a country’s economy competitive. For example, the U.S. Tax Cuts and Job Act of 2017 allow write-offs of new automation technology in the first year of purchase, vastly reducing the initial cost impact of implementing automation technologies. Many state and provincial governments provide grants for updating technology to improve safety and traceability.

Automation Will Feed the World

Technology and automation in agriculture and food production make a company competitive, but it is also an unavoidable requirement going forward. Looking at the big picture, it’s also necessary to meet the demands of a booming global population. Food is, in many ways, the most essential industry to human life.

In The Future of Food: Food Production, Innovation, and Technology, authors David B. Schmidt and Kimberly Reed say it clearly:

“Each U.S. farmer feeds more people worldwide than ever before, at 155 people per farmer. In 1960, that number was 25.8 people. By 2050, the same farmer will need to feed 232 people… With finite resources, it will take innovation and a variety of technologies to meet the world’s food demand. This includes using new technologies. At every step of the journey from farm to fork, technology is helping us produce a safe, abundant, sustainable, and nutritious food supply.”

It took centuries for the writing of letters to be replaced by telegrams. It took only 130 years from the invention of telegrams to the use of email. A farmer with a shovel is now a robot, with the agricultural robot market expected to increase by more than fivefold to $12.8 billion over six years. 94% of packaging operations use robotic technology today. A recent survey found that half of food companies interviewed plan to increase their use of automation in the next two years.

Where will food production be in 2020? And where will your company be in that near future?

Jordan Anderson, PAR Technology Corp.
FST Soapbox

How the IoT Influences Restaurant Food Safety & Management

By Jordan Anderson
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Jordan Anderson, PAR Technology Corp.

The Internet of Things (IoT) is changing the way restaurants do business in 2017. Today, business owners can trace products from point-of-purchase to their doorstep using IoT devices that monitor their location and more importantly, their temperature along the way. These devices are helping keep food safe, streamlining inventory management and giving owners the real-time information they need when managing multiple locations.

Monitoring Food Safety

Nothing gets the attention of a restaurant owner quicker than a foodborne illness outbreak. When it happens, they need to know which products were involved.

IoT devices allow owners to track their food from the time they order to the time it arrives. Even in the back of a tractor-trailer rolling down the highway, owners can check to see the temperature of their food, and can obtain the data trail during its entire journey to see how it was handled, and to ensure safety standards were met.

This data is especially important since the U.S. Federal Government enacted the Food Safety Modernization Act (FSMA) in 2011, which intends to protect public health by reinforcing the U.S. food safety program. Food-based businesses are now required to establish preventative control systems modeled after HACCP (Hazard Analysis and Critical Control Points) guidelines and prove their compliance by maintaining at least two-years of documentation.

Traceability measures utilizing IoT efficiently gathers and manages this information, giving owners the peace of mind they need to ensure their food has been handled properly. Not only that, but they have the data to prove it.

Inventory Control and Management

IoT devices help manage the cost of inventory by providing the real-time data that owners need when ordering stock and forecasting needs based on their menu. The data collected by the IoT devices ensures the freshest ingredients are available for dishes, and expired products are disposed of properly.

Tracking inventory from farm-to-fork prevents food waste, deters in-house theft and helps manage the cost of inventory.

Other questions and action items that IoT devices can help manage include:

  • Who placed the order, authorized the purchase, and accepted the delivery?
  • What was ordered and what are the products’ proper temperature ranges?
  • When did the order take place and when did it arrive? When is its expiration date?
  • What is the origin of the product and how did it travel to get to you?

This can help specifically within the restaurant retail market where pick-up and deliveries are becoming more prevalent.

For example: If a customer changes their scheduled pick-up, or drop-off times, retailers must have technology in place that will monitor food safety best practices. Deli, produce and dairy related products could use pre-determined checklists that will verify items were picked correctly, bagged properly and temperatures are checked to FDA regulated standards. While FDA regulations pertaining to FSMA are stricter than ever, it has never been more important for food safety technology to be integrated within the adoption of omnichannel restaurant practices. The likes of digitalized checklist management, temperature control and traceability will have a tremendous impact on continued growth and service within the marketplace.

IoT Devices and Temperature Control

Utilizing the IoT is a critical aspect of quality control. These devices are equipped with a temperature probe, barcode scanner and RFID infrared temperature reader that monitors and tracks your food throughout its journey in the supply chain.

Here’s how it works:

  • The probe, infrared and RFID scanner track and measure the temperature of each product.
  • The IoT software prompts employees to complete checklists, including temperature checks on a regular basis.
  • Each time the data is collected, it is immediately uploaded to a secure cloud and is accessible anytime, from anywhere.
  • While in the cloud, you can customize, store, filter and analyze the information.
  • Users are alerted immediately if any steps are overlooked, like non-observed items, missed checklists and violations, in addition to any corrective actions that address temperature concerns.
  • Should an issue arise, you have the detailed, automated audit trail to prove your company followed proper food safety protocol.

IoT Devices Can Create Modern Dining Experiences

Aside from helping to streamline and manage day-to-day operations, IoT devices can create a unique dining experience for your customers.

For example, if you love seafood – some restaurants are using IoT devices to track where and when seafood is harvested. One example of this kind of initiative is the Boat-to-Plate project funded by a grant from the Mid-Coast Fishermen’s Association. This project developed an app for anglers to upload information regarding their catch. Restaurant owners are using IoT information like this to create unique dining experiences.

IoT and You

How do you plan to use IoT technology in 2017? Integrating IoT practices gives your business the food safety solution needed to help keep food safe, improve supply chain traceability, manage your inventory and gain better control over your bottom-line.

FoodLogiQ

FoodLogiQ Launches API Platform to Centralize IoT, Data

FoodLogiQ

FoodLogiQ has announced the launch of its API as a Service offering within the company’s Connect platform. Companies can use the platform to centralize IoT and blockchain data.

“By connecting the data our customers are gathering in FoodLogiQ with other platforms serving the food industry, our customers will achieve supply chain visibility unlike any other in the industry,” said Dean Wiltse, CEO of FoodLogiQ in a press release. “Whether it is a consumer-facing loyalty app, temperature monitoring sensors, inventory management platforms or grocery delivery services, the food industry requires a centralized technology platform to connect these many complex data sources and reduce redundancies through integrations.”

The service offerings include temperature and location monitoring, blockchain, data pools, business intelligence, and food quality and auditing technology. For more information about FoodLogiQ API as a Service, visit the company’s website.

Jordan Anderson, PAR Technology Corp.
FST Soapbox

How Proper Record Keeping Can Help Reduce Food Waste in the Supply Chain

By Jordan Anderson
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Jordan Anderson, PAR Technology Corp.

One stringent component of FSMA and the Final Rule on Sanitary Transportation of Human and Animal Food is record keeping. Depending on the type and size of business, the FDA can demand proof of record anywhere from under one year and upwards to two years, all while needing to address their inquiry within 24 hours. Failure to do so will be considered a “prohibited act” and violators can be tried for civil and criminal penalties.
This new rule, put in place by the FDA, will put immense pressure on the food transportation industry, not only to make food safety a priority, but also to ensure that proper food safety practices and measures are being properly implemented, by way of record keeping.

While the litany of rules and regulations pertaining to record keeping best practices is intense, let us break down the basic requirements applying to records in layman’s terms:

  • If HACCP procedures aren’t documented, it didn’t happen
  • Records must be verbatim accounts of what happened
    • The need for real-time recording is paramount
  • Corrective actions must be executed immediately if an issue occurs
    • If not, liability risk increases exponentially

Companies must determine the most efficient and plausible manner by which they will comply. Traditional storage of records in filing cabinets and input of data in spreadsheets is antiquated, and leads to errors and the potential for misplaced records. Now, more than ever, is the time for businesses along the food chain to deliver value to their organization via digital technologies and automated data gathering solutions. This will ensure constant visibility and ensure quality control throughout the process from farm to fork.

Where Does Waste Happen?

While covering a lettuce farm in central California, National Geographic discovered that numerous loads were dumped each day due to procedural mistakes , including improperly filled, labeled and sealed containers.1 Due to the mishaps, the loads were then dumped. Between April and November that year, the local Waste Authority landfilled 4–8 million pounds of fresh vegetables from those fields.

The Food and Agriculture Organization (FAO) estimates that:

  • 54% of world food waste occurs during production, handling and storage
  • 46% occurs during processing & distribution

These numbers are not only staggering, but they illustrate the seriousness of this issue.

Many of these mishaps occur when standard recording procedures are done manually, which leads to improper documentation that invalidates the integrity of shipments—to which the above figures illustrate and corroborate.

But can shippers, loaders, receivers and the like secure their procedures and eliminate wasted product by implementing stricter digital HACCP solutions?

Lost Food

While improper execution of best practices can lead to FDA imposed sanctions and profit loss, it also perpetuates the problem of food waste globally. This issue has become an epidemic and one that greatly affects the lives of many.

In a recent National Geographic article, The Food and Agriculture Organization (FAO) suggests the following:1

  • One-third of food produced for global human consumption is annually lost or wasted along the supply chain
  • Food waste equates to 2.8 trillion pounds each year, which is enough to feed 3 billion people per year

Consider this: The World Food Programme estimates that nearly 795 million people in the world do not have access to the proper amount of food needed to live a healthy, active life, which equates to roughly one in nine people on earth.

The amount of waste created along the supply chain each year is enough to feed the hungry and malnourished people of the world three-times over. While waste is inevitable, even a 50% improvement would be able to feed those most in need.
We understand the nature of business is overcoming competition while expending the least capital possible, ultimately leading to profit. However, food-related businesses along the supply chain must ask themselves whether or not they are their own competition. Are best practices being properly executed? How can they ensure this in order to mitigate waste?

Ultimately, however, it becomes a human issue. Companies must be responsible and possess the empathy to understand this. While domestically we may not feel the effects of global hunger as much as other third-world countries, these businesses must be aware of the epidemic in order to elucidate this topic while simultaneously maximizing its businesses potential.

By leveraging new food safety solutions such as mobile devices, the cloud, IoT, sensors and more, you can better protect your customers while also gaining a tangible ROI. Wherever consumers purchase and shop for food today, they are likely to find a larger selection than ever before. From the bread aisle to the cheese counter to the produce section, food options and manufacturing processes today are more diverse than ever. While variety is positive on a consumer and cultural level, it can create challenges for food safety from farm to fork.

Reference

  1.  Royte, E. (October 13, 2014). “One-Third of Food Is Lost or Wasted: What Can Be Done”. National Geographic. Retrieved from http://news.nationalgeographic.com/news/2014/10/141013-food-waste-national-security-environment-science-ngfood/.
Judy Black, Rentokil
Bug Bytes

How the Internet of Things Helps Pest Management in Food Processing

By Judy Black
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Judy Black, Rentokil

As the applications of connected devices continues to drive innovation and create exciting possibilities throughout the food processing industry, the impact of the Internet of Things (IoT) on pest management in the food supply chain is already easy to recognize. An ecosystem of connected devices streamlines several processes that are integral to an effective integrated pest management plan, providing convenience and saving time for both food manufacturers and their pest management partners. From creating a smart network of devices that detect changes and track movement in the pest population to seamless reporting procedures that cut down on paperwork, we’re already seeing the benefits of a more connected world on a very important aspect of food safety. At the ground level—often quite literally—we have networked traps for pests ranging from stored product insects to rodents. Each trap tracks the pests it captures and reports its readings to a central hub in real time, providing an instant snapshot of changes in the pest population and triggering notifications when that population exceeds pre-set parameters—well before the pests create an issue. Beyond knowing when a pest population increases in a facility, this network of connected monitoring devices can pinpoint where those pests are congregating, allowing the facility’s pest management partner to identify and eliminate the source of the issue quickly.

Beyond those devices on the front lines, the IoT also has a major impact on the behind-the-scenes management of pest management processes. With the increase in reporting requirements brought on by the adoption of FSMA earlier in the decade came a lot of new paperwork for food manufacturers. On the pest management front, the paper trail required to track the steps taken to reduce the risk of pest infestation represents a significant commitment of time and effort on the part of facility managers. Working with a pest management partner that understands the opportunities connected devices provide means less paperwork; a centralized online hub allows facility managers to review their partner’s recommendations, indicate the steps they’ve taken to address issues and close the loop without having to touch a file cabinet.

The availability of this pest-tracking data allows forward-thinking pest management companies to be more efficient and better informed. By compiling and analyzing this data, they can identify regional trends in pest populations, allowing them to be better prepared to recognize and resolve pest issues early and to stay ahead of cyclical fluctuations in the pest population.

We often talk about technology in terms of the impact it will have in the future, but in the pest management business, we’re already seeing the benefits of a connected ecosystem of devices. While the technology will continue to evolve and improve, it’s important for food manufacturers to recognize the benefits of working with a pest management partner that embraces the IoT. By streamlining and centralizing the processes of monitoring and reporting on pest management practices, this technology saves time and reduces the risks pests pose throughout the food supply chain.